Operating Instructions

LINDE REACHSTACKER
C 4230, 4531, 4234, 4535 TL 4 / 5
C 4026, 4030, 4531 CH 4 / 5
With Cummins Diesel Engine

357 804 25 01 GB
0205
YOUR TYPE 357 03
Lind
Linde e Reach stacker offers the best in economy,
safety and driving convenience. Therefore it is ben-
eficial to the operator to preserve the qualities of
the trucks for a long and profitable service life and
to make full use of their benefits when at work.
For attachments, follow the proprietary operating instruc-
tions supplied with them.
Follow all operating instructions for your reach stacker
and carry out the maintenance and care specified in the
inspection and maintenance schedule regularly, on time
and with the specified lubricants.
This manual tells you all you need to know about starting,
running, servicing and maintaining your Linde Reach stack-
er.
The terms “front”, “rear”, “left” and “right” refer to the po-
sition in which the item concerned is installed in the truck,
looking forward in the travel direction.
Approved applications
Linde Reach stackers are designed for transporting
and lifting the loads stated in the load capacity dia-
gram.
In particular, we refer to the attached "Rules for the Normal
and Proper Use of Industrial Trucks" (VDMA) , the accident
prevention regulations of your employer’s liability insurance
and the special measures required for driving on public
roads.
The safety rules for the use of industrial trucks must be
followed under all circumstances by the responsible per-
sons, especially by the operator and service personnel.
The user, and not Linde, is responsible for any danger aris-
ing from applications not authorised by the manufacturer.
If you desire to use the truck for applications not
agreed or mentioned in the manual and convert or
supplement it for this purpose, please first contact
your authorised Linde dealer.
No changes, especially conversions or modifications, may
be made to your Reach stacker without the prior permissi-
on of the manufacturer.
Only qualified persons authorised by Linde are allowed to
service the Reach stacker.
To keep your warranty valid, all maintenance services must
be performed by qualified persons authorised by Linde.
2
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 de-
sign and construction of its products. As a result, the illu-
strations and technical details referring to design, fittings
and engineering are subject to change if progress warrants
it.
Therefore, the manufacturer will not accept any claims
based on the specifications, illustrations and descriptions
contained in this operating manual.
Please submit all enquiries concerning your Reach stacker
and all orders for spare parts to your authorised distributor,
making sure to state your correct shipping address.
For repairs, use only genuine Linde spare parts to ensure
that your Linde Reach stacker will maintain its original tech-
nical standard.
When ordering spare parts, it is important to specify the
part numbers and to include the following truck data:
Reach stacker model: ........................................................
Serial no./year built: ...........................................................
Takeover date: ....................................................................
Additionally specify the production no. of engine, boom,
hydraulic pumps and axles when ordering parts for these
assemblies.
Engine no.: .....................................................................
Transmission no.: ..........................................................
Drive axle no. : ...............................................................
Hydraulic pump no.: ......................................................
..................................................................................
..................................................................................
..................................................................................
Boom no.: ......................................................................
Boom extension cylinder no.: .......................................
Lift cylinder no. : ................................................................
Spreader serial no. : ......................................................
When taking over the truck, transfer the details from the
assembly type plates into this manual.
Truck takeover
Every Reach stacker 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 un-
der 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 certificate of conformity.
The following technical manuals are supplied with each
357 804 25 01 GB 0104
Reach stacker:
1 Operating instructions
1 EC certificate of conformity
(The manufacturer certifies that the industrial truck
conforms to EC directives for machines)
1 Rules for the Normal and Proper Use of Industrial
Trucks (VDMA)
Wishing you satisfactory operation,
Linde Heavy Truck Division Ltd.
 TYPE PLATES
1 Boom serial number
2 Spreader serial number
3 Load capacity plate
4 Drive axle number
5 Type plate
6 Transmission number
1
7 Hydraulic pump number
8 Diesel engine number
9 Steering axle number
10 Reach stacker type plate
11 Manufacturer
12 CE symbol
(The symbol certifies that EC directives 3 2
for machines and all applicable guide-
lines are fulfilled.)
357 804 25 01 GB 0104

13 Serial no./year 4
10
14 Unladen mass
15 Battery voltage 5
16 Rated load capacity
17 Type

10 11
7 6
8
9

17
12

16 13

14

15
3
REACH STACKER with Diesel Engine
The latest technology,
ergonomic operation, energy saving,
environment - conscious and minimal maintenance,
solid manufacture, incorporating Linde variable displace-
ment load sensing ' supply on demand' hydraulics,

357 804 25 01 GB 0104

Driver’s position and operating features are designed
using the latest findings in ergonomics.

Each operating element is designed in regard to position-

ing and operation to ensure minimum driver effort
and safe operation.

4

Page
Your type 357 0 033 reachstacker .................................. 2
Approved applications ................................................ 2
Technical note ............................................................. 2
Truck takeover .............................................................. 2
Type plates ................................................................... 3
Reachstacker 357 03 .................................................. 4
Table of contents ......................................................... 5
Technical Data ............................................................. 8
Technical description ................................................. 1 0
Engine .......................................................................... 1 0
Transmission ............................................................... 1 0
Driving cabin, controls, switches
and instruments ..................................................... 1 0
Drive axle ..................................................................... 1 0
Steer axle ..................................................................... 1 0
Brakes ........................................................................... 1 0
Safe load system ......................................................... 1 1
Working and steering hydraulics ............................... 1 1
Telescopic boom ......................................................... 1 1
357 804 25 01 GB 0104
Handler ......................................................................... 1 1
Electrical system ......................................................... 1 2
Safety systems and shut down devices .................... 1 2
Automatic lubrication system ..................................... 1 2
General view of truck .................................................. 1 3
General view of container handler ............................ 1 4
Controls and Indicators ............................................... 1 5
Gauges, switches and warning lights ....................... 1 6
Left-hand control panel (LHP) ................................... 1 6
Steering column (SC) ................................................. 1 6
Right-hand control panel (RHP) ................................ 1 6
Driver's control centre (DCC1) .................................. 1 7
Load safety system panel (LSSP) ............................. 1 7
Twistlock indicators (TI) .............................................. 1 7
Combi-handler indicator (CHI) .................................. 1 7
Cab rear bulkhead (CRB1) ......................................... 1 7
Trouble shooting guides gauges and lights ............ 1 8
Safety rules ................................................................... 2 0
Wind speed .................................................................. 2 0
Operator safety ............................................................ 2 0
Safety precautions ....................................................... 2 0
Handling fluids and lubricants .................................. 2 0
Stored hydraulic energy .............................................. 2 0
Operation of Reach stackers in the plant area ........ 2 1
Diesel engine emissions ............................................ 2 1
Running-in instructions .............................................. 2 1
Checks and services prior to initial operation* ........ 2 1
Daily checks and services* ........................................ 2 1
TABLE OF CONTENTS
Page Page
Beginning operation ............................................ 2 2 Cold start ...................................................................... 35
Opening the cabin door from the outside ................ 2 2 Stopping the engine .................................................... 35
Opening the cabin door from the inside ................. 2 2 Malfunctions during operation .................................. 36
Securing the open cabin door ................................... 2 2 Load safety system ...................................................... 37
Cab Drivers Door - Closing ........................................ 2 2 Start-up indications ..................................................... 37
Releasing and moving the cabin .............................. 2 3 Working indications .................................................... 37
Repositioning and securing the cabin ...................... 2 3 Lowering the handler after shutoff ............................ 38
Opening the bonnet .................................................... 2 3
Operation ................................................. 38
Closing the bonnet ...................................................... 2 3
Truck status display screen ........................................ 39
Opening the transmission cover ................................ 2 3
Gear shift selection ..................................................... 48
Closing the transmission cover ................................. 2 3
Driving ........................................................................... 48
Opening the cabin rear compartment door ............. 2 4
Selecting the travel direction ..................................... 49
Closing the cabin rear compartment door ............... 2 4
Moving off ..................................................................... 49
Opening the working hydraulic
Slowing down and stopping ....................................... 50
system oil tank cover ............................................. 2 4
Manual 1st gear selection when stopped ................ 50
Closing the working hydraulic system oil tank cover 2 4
Preselection of 1st gear when travelling .................. 50
Opening the brake hydraulic system oil tank cover 2 4
Stopping the truck ....................................................... 51
Closing the brake hydraulic system oil tank cover .. 2 4
Operating the transmission dump ............................. 51
Opening the battery and air filter
Steering ........................................................................ 51
compartment door ................................................. 2 5
Service brake ............................................................... 52
Closing the battery and air filter compartment door 2 5
Parking brake .............................................................. 52
Isolating the battery ..................................................... 2 5
Turning on the lights ................................................... 53
Opening the electrical box cover ............................... 2 6
Turning on the main beam headlights ..................... 53
Closing the electrical box cover ................................ 2 6
Turning on the turn indicator lights ........................... 53
Check tyre condition and inflation pressure ............ 2 6
Operating the horn ...................................................... 54
Tyre specifications - drive and steer axle ................. 2 6
Turning on the front windscreen wiper ..................... 54
Check working hydraulic system oil level ................. 2 7
Turning on the front windscreen washer .................. 54
Check the brake hydraulic system oil level .............. 2 7
Operating the rear screen wiper and washer .......... 55
Check coolant level in radiator header tank ............ 2 8
Operating the top screen wiper and washer ............ 55
Check the engine oil level .......................................... 2 8
To operate the ventilation and heater system ......... 55
Check windscreen washer reservoir fluid level ....... 2 9
To operate Climate control* ....................................... 56
Checking the fuel level ............................................... 3 0
Fuses ............................................................................. 56
Filling fuel ..................................................................... 3 0
Operating the hazard warning lights ........................ 57
Checking the transmission oil level .......................... 3 1
Boom and handler controls ....................................... 57
Checking the handler for visible damage ................ 3 2
Central control lever (joystick) ................................... 57
Checking the twistlocks and warning lights
Lifting the boom ........................................................... 58
for proper operation ............................................... 3 2
Lowering the boom ..................................................... 58
Adjusting the driver’s seat .......................................... 3 3
Extending the boom .................................................... 58
Setting the driver’s weight .......................................... 3 3
Retracting the boom ................................................... 58
Adjusting the seat position ......................................... 3 3
Operating the sideshift ............................................... 58
Setting the seat height ................................................ 3 3
To sideshift left ............................................................ 58
To raise the seat cushion ........................................... 3 3
To sideshift right ........................................................ 58
To lower the seat cushion .......................................... 3 3
Rotating the handler ................................................. 59
Adjusting the seat cushion angle .............................. 3 3
Rotating the handler clockwise ............................. 59
Adjusting the seat backrest angle ............................. 3 3
Rotating the handler anticlockwise ...................... 59
Normal start ................................................................. 3 4
Operating the beam spreader ................................ 60
ECM system ................................................................. 3 4
5
TABLE OF CONTENTS
Page
Opening the beam locks ..........................................
Closing the beam locks ...........................................
Setting the spreader to container width ..............
Operating the twistlocks ..........................................
Locking the twistlocks ..............................................
Unlocking the twistlocks ..........................................
Operating the twistlock override ............................
Traversing the cab ....................................................
To move the cab forward .........................................
To move the cab backwards ...................................
Raising and lowering the attachment legs CH ..
Lowering the back legs ............................................
Raising the back legs ...............................................
Lowering the front legs ............................................
Raising the front legs ...............................................
Clamping and unclamping the legs ......................
To clamp the legs ......................................................
To unclamp the legs .................................................
To slope pyle the spreader .....................................
To slope pyle the spreader left ..............................
To slope pyle the spreader right ...........................
Before lifting a load ..................................................
Load safety indication and warnings ...................
Load diagrams TL .....................................................
Load diagrams CH ....................................................
Picking up a container TL .......................................
Picking up a container CH ......................................
Travelling with loads ................................................
Depositing the load ..................................................
Parking the truck .......................................................
Trailer coupling .........................................................
Jack locations for changing wheels .....................
Wheel change ............................................................
Removing the drive wheels .....................................
Drive axle outer wheel .............................................
Drive axle inner wheel .............................................
Fitting the drive wheels ............................................
Inner drive wheels .....................................................
Outer drive wheels ....................................................
Removing the steer wheels ....................................
Fitting the steer wheels ...........................................
T o w i n g ..........................................................................
Towing procedure .....................................................
Releasing the parking brake ..................................
Removing the propeller shaft .................................
After towing .................................................................
6
Page Page
60 Resetting the parking brake ................................... 7 5 500 hours service .................................. 9 0
60 Refitting the propeller shaft .................................... 7 5 Check the drive axle mounting .............................. 9 0
60
Check the drive axle centre differential oil level 9 0
61
62 Maintenance .......................................... 7 6 Check the drive axle hub oil level ......................... 9 0
62 Hoisting the truck ...................................................... 7 6 Check the hydraulic system, pumps, valves and
63 Handler removal ........................................................ 7 6 lines... ....................................................................... . 9 1
63 Taking the truck out of operation .......................... 7 7 Check electric cables, connectors and
63 Measures before taking the connections for condition and tightness ........ 9 1
63 truck out of operation .......................................... 7 7 Change the transmission oil filter canisters ....... 9 1
64 Putting the truck back into operation ................... 7 7 Change the pilot circuit oil filter ............................ 9 1
64 General information ................................................. 7 7 Change the engine oil .............................................. 9 2
64 Work on the boom and the Change the engine oil filter canisters .................. 9 2
64 front part of the truck .......................................... 7 7 Change the fuel pre-filter with water monitor .... 9 3
64 Inspection and maintenance chart ....................... 7 8 Fuel pre filter, draining of condensation water . 9 3
64 Checks and maintenance work after the first Renew the fuel filter canister ................................. 9 4
64 50 service hours ................................................... 8 0 Check mounting of turbocharger intake pipe ..... 9 4
64 Routine maintenance ............................................... 8 0 Check the front cab mountings .............................. 9 4
357 804 25 01 GB 0104
65 Clean the truck ........................................................... 8 1 Check the rear cab mountings ............................... 9 4
65 Tighten the wheel nuts ............................................ 8 1 Check and lubricate the handler
65 Check the tyres for damage and foreign objects 8 1 sliding bearing ..................................................... 9 5
65 Drain the fuel filter .................................................... 8 2 Check and lubricate sideshift sliding bearings . 9 5
65 Prime the fuel system ............................................... 8 2 Lubricate locking cylinder pin on the handler ... 9 6
66 Check the battery condition .................................... 8 2 Lubricate the sideshift cylinder bearings ............ 9 7
67 Check the air filter ..................................................... 8 3 Check and tension drive-belts ................................ 9 8
68 Renew the safety element ....................................... 8 4 Coolant pump drive ................................................... 9 8
69 Clean the radiator and oil cooler, Alternator drive ........................................................... 9 8
70 check for leaks ..................................................... 8 4 Renew hydraulic tank air filter ............................... 9 8
70 Check and clean the climate control Engine Diagnostic System Check ......................... 9 8
71 filter element ......................................................... 8 4
71 Check the steering lock ........................................... 8 5 1000 hours service ................................ 9 9
71 Check the central lubrication* Renew the working hydraulic system oil
73 lubricating points ................................................. 8 5 suction filters ........................................................ 9 9
73 Fill central lubrication* canister with grease ..... 8 5 Renew the brake hydraulic system oil
73 Lubricate slewing ring bearing and gear ............ 8 6 suction filter .......................................................... 9 9
73 Check and lubricate the twistlocks ....................... 8 6 Change the air filter element, check the vacuum
74 Check the slewing gearbox and brake oil level . 8 7 switch...........................................................101
74 Check and lubricate the leg folding group ......... 8 7 Renew the brake hydraulic system oil pressure
74 Check and lubricate feet at the bottom filter................................................................101
74 of each leg ............................................................. 8 7 Renew the transmission oil and
74 Clean and lubricate steer axle, clean the filter screen...................................102
75 check the mounting ............................................. 8 8 Check the engine mountings.............................103
75 Check the steer axle hub oil level ......................... 8 8 Check transmission mountings.........................104
75 Check and lubricate the drive shaft ...................... 8 8
75 Check and lubricate boom cylinder,
75 boom pivot and sliding bearings ..................... 8 9

Page
Check the cooling system for leaks
and tightness ................................................. 1 0 4
Check the parking brake condition
and mounting ................................................. 1 0 4
Lubricate handler extension
cylinder bearing pads .................................. 1 0 5
Check the intake and exhaust system for
leaks and tightness ...................................... 1 0 5
Change the drive axle centre
differential oil ................................................ 1 0 6
Change the drive axle centre hub oil ............ 1 0 6
Change the steer axle centre hub oil ............ 1 0 6
2000 hours service ........................... 1 0 7
Renew engine coolant ...................................... 1 0 7
Change the coolant filter .................................. 1 0 7
Check the condition of structured
357 804 25 01 GB 0104
c o m p o n e n t s .................................................... 1 0 8
Check valve clearances .................................... 1 0 8
Renew the brake hydraulic system oil .......... 1 0 9
Change the fuel tank breather filter ............... 1 1 0
3000 hours service ........................... 1 1 0
Clean the hydraulic tank pre-filter ................. 1 1 0
Renew handler slewing brake and
gearbox oil ..................................................... 1 1 0
Check, renew hydraulic oil
of working hydraulic system ....................... 1 1 1
Renew the safety element ................................ 1 1 1
General overall check ....................................... 1 1 2
5000 hours service ........................... 1 1 3
Renew the twistlocks ......................................... 1 1 3
Check the handler extension cylinder bearing
p a d s .................................................................... 1 1 3
6000 hours service ........................... 1 1 3
Check the vibration damper ............................. 1 1 4
Check the fan drive idley pulley assembly ... 1 1 4
Fan hub, belt driven ........................................... 1 1 5
Flushing the cooling system ............................ 1 1 5
Check the turbocharger .................................... 1 1 6
TABLE OF CONTENTS
Page
Check the radial bearing clearance .............. 1 1 6
Check the axial clearance ................................ 1 1 7
Renew the lift chains ......................................... 1 1 7
Inspection and maintenance data ................. 1 1 8
Fuel and oil recommendation ......... 1 1 9
Oil grades ............................................................. 1 1 9
Gear oil ................................................................. 1 1 9
Transmission oil (drive axle) ........................... 1 1 9
Transmission oil (handler slew gearbox and
b r a k e ) ................................................................. 1 1 9
Hydraulic oil for working hydraulics .............. 1 1 9
Hydraulic oil analysis ........................................ 1 1 9
Hydraulic oil
(brake system, brake cylinder) .................. 1 1 9
Hydraulic oil additives (brake system) .......... 1 1 9
Multipurpose grease ......................................... 1 1 9
Handler ring gear grease ................................. 1 1 9
General lubricating oil ...................................... 1 1 9
Battery grease ..................................................... 1 1 9
Central lubrication ............................................. 1 1 9
C o o l a n t .................................................................. 1 1 9
Diesel fuel ............................................................ 1 2 0
Troubleshooting guide (diesel engine) ........ 1 2 1
Troubleshooting guide (hydraulic system) .. 1 2 3
Circuits ............................................... 1 2 4
Electrical circuit .................................................. 1 2 4
Hydraulic circuit .................................................. 1 4 0
Elme spreader electrical circuit ..................... 1 4 2
Elme spreader hydraulic circuit ...................... 1 4 4
Brake circuit ......................................................... 1 4 5
I n d e x ...................................................................... 1 4 6
7
TECHNICAL DATA DESCRIPTION

LINDE R each S tacker 357 03 DFG

Designation acc. to VDI 3586
Data s heet for material handling equipment R egistration note to VDI 3586
VDI 2198
January 2004
1.1 Manufacturer Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde Linde
1.2 Model designation C 4230 TL / 4 C 4230 TL / 5 C 4531 TL / 4 C 4531 TL / 5 C 4234 TL / 4 C 4234 TL / 5 C 4535 TL / 4 C 4535 TL / 5 C 4026 C H / 4 C 4026 C H / 5 C 4030 C H / 4 C 4030 C H / 5 C 4531 C H / 4 C 4531 C H / 5
1.3 Power unit: battery, diesel, LP gas, mains power Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel
C haracteristics

1.4 Operation: manual, pedestrian, stand-on, seated, order picker R ider S eated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated R ider seated
1.5 Load capacity (L 1, L 2, L 3) Q (kg) 42000/30000/16000 42000/30000/16000 45000/31000/16000 45000/31000/16000 42000/34000/17000 42000/34000/17000 45000/3500 0/19000 45000/35000/19000 40000/26000/12000 40000/26000/12000 40000/30000/13000 40000/30000/13000 45000/31000/15000 45000/31000/15000
1.6 Load centre, First row (L 1) c (mm) 1760 1760 1760 1760 1760 1760 1670 1670 1760 1760 1760 1760 1670 1670
Load centre, S econd row (L 2) c (mm) 3810 3810 3810 3810 3810 3810 3810 3810 3810 3810 3810 3810 3810 3810
Load centre, Third row (L 3) c (mm) 6250 6250 6250 6250 6250 6250 6250 6250 6250 6250 6250 6250 6250 6250
1.8 Axle centre to fork face (L 1…1/2 high) x (mm) 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600 2800 /2600
1.9 Wheelbase y (mm) 6400 6400 6400 6400 6400 6400 6400 6400 6400 6400 6400 6400 6400 6400
2.1 S ervice weight kg 70400 70400 71400 71400 73200 73200 76300 76300 73950 73950 76700 76700 81250 81250
2.2 Axle load with load, front/rear (L 1) kg 97180 /15220 97180/15220 101900 /14500 101900 /14500 97030 /18170 97030 /18170 103250 /18050 103250 /18050 99000 /14950 99000 /14950 98870 /17830 98870 /17830 110100/16150 110100/16150
Weights

Axle load without load, front/rear (L 2) kg … … … … … … … … … … … … … …

2.3 Axle load without load, front/rear (L 1) kg 35900 /34500 35900 /34500 36400 /35000 36400 /35000 36100 /37100 36100 /37100 38500 /37800 38500 / 37800 41320 /32630 41320 /32630 41450 /35250 41450 /35250 44320 /36920 44320 /36920
Axle load without load, front/rear (L 2) kg … … … … … … … … … … … … … …
3.1 Tyres, front/rear. S E = (superelastic), P = (pneumatic) P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P P/P
Wheels and tyres

3.2 Tyre size, front 18.00 x 25 /40pr 18.00 x 25 /40pr 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 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
3.3 Tyre size, rear 18.00 x 25 /40pr 18.00 x 25 /40pr 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 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
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 4x /2
3.6 Track width, front b10 (mm) 3030 3030 3030 3030 3030 3030 3030 3030 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 2786

357 804 25 01 GB 0104

4.1 Telescopic boom lift angle, R aised /lowered / ˚ 56 /0 61/0 56 /0 61/0 56 /0 61/0 56/0 61/0 56 /0 61/0 56 /0 61/0 56/0 61/0
4.2 Height telescopic boom lowered h1 (mm) 4900 4900 4900 4900 4900 4900 5000 5000 5000 5000 4900 4900 5000 5000
4.4 Lift (L 1, L 2, L 3) h3 (mm) 13400 /11120 /6850 15900 /14100 /11350 13400 /11120 /6850 15900 / 14100 /11350 13400 /11120 /6850 15900 /14100 /11350 13500/11220 /6950 16000/14200 /11550 13075/10800 /6550 15575 /13780 / 11050 13075 /10800 /6550 15575 /13780 /11050 13175 /10900 /6650 15675 /13880 /11550
4.5 Height, telescopic boom extended h4 (mm) 16560 19000 16560 19000 16560 19000 16660 19100 16560 19000 16560 19000 16660 19100
4.7 Height of overhead guard (cabin) h6 (mm) 3900 3900 3900 3900 3900 3900 4000 4000 3900 3900 3900 3900 4000 4000
4.8 Height, operators seat/stand-on platform h7 (mm) 2840 2840 2840 2840 2840 2840 2940 2940 2840 2840 2840 2840 2940 2940
4.12 Towing coupling height h10 (mm) 600 600 600 600 600 600 700 700 600 600 600 600 700 700
4.15 Twistlock height lowered h13 (mm) 1495 1495 1495 1495 1495 1495 1595 1595 1495 1495 1495 1495 1595 1595
Dimensions

4.19 Overall length with attachment l1 (mm) 11618 11618 11618 11618 11618 11618 11618 11618 11618 11618 11618 11618 11618 11618
4.20 Overall length l2 (mm) 8408 8408 8408 8408 8408 8408 8408 8408 8408 8408 8408 8408 8408 8408
4.21 Overall width b1/b2 (mm) 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /3400 4180 /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 6050 /12150
4.31 Ground clearance minimum m1 (mm) 345 345 345 345 345 345 345 345 345 345 345 345 345 345
4.32 Ground clearance, centre of wheelbase m2 (mm) 300 300 300 300 300 300 300 400 400 300 300 300 400 400
4.33 S tacking aisle 20 container Ast (mm) 10225 10225 10225 10225 10225 10225 10225 10225 10225 10225 10225 10225 10225 10225
4.34 S tacking aisle 40 container Ast (mm) 13050 13050 13050 13050 13050 13050 13050 13050 13050 13050 13050 13050 13050 13050
4.35 Turning radius Wa (mm) 8605 8605 8605 8605 8605 8605 8605 8605 8605 8605 8605 8605 8605 8605
4.36 Minimum pivoting point distance b13 (mm) 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400
5.1 Travel speed, with/without load km/h 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25 22/25
5.2 Lift speed, with/without load m/s 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39 0.28/0.39
5.3 Lowering speed, with /without load m/s 0.39/0.39 0.39/0.39 0.39/ 0.39 0.39/0.39 0.39/0.39 0.39/ 0.39 0.39/0.39 0.39/0.39 0.39/0.39 0.39/ 0.39 0.39/0.39 0.39/0.39 0.39/0.39 0.39/ 0.39
Performance

5.5 Tractive force, with/without load 1 kph N 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/… 325/…
5.6 Maximum tractive force, with /without load N 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/… 370/…
5.7 C limbing ability, with/without load 1 kph % 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/… 29/…
5.8 Maximum climbing ability, with/without load % 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5 33.9/34.5
5.9 Acceleration time, with /without load s … … … … … … … … … … … … … …
5.10 S ervice brake Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc Wet disc
6.4 B attery voltage, rated capacity V/Ah 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143) 24 V (2 x 12 /143)
7.1 Engine manufacturer/type C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11 C ummins QS M 11
7.2 Engine performance according to IS O 1585 kW 246 246 246 246 246 246 246 246 246 246 246 246 246 246
Drive

7.3 R ated speed 1/min 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100
7.4 Number of cylinders /displacement /cm3 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820 6 /10820
7.5 Fuel consumption according to VDI cycle l/h … … … … … … … … … … … … … …
8.1 Type of drive control Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4 Torque conv. 4/4
8.2 Working pressure for attachments bar 160 160 160 160 160 160 160 160 160 160 160 160 160 160
Other

8.3 Oil flow for attachments l/min … … … … … … … … … … … … … …

8.4 Noise level, at operator s ear, Overhead guard/C ab dB (A) 74 74 74 74 74 74 74 74 74 74 74 74 74 74
8.5 Trailer coupling, design/type DIN ø (mm) 50 50 50 50 50 50 50 50 50 50 50 50 50 50

8
 DESCRIPTION TECHNICAL DATA
Ast
Ast
40’

a
2 20’
Wa
a
2 AST Travelling aisle
b13
4 5 b11
b11 b1 b2
b1 b2 b3
b3 20' 10225 10225 b10
a
2
b10
40' 13050 13050 b13

Wa
20’

40’
a
x 500
2
357 804 25 01 GB 0104

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

TL
h4

?/?
CH L1

h3/L1
L1 h4
L2 L1

h3/L1
h3/L2
L2 L1 L3 L2 L1
h3/L2

h1 h3/L3
h3/L3
L3 L2 L1 L3 L2 L1
h6
h7
h13
m2
h10
h13
9’ 6"
L3 L2 L1 1495
9’ 6"
L3 L2 L1
y
m1
1790 1790
l2
3840 3840

l1 6280 6280

Q Q Q Q Q Q

9
TECHNICAL DESCRIPTION
Type 357 03 reachstackers are designed to lift and trans-
port containers between 20 ft and 40 ft in length at weights
up to 45 tonnes. The maximum travel speed is 24.9 kph,
without a load. The maximum climbing gradient is 30.9%.
The handler has automatic self-levelling and sway damp-
ing, 95°/185° rotation and +/- 800 mm sideshift.
Engine
The trucks are fitted with a Cummins 11 litre liquid cooled,
6 cylinder turbocharged direct injection diesel engine which
develops a rated output of 246 kW. Maximum engine torque
of 1674 Nm is attained at 1100 rpm. The engine draws fuel
from two tanks fitted in the chassis left hand compartment.
Engine lubricating oil is filtered by a twin element oil filter
and a rotary bypass filter.
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 trans-
mission oil is fitted 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 four-speed
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 is activated when either
of the brake pedals are depressed and throttle
selected.
The transmission oil is filtered through a twin ele-
ment filter fitted to the left hand side of the chassis
in the engine compartment.
Driving cabin, controls, switches and instru-
ments
The driving cab frame forms the load guard. It
conforms to international safety standards.
The cab is fitted to a rolling platform and locked at
the rear of the chassis. (CH versions are provided
10
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 fitted 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 func-
tions are controlled by a central control lever mount-
ed on the driver's control centre. Operational travel
speed of the truck is restricted to 5km/hr when:
- The load lifted exceeds 70% of the truck capacity
at the given boom position.
- The boom is extended more than 930 cms.
A central system fault warning light is fitted in the
top steering column cover in front of the steering
wheel. System warning lights, truck status display
and the working light switch are mounted in panels
fitted on both sides of the steering column at the
front windscreen lower corners.
Located in the upper right corner of the cab, is the
MDM display screen which, when driving will dis-
play the actual gear selected and the fuel level in
litres. When lifting actual load weight and maxi-
mum load weight at that boom position is displayed.
The gearchange control unit and combined electri-
cal control switch are fitted on either side of the
steering column. The switches for the top and rear
windscreen wipers and washers are fitted on the
driver's control centre.
The windscreen washer reservoir is fitted to the
right rear of the cab, with access to the filler cap
from the outside of the cab. The ventilation switch
and temperature regulator is fitted 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.
DESCRIPTION
The heater / fresh air unit is fitted behind the rear
access door. This can be pivoted outwards to allow
access for maintenance.
The electrical fuse box for main truck systems, are
located at the rear right of the cab.
The batteries and air cleaner are mounted within a
compartment in the left hand side of the chassis
behind a lockable door.
Drive axle
The drive axle is driven by the transmission through
a propeller shaft. The axle is a double reduction
type with hub planetary reduction gears.
Steer axle
The steer axle is mounted on bushes which allow
sufficient wheel movement for stability over uneven
357 804 25 01 GB 0104
ground. Steering movement is provided by a dou-
ble-acting hydraulic cylinder acting on fixed length
steering links. Both the steering stub axles and the
steering links are fitted with plain bush bearings.
Brakes
The truck braking system is hydraulically operated.
It is designed as a fail-safe brake, the parking brake
will acitivate, or not release if hydraulic pressure in
the system is correct. Audible warning of low pres-
sure in the braking system is given by buzzer fitted
in the driver's cabin.
The service brake is controlled by connected foot
pedals, one fitted on either side of the steering
column.
The parking brake is operated by a push-button
switch mounted within the Drivers control centre.
The parking brake is automatically applied after the
truck has been stationary for 4 seconds.
The service brakes are of the oil immersed disc type. The
parking brake is fitted to a disc mounted at the drive axle
differential.
The service brake is controlled by a valve fitted under the
service brake foot pedals.
 TECHNICAL DESCRIPTION
Working and steering hydraulics
The working and steering hydraulic systems are
supplied by two variable displacement pumps fitted
to the transmission drive. With the truck stationary
and no working or steering function selected, pres-
sure in the pump control system is maintained
between 30 and 50 bar.
The flow selection, steering priority and hydraulic
control valves for the boom and container handler
are mounted under the transmission covers on the
right-hand side of the chassis. They are operated by
the central control lever (joystick) and switches
mounted on the driver's control centre and the
steering hand pump.
During operation, the steering system is given pri-
ority over the other working hydraulic functions
selected as demand requires. When there is no
steering demand, all steering pump delivery is
357 804 25 01 GB 0104
diverted, if required, to the working system. Pres-
sure relief valves are fitted in all hydraulic circuits
for system safety.
Telescopic boom
The telescopic boom comprises two square section tubes.
It is raised and lowered by two single-acting hydrau-
lic lift cylinders fitted between the chassis and the
boom, and it is extended and retracted by a double
acting hydraulic cylinder fitted 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 fitted to the outer section, with the head of
the inner section having bearings for the handler
turntable and levelling cylinders.
The hydraulic service lines to the lift and extension
cylinders have lock valves fitted to prevent sudden
lowering of the boom upon loss of hydraulic pres-
sure.
The extension cylinder is attached to the inner and
outer boom sections.
Handler
The container handler has a hydraulic rotator and a
spreader beam assembly. The hydraulic rotator is
attached to the boom by bearings fitted at the
turntable top plate. Two hydraulic brake drive units
are fitted on the turntable top plate and both units
are meshed to a slewing gear fitted on the turntable
bottom plate.
The spreader beam has a centre section manufac-
tured from two square tubes in which the beam
extensions slide.Two hydraulic cylinders for ex-
tending 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 fitted 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
fitted 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 fitted in each end of
the cross beams. They engage in the corner cast-
ings 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 fitted 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 flags are fitted to the rear
twistlocks to show the positions. Interlock switches
cut out the boom lift function if all four twistlocks are
not locked properly.
DESCRIPTION
Safe load system
The truck safety system uses sensors fitted 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.
If hazardous operating conditions are detected, the
yellow indicators illuminate progressively as the
condition becomes less safe.
If unsafe operating conditions occur, the red indica-
tors illuminate and the safety system prevents fur-
ther unsafe operation. Any further movement of the
boom or handler is allowed only if it gives a safe
load state.
When the red indicators illuminate an audible buzz-
er sounds within the cabin.
A second buzzer is fitted 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.
11
TECHNICAL DESCRIPTION
Electrical system
The truck has a 24 V DC electrical system supplied
by the alternator
alternator.. Two 12 V 143 Ah heavy-duty
batteries connected in series are fitted in the left-
side chassis compartment beside the air filter. A
battery isolator facility is included with safety in
mind, as well as acting as an anti-theft device.
The truck is fitted with basic road lighting, including
sidemarker and tail lights, headlights, stop lights
and turn indicator lights, and reverse warning buzz-
er. The working lights, 8 chassis, 4 boom, are fitted
to illuminate the area around the truck.
DESCRIPTION
Automatic lubrication system*
around the truck (as indicated below - .
The truck is fitted with an electrically operated automatic
lubrication system which supplies grease to key points
).
Measured quantities of new grease are supplied at regular
pre-programmed timed intervals to ensure efficient opera-
tion of wear pads, bearings etc..
Indicator lights are fitted inside the drivers cab
which inform the operator of the status of the lubri-
cation system.
* option

Safety systems and shut down devices

The truck is equipped with safety and shutdown
systems which monitor mechanical defects, brake
operation and handler operating safety.

357 804 25 01 GB 0104

The mechanical defect system senses abnormal
temperatures and pressures in the engine and
transmission lubricating and cooling systems. If
abnormal operating conditions occur, the central
system warning light illuminates, together with the
appropriate system warning indicator and the en-
gine will revert to low idle.
The truck has a fail-safe brake, which will stop the
truck or not allow movement if the hydraulic pres-
sure in the braking system is low. Under low pres-
sure conditions a warning buzzer sounds in the
driving cab and the central system fault warning
light illuminates.

12
 DESCRIPTION GENERAL VIEW
1 Lift cylinder

2 Boom

3 Boom extension cylinder

4 Levelling cylinder 2 3
5 Rotator head 1

6 Indicator lights 20
4
7 Container handler

8 Transmission cover 5
6
7
9 Drive axle

10 Transmission 8
357 804 25 01 GB 0104

19
11 Variable displacement pumps
18
17
12 Engine
16 9
13 Exhaust system 15
14 Steer axle

15 Cooling system radiator

16 Bonnet

17 Heater / Climate control* system

18 Air intake system

10
12 11 21
19 Driver's cab 14 13
2 0 Fuse and relay box

21 Battery and air filter access door

13
GENERAL VIEW OF CONTAINER HANDLER DESCRIPTION
1 Inner boom

2 Levelling cylinder

3 Rotator drive motor

4 Handler electrics box

1

5 Spreader contre beam

6 Sideshift sliding bearings

2
7 Sideshift cylinder

8 Twistlocks

9 Extension sliding bearings 3

10 Twistlock guides 15
4

357 804 25 01 GB 0104

11 Handler extension 14
12 13
12 Hydraulic system control valves 5

13 Rotator gearbox
11
14 Rotator brake

15 Handler mounting pin

6
7

10 9

14
 CONTROLS AND INDICATORS
1 Left-hand display unit (LHD)

2 Electronic gear shift control lever (EGS)

3 Central system fault warning lamp

Up

4 Steering wheel F1 F2 F3
Dn

Esc
6

5 Load safety system indicator panel

7
6 Twistlock Indicator panel (TI) 5

7 MDM display screen

8 Multiple function electrical control lever

9 Ignition key switch

8
357 804 25 01 GB 0104

2 3 4
10 Right-hand display unit (RHD)

11 Central control lever (joystick)

1 9
12 Driver's control centre DCC
F

13 Parking brake switch N

R 10

14 Hazard warning light switch 11

15 Emergency shutdown switch 12

16 Emergency override key 13

17 Heater control 14

18 Accelerator pedal 19 18
15
19 Service brake pedals

17

16

15
GAUGES, SWITCHES AND WARNING LIGHTS
Left-hand control panel (LHP)
LHP RHP
1 Left hand panel 1
2 Headlamp main beam indicator light 1
3 Turn indicator warning light
4 Headlamp switch
5 Headlamp switch 2
6 Parking brake warning light
7 Low fuel warning light
8
8 Battery charge warning light

Right-hand control panel (RHP)

7
1 Right hand panel
2 Truck status display 6
3

Steering column (SC) 5

357 804 25 01 GB 0104

4
1 Electronic gear shift control lever (EGS) 2
2 Central system fault warning light SC
2
3 Multiple function electrical control lever

NOTE
A warning buzzer will sound if brake system
hydraulic pressure is low.

F
N
R

1
3

* Option

16
 GAUGES, SWITCHES AND WARNING LIGHTS
Driver's control centre (DCC)
1 Central control lever (joystick) LSSP
DCC
2 Twistlock switch
2
3 Top screen wiper and washer switch
4 Rear screen wiper and washer switch 1
5 Parking brake button Up

Dn

6 Hazard warning indicator light switch

F1 F2 F3 Esc

3
7 Override switch 4
8 Emergency stop button 5 2
1
Load safety system panel (LSSP) 6
1 Load state indicators
7
Note:
A warning buzzer will sound if maximum
load / position is approached (red
illuminated LED 's)
LED's)
357 804 25 01 GB 0104

2 MDM display screen 8

Twistlock indicators (TI)

2
1 Cab indicator lights
2 Boom indicator lights Up
TI CHI
3 Flag indicators on handler F1 F2 F3
Dn

Esc

3
Combi-Handler indicators (CHI)
1 2
1 Handler indicator lights
2 Boom indicator lights

Cab rear bulkhead (CRB 1) 1

1 Climate control unit
CRB 1
2 Fan speed switch 1
3, 4 Temperature regulation switches 2 3
5 Climate control switch
4

* option

17
GAUGES, SWITCHES AND WARNING LIGHTS
Indicator
Headlight main beam indicator light (LHP, 2)
Turn Indicator light (RHP, 3)
Headlight switch (LHP, 4)
Headlight switch (LHP, 5)
Parking brake warning light (LHP, 6)
Low fuel warning light (LHP, 7)
Battery charge warning light (LHP, 8)
Truck status monitor (RHP, 2)
Electronic gear shift control lever (SC, 1)
Central system fault warning light (SC, 2)
Multi-function electrical control lever (SC, 3)
* Option
18
Purpose Possible Cause(s)
Illuminates to indicate main beam headlight is on.
Illuminates to indicate turn indicator light is operating.
Toggle to switch on the spotlights.
Toggle to switch on the spotlights.
Indicates parking brake is ON.
Indicates low fuel
Indicates the battery state of charge.
- Drive belt broken or slack.
- Cable(s) broken.
- Alternator faulty.
- Regulator or relay faulty.
357 804 25 01 GB 0104
- Contact your authorised dealer.
Indicates gear selected, fuel level, load weight, boom
position, elapsed hours, etc.
Used to select required gear
Illuminates to inform the operator that a fault has been
When illuminated, check warning light in ques-
detected, and remedial action may be required.
tion on the control panels.
For switching on horn, lighting and turn indicator light.

Indicator
Central control lever (joystick) (DCC, 1)
Twistlock switch (DCC, 2)
Top screen wiper and washer switch (DCC, 3)
Rear screen wiper and washer switch (DCC, 4)
Parking brake switch (DCC, 5)
Hazard warning indicator light switch (DCC, 6)
Overload safety switch (DCC, 7)
Emergency stop button (DCC 8)
Load state indicators (LSSP, 1)
357 804 25 01 GB 0104
MDM Display screen (LSSP, 2)
Cab indicator lights (TI, 1)
Boom indicator lights (TI, 2)
Flag indicators on handler (TI, 3)
Climate control (CRB1)
Fan speed switch (CRB 1-2)
LCD display (CRB 3)
Temperature setting display (CRB 4)
Quick air conditioning switch (CRB 5)
* Option
GAUGES, SWITCHES AND WARNING LIGHTS
Purpose Possible Cause(s)
For operating lift/lowering and boom extend/retract.
For operating twistlocks.
For turning on top screen wiper and washer.
For turning on rear screen wiper and washer.
For applying the parking brake.
For turning on the hazard warning flashers.
For overriding the overload inhibitor.
Push button to stop machine in emergency. Pull to restore
system, restart using ignition switch.
Graduated led display indicates status of machine loading
Top field shows actual load in kg.
Bottom field shows maximum admissible load.
Indicate truck load status, boom position, engine speed etc..
Lamp (1) illuminated red, no flag (3) visible - twistlock not
seated, not locked. Red lamp illuminated, warning buzzer sound-
Lamps (1, 2) illuminated red and yellow, no flag (3) visible ing - operation not safe, load/truck combina-
tion not stable.
- twistlock seated, not locked.
Lamps (2, 3) illuminated yellow and green, flag (3) visible Yellow lamp illuminated - approaching unsafe,
- twistlock seated, locked. unstable condition.
Lamps (1, 3) illuminated green, flag (3) visible twistlocks Green lamp illuminated - safe lift condition.
locked- load raised, no load on sensor. Static load display
Turn dial clockwise to increase heat/ anticlockwise to
decrease heat.
3 position / two speed fan switch, toggle to position.
Turn switch to desired postion.
Select temperature setting required.
Press switch - activates air conditioning / deselect heater.
Push switch again to revert to heating.
19
SAFETY RULES
Wind Speed
WARNING
Exercise care when operating your machine in
wind velocities of 6 (24 knots/28 mph or
45 km/h) or greater, handling characteristics
may be affected, specifically, high lifting and
lowering operations. Further information
should be sought from the manufacturer, your
authorised distributor, or local statutory
authorities
Operator Safety
The responsible persons, particularly the truck operator
and servicing personnel, must be instructed in the safety
rules for the normal and proper use of trucks included with
these operating instructions.
The employer must ensure that the operator has under-
stood all safety information.
Please observe the guidelines and safety rules therein for
example:
- information on the operation of Reach stackers
- rules for roadways and work areas
- rights, duties and safety rules for the operator
- operation in special areas
- information related to starting, driving and braking
- service and repair information
- recurrent inspections, accident prevention check
- disposal of greases, oil and batteries
- remaining risks.
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 Reach stacker
- optional attachments
- special operating and working area characteristics,
by training and practising driving, shifting and steering
operations until they are completely mastered.
Only then start to train for stacking operations.
In case of tip-over
! Follow these Stay
WARNING Instructions buckled up
20
The stability of the truck in the work area is ensured if
employed properly.
Should the truck tip over during an unauthorised applica-
tion or due to incorrect operation, always follow the in-
structions depicted below.
Safety precautions
The precautions WARNING, CAUTION, ATTENTION
and NOTE in this manual are provided to indicate
special dangers or unusual information requiring
special identification:
WARNING
Indicates hazards that may result in personal
injury or death and/or substantial damage to
the product.
CAUTION
Indicates hazards that may result in personal
injury and/or substantial damage to the pro-
duct.
ATTENTION
Indicates hazards that may result in damage to
or destruction of the product.
This note is found on various positions of
the truck where special attention is re-
quired. Read the appropriate section of
your operating instructions.
NOTE
Identifies technical information requiring spe-
cial attention because the connection may not
even be obvious to skilled personnel.
Don't jump Hold on tight Brace feet lean away
Handling fluids and lubricants
Always handle fuel, lubricants and coolant as required and
as specified by the manufacturer.
Only store fluids and lubricants in approved containers at
specified storage places. As they could be inflammable, do
not allow contact with hot objects or a naked flame.
Follow the manufacturer’s safety and disposal instruc-
tions when using fluids and lubricants and cleaning com-
pounds.
Avoid spilling fluids and lubricants. Remove any spillage
immediately with a suitable binding agent and dispose of
as specified.
Also dispose of used or contaminated fluids and lubricants
as specified.
Follow laws and regulations.
Clean the area surrounding the part in question before
lubrication, filter renewal or repairs in the hydraulic sys-
tem.
357 804 25 01 GB 0104
Only use clean containers when replenishing fluids and
lubricants.
Discard parts in a way friendly to the environment.
CAUTION
Do not allow hydraulic oil under pressure, for
example at a leak, to penetrate the skin. Med-
ical aid is required if such an injury occurs.
CAUTION
Improper handling of coolant and coolant addi-
tives puts your health and the environment at
risk.
Stored Hydraulic Energy
This machine is fitted with hydraulic accumulators on the
brake and pilot circuits. This stored energy must be de-
pleted before undertaking any maintenance work on these
circuits. This is accomplished by repeatedly operating the
brake pedal, parking brake and central control lever, with
the engine stopped and the ignition on.
WARNING:
Danger of personal injury due to high pressure
gas. Under no circumstances should the ac-
cumulators be worked on.

Operation of Reach stackers in the plant
area
ATTENTION
Many plant areas are so-called limited public
traffic areas.
We advise you to check if your company liabil-
ity insurance covers any damages occ urring
occurring
with your truck against third parties on "limited"
public traffic areas.
Diesel engine emissions
In Germany, fork trucks equipped with diesel engines must
conform to TRGS 554. According to this regulation, diesel
emissions are carcinogenic and they should, if at all
possible, not permeate the air of workplaces.
If trucks equipped with diesel engines are used in totally or
partially enclosed spaces, the labour protection authority
357 804 25 01 GB 0104
must first be notified. Appropriate notices must be posted
in the work areas (refer to TRGS 554 for an example).
Running-in instructions
The Reach stacker can be operated at full speed directly.
Avoid sustained high loads on the working hydraulic sys-
tem and the travel drive in the first 50 hours of operation.
Tighten wheel nuts daily before each shift until they are
seated firmly, 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.
Tighten wheel nuts of
wheel - mounting
- prior to starting operation
of the truck
- then every 10 hrs until
wheel nuts are settled
- after that every 100 hrs
(For torque see operating manual)
SAFETY RULES
Checks and services prior to initial operation*
- Check tyre inflation pressure
- Check tightness of wheel nuts
- Check working hydraulic system oil level
- Check brake hydraulic system oil level
- Check condition of the batteries
- Check security of electric cables, connectors and con-
nections
- Check drive axle differential oil level
- Check coolant level in radiator header tank
- Check engine oil level
- Check fluid level in washer reservoir
- Fill diesel fuel
- Check powershift transmission oil level
- Check drive axle oil level
- Check hub differential oil level (drive axle)
- Check hub oil level (steer axle)
- Steering system
- Braking system
- Spreader
Daily checks and services*
- Check tyre condition and inflation pressure
- Check working hydraulic system oil level (sight glass)
- Check brake hydraulic system oil level (sight glass)
- Check coolant level in header tank
- Check engine oil level
- Check fluid level in washer reservoir
- Check fuel level
- Check powershift transmission oil level
- Check handler for visible damage
- Check the twistlocks and warning lights for proper
operation
- Adjustment of driver's seat and seat belt
* A description of the service can also be located in the
alphabetical index.
21
BEGINNING OPERATION
Opening the cabin door from the outside
- Press button (1) on the handle (2).
- Open the door.
Opening the cabin door from the inside
- Hold the handle (3) and press lever (4).
- Open the door.
Securing the open cabin door
- Open the cab door.
- Swing door fully rearward until spring loaded
plunger (2) locks into retainer (3).
Cab Drivers Door - Closing
- Lift the 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 and press lightly until it engages.
NOTE:
Lock the cabin door with the key when leaving the
truck unattended.
Releasing and moving the cabin
- Check that the transmission cover is closed. Remove
any foreign objects from the cover.
- Raise handle lock (1) up and release stay (2).
- Pull the cabin forward using the door pillar as a
handhold.
Repositioning and securing the cabin
- Check that the bonnet is closed. Remove any foreign
objects from the truck.
- Push the cabin to the rear using the left-hand door pillar
as a handhold.
- Re-fit stay (2) and push down handle lock (1).

357 804 25 01 GB 0104

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2
1
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22

Repositioning and securing the cabin
(motorised cabin*)
ATTENTION:
Do not traverse the cab with the door
open.
To move the cab forward
- Push the cab traverse switch to the first position.
To move the cab backwards
- Push the cab traverse switch to the second posi-
tion.
NOTE
Switch is sprung and will return to the
neutral position when released.
CAUTION:
357 804 25 01 GB 0104
Exept in cases of emergency exit, move
the cab to the fully rearward position be-
fore exiting. Walkways, steps and hand-
rails should be used whenever possible.
*option TL models
Opening the bonnet
CAUTION
The bonnet opens forward leaving open ac-
cess to the engine compartment from both
sides of the truck.
CAUTION
The bonnet is raised by gas-filled struts, which
operate as it is released. Ensure that the cabin
is moved forward far enough to allow the bon-
net to open vertically.
- Unlock the cab and move it forward.
- Insert the key (1) and turn it fully anticlockwise (two
locks).
- Lift the bonnet (3) with the handles (2).
Closing the bonnet
- Pull the bonnet (3) down against gas strut pressure.
- Insert the key (1) into the lock and turn it fully clockwise.
- Reposition and secure the cabin.
2
1
3
BEGINNING OPERATION
Opening the transmission cover
CAUTION
The transmission cover opens forward by gas-
filled struts, leaving open access to the trans-
mission compartment.
ATTENTION
Open the transmission cover before moving
the cabin if working with both the bonnet and
transmission cover open.
- The cab must be moved back.
- Insert the key (1) and turn it fully anticlockwise (two
locks).
- Lift the cover (3) with the handles (2).
Closing the transmission cover
- Pull the transmission cover (3) down against gas strut
pressure.
- Insert the key (1) into the lock and turn it fully clockwise.
2
23
BEGINNING OPERATION
Opening the cabin rear compartment door Opening the working hydraulic system oil Opening the brake hydraulic system oil tank
- Release the catches (1 and 2) on the door (3). tank cover cover
- Open the door under control until the strut (4) engages. NOTE NOTE
The cover is located on the right-hand side on top of The cover is located on the left-hand side under
Closing the cabin rear compartment door the chassis. the platform.
- Raise the door (3) until the strut (4) disengages, then
- Check that the cover (1) is free from obstruction. - Check that the cover (1) is free from obstruction.
close it.
- Insert key (2) into lock (3) and turn anticlockwise to open - Insert key (2) into each lock (3) and turn anticlockwise
- Push the door inward until the catches (1 and 2) engage.
the lock. to open the lock.
- Raise the cover. - Raise the cover.

NOTE NOTE
Cover is free standing and not retained, free to fall. Cover is free standing and not retained, free to fall.
Cover can be lifted and removed for safety. Cover can be lifted and removed for safety.

Closing the working hydraulic system oil Closing the brake hydraulic system oil tank
tank cover cover

357 804 25 01 GB 0104

- Check that all tank covers and fillers are closed. - Check that all tank covers and fillers are closed.
- Lower the cover (1). - Lower the cover (1).
- Insert key (2) into lock (3) and turn clockwise to close the - Insert key (2) into lock (3) and turn clockwise to close
lock. the lock.

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24

Opening the battery and air filter compart-
ment door
- Check that door (1) swing area is free from obstruction.
- Insert key (2) and turn anticlockwise to open the lock.
- Pull door open and turn it fully back.
Closing the battery and air filter compart-
ment door
- Check that door (1) swing area is free from obstruction.
- Close door, turn key (2) fully clockwise and remove key.
357 804 25 01 GB 0104
Opening the electrical box cover
- Check that door (3) swing area is free from obstruction.
- Insert key (1) into lock (2) and turn anticlockwise to open
the lock.
- Pull door open and turn it fully back.
Closing the electrical box cover
- Check that door (3) swing area is free from obstruction.
- Close door, insert the key (1) into lock (2) and turn fully
clockwise and remove key.
BEGINNING OPERATION
Isolating the battery
NOTE
In case of an electrical fire 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.
- To isolate the battery rotate the isolator handle (1) fully
anti clockwise and remove.
- To reconnect the battery insert key and rotate the isola-
tor handle (1) fully clockwise.

1 3
1

2
_ +

ISOLATOR

2
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25
 BEGINNING OPERATION
Opening the fuse box cover Daily pre-operational checks and services
- The fuse box is situated inside the cabin, to the Check tyre condition and inflation pressure Tyre specifications - drive and steer axle
rear of the driver's seat.
ATTENTION C4230 TL C4234 TL, C4531 TL, C4026CH,
- Check that fuse box door (1) lowering area is free Low tyre pressure reduces the tyre service life C4030 CH
from obstruction. and the stability of the truck.
Front 1 8 . 0 0 x 2 5 / 4 0 P R .......................... 10.0 bar
- Insert key (2) into lock (3) and turn anticlockwise - Check tyres for damage and wear.
Rear 18.00x25/40PR .................................. 10.0 bar
to open the lock.
- Remove any foreign objects from the tyre tread.
- Lower the door to open. C4535 TL, C4531 CH
- Check the tyres for the specified inflation pressure. Front 18.00x33/40PR .................................. 10.0 bar
Closing the fuse box cover
- Adjust the air according to the specifications on the Rear 18.00x33/40PR .................................. 10.0 bar
- Check that door ((1
1 ) raising area is free from ob- stickers (1).
struction.
- If necessary, add air at the filler valves (2). Drive axle,
- Close door ((11 ), insert key ((2
2 ) into lock ((3
3 (and two valves each side; steer axle, one valve each wheel.
turn fully clockwise.

357 804 25 01 GB 0104

1

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26

Daily pre-operational checks and services
Check working hydraulic system oil level
CAUTION
Follow the precautions for handling fluids and
lubricants. The hydraulic oil and tank may be at
operating 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 oil level at sight glass (3) situated on the right
side of the chassis.
- If required, replenish with hydraulic oil to the high mark
on sight glass (3).
- Open tank cover.
- Rotate breather cap (1) slowly until escaping air is no
longer heard.
- Remove filler cap (2).
357 804 25 01 GB 0104
- Fill to upper level in sight glass (3).
- Refit filler cap (2) and close tank cover.
2
BEGINNING OPERATION
Check the brake hydraulic system oil level
CAUTION WARNING
Follow the precautions for handling fluids and The oil level must not drop under the low mark-
lubricants. The hydraulic oil and tank may be at ing, otherwise the brake may malfunction.
operating 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 oil level at sight glass situated on the right side
of the chassis (4).
- If required, replenish with hydraulic oil to the high mark
on sight glass (4).
- Open tank cover (2).
- Remove filler cap (3).
- Fill to upper level in sight glass (4).
- Refit filler cap (3) and close tank cover (2).
3
2
27
BEGINNING OPERATION
Daily pre-operational checks and services
Check coolant level in radiator header tank
CAUTION
Do not remove the header tank cap when the
radiator is hot or with the engine running.
Danger of scalding.
- Check that coolant level is between low and high marks.
- Remove the filler cap (1).
- If required, replenish with coolant mixture.
Check Engine Oil Level - If necessary, unscrew the filler cap (2) on the en-
gine and fill engine oil as far as the high mark on
CAUTION: dipstick (1).
The bonnet opens forward leaving open access - Insert dipstick (1), refit filler cap (2) .
to the engine compartment from both sides of - Close the bonnet
the truck. Danger of injury due to slips and falls.
NOTE:
CAUTION: Filling capacity between High and Low level
The engine may be at operating temperature. marks is approximately...............................5 lts
Danger of scalding.
Total filling capacity ............................................. 17 lts
ATTENTION:
Follow the precautions for handling fluids and
lubricants.

- Refit the filler cap (1).
NOTE
In hot climates check the coolant level twice daily.
- Park the truck on firm level ground, put the parking brake
ON and stop the engine.
- Open the bonnet from the right hand side of the truck.
- Remove dipstick (1) and wipe with a clean cloth.
- Fully re-insert dipstick (1) and remove it again.

357 804 25 01 GB 0104

- The oil level should be between the High and Low
marks on dipstick (1).

2
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28
 BEGINNING OPERATION
Daily pre-operational checks and services

Check windscreen washer reservoir fluid

level
NOTE
The windscreen washer reservoir is fitted under a
flexible cover in the cab right rear bulkhead. The
reservoir should be replenished using a good
quality washer fluid/water mixed to the fluid
manufacturer's specifications.

- Lift the flexible cover (1).

- Remove the reservoir cover (2).

- Fill the reservoir to the base of the filler neck with

washer fluid/water mixture.
357 804 25 01 GB 0104

- Fit the reservoir cover (2).

- Fit the flexible cover (1).

29
BEGINNING OPERATION
Daily pre-operational checks and services
Checking the fuel level
- Turn the ignition key (1) to position II.
- Check the fuel level displayed on truck status
monitor (2) on the right-hand instrument panel
(RHP).
- If necessary, fill the tank with diesel fuel.
Filling fuel
CAUTION
Stop the engine before filling fuel. No smok-
ing or naked lights when filling fuel. Do not
spill or allow fuel to contact hot parts. Follow
local regulations for handling of diesel fuel.
ATTENTION
Do not allow the fuel tank to run dry to
prevent damage to the fuel injection
system.

- Turn the ignition off.

- Open the fuel tank filler cap (1) located in front of
the left-hand rear wheel.
- Fill the tank with clean diesel fuel.
- Fit fuel tank filler cap (1).

357 804 25 01 GB 0104

NOTE
Maximum fuel capacity ............................ 450 L

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30

Daily pre-operational checks and services
Checking the transmission oil level
CAUTION
The engine must be running when mak-
ing the oil level check. Ensure that the
truck is parked on firm level ground with
the parking brake on and the transmis-
sion in neutral.
CAUTION
The engine and transmission will be at
working temperature. Danger of burns
and scalds. Follow the precautions for
handling fluids and lubricants.
- Start the engine and run it until the transmission
oil is at operating temperature.
- Open the transmission cover.
357 804 25 01 GB 0104
BEGINNING OPERATION
- Remove the dipstick (2) and wipe it with a clean
cloth.
- Re-insert the dipstick and remove it again.
- Check that the oil level is between the high and
low marks on the dipstick.
- If necessary, replenish oil through the filler tube
(3) up to the high mark on the dipstick.
NOTE
Capacity between high and low marks .. 10 L
- Refit the dipstick.
- Fit the transmission filler cap (2).
- Close the transmission cover (1).

- Remove the transmission oil filler cap (1) on the

left-hand chassis wall.

1
1

LL
FU
2

D
AD
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31
BEGINNING OPERATION
Daily pre-operational checks and services
Checking the handler for visible damage
- Make a visual inspection of the handler (1) for
any external visible damage.
- In particular, check the four twistlocks (2) on the
extension left and right side for damage and
wear.
- Check security of container guide brackets (3).
2
3
32
Checking the twistlocks and warning lights
for proper operation
NOTE
- Lock the twistlocks.
A container is required for this inspection. The
- The green indicator lights (6) illuminate in addi-
operation of the controls is described in the
section on the lifting device and handler. tion to the yellow indicator lights (5) and simul-
taneously the red indicator lights (4) extinguish.
The indicator flags (3) must be in the "locked"
- Turn on the ignition.
position.
- The red indicator lights (4) on the boom and in
the cabin are illuminated. - Lift the handler slightly.
- The indicator flags (3) on the handler are in the - The yellow indicator lights (5) extinguish.
"not locked" position. The handler and indicator lights function correctly.
- Position the handler over a container and lower
the twistlocks (2) into the corner castings. CAUTION
Contact your authorised dealer if one of
- The yellow indicator lights (5) illuminate in addi-
the functions and indicator lights does
tion to the red indicator lights (4) when the
not operate as described above.
twistlocks are seated.
357 804 25 01 GB 0104
Up
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 BEGINNING OPERATION
Daily pre-operational checks and services Adjusting the seat position To lower the seat cushion
Adjusting the driver’s seat - For a horizontal adjustment of the seat lift lever - Lift both levers (4 and 5) and lower the cushion
(2). to the required height.
NOTE
- Slide the seat forward or back until the desired - Re-engage the levers.
Maximum driving comfort is obtained and
position to the steering wheel, pedals and con-
vibrations are reduced by setting the seat to
the correct weight of the driver.
trol levers is achieved. Adjusting the seat cushion angle
- Re-engage the lever (2).
- Lift both levers (4 and 5) individually and raise or
Setting the driver’s weight lower the cushion to the desired angle.
Setting the seat height
- Sit down on the driver’s seat. - Re-engage the levers.
To raise the seat cushion
- Rotate the weight setting adjuster (1) until the Adjusting the seat backrest angle
driver's weight appears in the window. - Lift both levers (4 and 5) and raise the cushion to
- Weight range 50kg to 120kg. the required height. - Push the handle (3) forward and set the backrest
to the desired angle.
- Re-engage the levers.
- Re-engage the handle.

NOTE
357 804 25 01 GB 0104

Long sitting puts excessive strain on the spi-

nal column. Prevent strain with regular, light
exercising.

1
5

2
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33
STARTING THE ENGINE
Normal start
NOTE
The engine is equipped with a start-stop sys-
tem 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 con-
tact your authorised dealer.
CAUTION
If this start-stop system is activated, dis-
continue the starting procedure to pre-
vent damage to the engine.
WARNING
Danger of carbon monoxide poisoning!
Do not let the engine run in unventilated
enclosed spaces.
Starting the Engine
NOTE:
The directional lever to the left of the steering
column must be in the neutral position.
- Sit in the drivers seat.
- Insert the ignition key (1) into the preheat/starter
switch
- Turn the key clockwise to position (I). The elec-
trical 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 specifications.
- The battery charge warning light (2) on the LHP
and the engine warning lights (3) on the RHP il-
luminate.
- The red indicator lights on the mast and in the
cabin are illuminated.
- After the buzzer has stopped, turn tthe
he key clock-
BEGINNING OPERATION
Electronic control module System
The Cummins engine is fitted with an advanced elec-
tronic monitoring and fuel injection system control-
led by the ECM (electronic control module). This unit
will indicate faults or potential problems on display
screen (3).
On start up all of the lights will illuminate, and ex-
tinguish 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 in-
formation.
CAUTION
Failure to observe the warning lights
could lead to serious engine damage.

357 804 25 01 GB 0104

CAUTION wise to position (III).
Do not operate the starter with the engine - As soon as the engine starts, release the ignition
running to prevent damage to the engine key.
and starter. - The battery charge warning light (2) and the en-
gine warning lights extinguishes.
0 I
NOTE:
II

If the engine does not start after 20 seconds,

wait at least 1 minute before repeating the
III

starting procedure. If the engine fails to start

after the third attempt or the engine oil pres-
sure warning light does not extinguish, check
the viscosity of the lubricating oil, the fluidity
of the diesel fuel and the battery charge lev-
els against the recommended values.

34
 BEGINNING OPERATION
ATTENTION
On start up, the truck must always be in
neutral. If forward or reverse gears are
selected before switching on the ignition,
startup is islolated, and the truck cannot
be started.
357 804 25 01 GB 0104
STARTING THE ENGINE, COLD START, STOPPING THE ENGINE
Cold Start
- Turn the ignition key (1) to position II and hold it
there for 15 - 20 seconds.
- Fully depress the accelerator pedal (4).
- Turn the key (1) clockwise to position (III).
- As soon as the engine starts, release the accel-
erator pedal and return the key to position (II).
- Maintain the key in position (II) until the engine
oil pressure warning light extinguishes.
- The battery charge warning light on display (2)
extinguishes.
- Release the ignition key.
NOTE:
Do not warm up the engine at idle speed. Al-
ways allow time for the engine to warm up
before using maximum speed, especially in
cold climates. The engine will attain its oper-
ating temperature after running briefly with a
moderate load and at various revs.
2 3
Stopping the engine
NOTE
Do not stop the engine at full speed, allow to
idle for a short while before shutting off.
- Release the accelerator pedal (4).
- Bring the truck to a controlled stop.
- Press the parking brake button (3).
- Shift the electronic gear shift control lever to
neutral and let the engine idle for two minutes to
achieve a temperature balance.
ATTENTION
With engines fitted with a turbocharger
there is also the danger of the shaft bear-
ing running dry and becoming damaged
due to the high speed of the turbocharger
shaft (approx. 100,000 rpm at full speed).
- Turn the ignition key (1) anticlockwise to the zero
position.
- Remove the ignition key when leaving the truck.
35
MALFUNCTIONS BEGINNING OPERATION
Malfunctions during operation
CAUTION
If a fault is detected and displayed on
the LHP indicators or the truck status
display screen, stop the engine immedi-
ately and eliminate the
malfunction.

Examples of faults detected;

- Low Battery voltage
- Low Battery charge
- Engine coolant temperature
- Air cleaner restriction
- Hydraulic oil temperature
- Brake oil temperature
- Engine oil pressure
- Coolant temperature

357 804 25 01 GB 0104

- Low oil pressure in brake system

36
 BEGINNING OPERATION
Load safety system
The load safety system monitors the load state of
the truck continuously whenever the electrical sys-
tem is energised and gives visual indication of the
load safety state.
WARNING
The load safety system is installed for
operating safety and it prevents the Reach
stacker from getting into an unsafe, dan-
gerous position. If safety is reduced be-
fore and during operation, the system
cuts out the handler lowering and boom
extension functions.
NOTE
The load safety system operates continuously
and it indicates the load state with the illumi-
nation of green, yellow and red LEDs when the
truck is operating.
The driver must heed the indications of the
load safety system and move the load if
necessary or change the travel mode to achieve
a safe load state.
LOAD SAFETY SYSTEM
Start-up indications
The load safety system has an automatic self-test
function, which operates whenever the truck electri-
cal system is energised. After a successful self-test
(duration approx. 10 sec), the green LEDs will
illuminate.
WARNING
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 horn. Contact your authorised deal-
er in case of defect.

Operating the 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.
357 804 25 01 GB 0104

switc (1) may only be used by

The overload safety switch
authorised persons who can estimate and bear
responsibility for the safety risk when lowering the
load.
Up

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37
LOAD SAFETY SYSTEM
Working indications
The display unit (1) indicates the state of the load
depending on the weight of the container and the
position of the boom, the LEDs light up green,
yellow or red. The weight of the container and the
position of the boom is also displayed on the MDM
display screen (2).
LEDs Green - Load Centre "Normal"
LEDs Yellow - Load Centre "Critical"
LEDs Red - Load Centre "Danger Zone"
NOTE
During operation the load safety system will
give the driver the following indications on the
load safety system panel.
- If the Reach stacker is operated within safe load
states, the green LEDs on the load safety system
NOTE
As the load increases or the load state moves
towards an unstable attitude, more green
indicator lights will illuminate and the values
in display (2) will change. An audible buzzer
will sound whenever the load exceeds 70% of
the trucks capacity at the given boom position,
and, when the boom is extended more than
930 cms.
- When an operation is approaching the safe limit,
the yellow indicator LEDs will illuminate on the
LSSP. More yellow LEDs will illuminate as the
operation becomes less safe.
- When the load state reaches the extent of the
safe limit, all the red and yellow LEDs will illumi-
nate and the warning buzzer will sound.
OPERATION
THE LOAD SAFETY SYSTEM WILL PREVENT
ANY FURTHER MOVEMENT OF THE LOAD
EXCEPT TOWARDS A SAFE ATTITUDE.
THE BOOM CAN BE RETRACTED.
Lowering the handler after shutoff
WARNING
The overload safety switch (1) may
only be used by authorised persons.
- Insert the key into the overload safety switch
(1) at the console (2), turn clockwise and
hold it.
- Push the central control lever (joystick) (3)
forward to lower the handler.

357 804 25 01 GB 0104

panel are illuminated. - Release the overload safety switch (1).
- The maximum safe load and the actual load in kg
is indicated in MDMdisplay screen (2). As the load is moved towards a safe attitude,
the red and yellow LEDs will extinguish in turn
and the warning buzzer will shut down.
Up

Operation of the handler with the central con-

Dn

F1 F2 F3 Esc

trol lever (3) is possible again.

- Remove the key from the overload safety

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38
 OPERATION
Truck status display screen
- The truck status display screen (1), incorporates
a graphics LCD with five ‘soft’ keys (2), mounted
at the bottom of the LCD.
- Associated with the ‘soft’ keys (2), is a graphi-
cal menu structure that uses easy to understand
icons to indicate the key’s current function. This
enables the operator to select the required en-
gine data and display it in the following formats:-
· Analogue gauges
· Digital data
· Graphs
· Multi-data (a combination of the above)
· Current active alarm messages
TRUCK STATUS DISPLAY SCREEN
After power is applied the start-up screen shown
below will be displayed for approximately 7 seconds.
If the unit bleeps with a low-pitched tone, the self-
test has failed. Contact you authorised Linde deal-
er.
Once the self-test is complete, the display will change
to show the default engine data screen.
Should the screen (1), need adjusting to improve
legibility, press the blue key (3), to select the Con-
trast and lighting menu. The setting of brightness
and contrast is described in greater detail on page
40.
The truck status display screen will now start dis-
playing readings on the gauges shown on the LCD
screen.

Additionally, various diagnostic screens are acces-

357 804 25 01 GB 0104

sible, allowing detailed investigation of the engine’s

status.

1
1

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39
TRUCK STATUS DISPLAY SCREEN
On power-up the truck status display screen per-
forms a series of self-test routines. The progress of
these is shown in the lower right-hand corner of the
display. In the unlikely event of a fault occurring the
unit will emit a low-toned bleep. Should the fault
persist please contact your authorised Linde deal-
er.
Following successful self-test, truck status display
screen will commence to display engine data using
the configuration settings held in its non-volatile
memory.
Press any of the four grey keys (key 1 to key 4) to
make the menu bar visible on the LCD. Press the
key below the relevant icon to select a display mode.
A folded page icon with an arrow on the page indi-
cates that pressing the associated key will step
through the various displays associated with a par-
ticular display format.
OPERATION
Setting Display Contrast and Lighting
Pressing the right-hand blue key (5) when the menu The contrast and lighting menu is exited by
icons are not on display will bring up the lighting pressing key 5.
and contrast menu. The chosen settings are stored in non-volatile
The LCD has four back-light levels that allow the memory and will be automatically reinstated
display to be read in the dark. The appropriate level whenever the truck status display screen is pow-
is selected by pressing key 1 to decrease the illumi- ered up. 1
2
4
3
nation or key 2 to increase it.
Adjusting the contrast of the LCD to an optimum level
ensures that the display is clearly legible and that
grey-scales are appropriately displayed. Contrast is
reduced by pressing key 3 (which will tend to light-
en the display) and increased by pressing key 4
(which will tend to darken the display).

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The menu bar will disappear after approximately five
seconds of key inactivity.

Some of the displayed data can be customised to

show, for example, metric or imperial units. In ad-
dition, it is possible for the user to define the full-
scale reading of several gauges to suit the engine
in use. Use of the configuration menu is described
in more detail on page 41.

1 2 3 4 5

40
 OPERATION
Using the Soft Keys
The use of ‘soft’ keys vastly simplifies the truck dis-
play screen operator interface by ensuring the user
is only presented with active keys that are appropri-
ate to the current function. This is achieved by us-
ing the LCD to display icons that represent the cur-
rent function of each key. Positioning the icons above
the appropriate key allows each key’s function to
change whilst ensuring that the operator is always
presented with a clear and unambiguous under-
standing of what each key-press will do.
TRUCK STATUS DISPLAY SCREEN
The Main Engine Display
This display incorporates three independent win-
dows and is intended to show the most important
and frequently accessed engine data.
To select the main engine display, press any of the
four grey keys to show the top-level menu icons and
then press key 1 (the left-hand key).
The main window, at the top of the display, shows
two gauges; engine rpm on the left and speed on
the right.
The window at the bottom-left of the display gives
access to the fuel computer data and is similar to
an automotive in-car fuel computer. Various param-
eters can be displayed by repeated presses of key 1
(the left-hand key) which sequentially steps the win-
dow through the displays shown below.
NOTE
Fuel data parameters can only be shown if
the required data is being received from the
engine.

NOTE
If speed data is not available the right-hand
gauge will display engine oil pressure.
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The window at the bottom-right of the display shows

the coolant temperature.

41
TRUCK STATUS DISPLAY SCREEN
Instantaneous Fuel Rate
The instantaneous fuel rate received from the en-
gine displayed as a volume per hour.
Average Fuel Rate per hour
If total fuel consumption and fuel rate are being
received then the average will be calculated since
the last trip fuel and trip hours reset. This is dis-
played in units of volume per hour.
Average Fuel Consumption per distance
If vehicle speed is being received then the average
will be calculated since last trip fuel reset. This is
displayed in units of volume per distance.
Trip Fuel
If total fuel used is received from engine then this
will be calculated since the last reset.
42
OPERATION
Engine Hours The Quad Display
This display gives the user quick access to three
Total engine hours received from engine. screens, each displaying four gauges. The first
screen shows four digital gauges, whilst the sec-
ond and third screens each show four analogue
gauges. Example displays are shown below.
To select the quad display, press any of the four
grey keys to show the top-level menu icons and then
press key 2.
Trip Engine Hours
Engine hours since last reset. Calculated from To-
tal Engine hours.
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To carry out a ‘reset’ for each resetable fuel com
puter parameter allow the menu bar to disappear
and press and hold key 1 for at least 3 seconds.
NOTE
If the menu bar is not allowed to disappear
then the display will move to the next param-
eter before the ‘reset ’.
‘reset’.
 OPERATION
The screens are displayed sequentially in response
to repeated presses of key 2.
Using the adjust mode, each individual gauge dis-
played on the screens can be configured by the user
to show a different engine parameter selected from
an extensive list. The adjust mode is entered by
pressing key 5 when the truck status display screen
is running in quad display mode and the menu is
visible (if the menu isn’t visible, simply press any of
the grey keys to make it re-appear).
In adjust mode, the menu will appear as shown be-
low:
Pressing key 1 will cycle the top-left display through
all available engine parameters, key 2 will cycle the
top-right display etc. The adjust mode is exited by
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pressing key 5.
For a list of engine parameters that can be displayed
see page 44.
Quad 1 Quad 2
Quad 3 Quad 4
TRUCK STATUS DISPLAY SCREEN
The Graph Display
The graph display shows data trends in one large The maximum and minimum values of the Y axis
window and is analogous to a traditional data plot- (defining the span of readings displayed) are ad-
ter. justed automatically to give the optimum view of the
visible data.
This mode is selected by pressing any of the four The data to be displayed can be selected by repeat-
grey keys to show the top-level menu icons and then edly pressing key 3 whilst in the graph display mode.
pressing key 3.
For a list of engine parameters that can be displayed
Data is shown in graph form, with the most recent see page 44.
data scrolling from the right of the display towards
the left. The viewed time range can be adjusted in
the configuration menu from 2, 10 or 30 minutes up
to 1, 2, 4 or 8 hours.
43
TRUCK STATUS DISPLAY SCREEN OPERATION
The Quad and Graph Parameters

Following is a list of engine parameters that can be

displayed in the Quad and Graph screens:-
Parameter Quad Graph Icon
a) Engine Speed (rpm) 9 9

b) Coolant Temperature 9 9

c) Battery Voltage 9 9

d) Turbo Pressure 9 9

e) Coolant Pressure 9 9

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f) Fuel Pressure 9 9

g) Engine Oil Pressure 9 9

h) Transmission Oil Pressure 9 9

i) Transmission Oil Temperature 9 9

j) Exhaust Temperature 9 9

k) Engine Oil Temperature 9 9

l) Inlet Manifold Temperature 9 9

m) Engine Torque (actual) 9 -

n) Accelerator Position 9 -

o) Fuel Rate - 9

44
 OPERATION
The Alarm Display Screen
The truck status display screen recognises alarm
messages received from the engine via the data link.
When a new alarm is received the truck status dis-
play screen will start to beep and a flashing pop-up
window will appear with the latest alarm details.
Pressing any key will display the alarm list screen
which contains details of all previous alarms. Those
that have already been acknowledged are shown
as black text on a grey background. New alarms,
that have not yet been acknowledged, are shown as
highlighted grey text on a black background. If en-
gine hours data is available, the list will also indi-
cate the engine hours when the alarm message was
first received.
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TRUCK STATUS DISPLAY SCREEN
When first entering the alarm page the list will au-
tomatically go to the most recent alarm received. If
the list is longer than the screen size, the alarm list
can be scrolled up and down using keys 1 and 2.
The screen cannot be exited until all alarms have
been acknowledged by pressing key 3. Alarm mes-
sages will be automatically cleared from the list if
no longer received.
The alarm list screen can be viewed, at any time, by
pressing key 4.
Pop-up Messages and Warnings
When a service is due, it will display a “SERVICE
REQUIRED” message overlaying the start-up screen
which appears for seven seconds following power-
up.
Should the truck status display screen not detect
valid engine data, a flashing pop-up window will
appear displaying a “Communications Failure” icon
denoting this fault condition. Once engine data trans-
missions have been detected the pop-up window
will disappear and normal data display will contin-
ue.
45
TRUCK STATUS DISPLAY SCREEN OPERATION
1.1. Configuration
The SETTINGS sub-menu allows the truck status Selecting UNITS from the SETTINGS sub-menu
The configuration mode allows the user to set vari-
display screen to be configured according to the gives access to five parameters which can be
ous operating parameters and modes of the truck
user’s preferences whilst SYSTEM accesses main- displayed in units selected from a list. Use the
status display screen . These include such choices
tenance and low-level system configuration settings. up and down keys (key 1 and key 2) to select
as imperial or metric units, scale limits for the speed-
the required parameter, then press key 4 to cycle
ometer gauges, engine service interval etc.
through the permitted units of measurement.
Pressing key 5 returns the user to the main
The configuration menu is entered by pressing and
SETTINGS menu.
holding key 5 (the blue key) for at least 3 seconds
when the truck status display screen is in its normal
operating mode. The top-level configuration menu
will be displayed on the LCD, as shown below.

Keys 1 and 2 allow the operator to move up and

down the menu whilst key 4 enters the highlighted
menu item. Key 5 exits the configuration menu and
saves all configuration data into non-volatile mem-
ory.

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Figure 5.10.1: The top-level configuration menu and
SETTINGS and SYSTEM sub-menus.

46
 OPERATION TRUCK STATUS DISPLAY SCREEN

The LANGUAGE sub-menu allows the user to select

The DISPLAY sub-menu allows the user to define SERVICE informs the user of engine service inter-
which language truck status display screen uses to
the maximum rpm shown on the tachometer, the val so that the truck status display screen will, on
display messages and prompts. Use the up and
maximum speed shown on the speedometer and power-up, remind the operator when a service be-
down keys (key 1 and key 2) to high-light the re-
the speed with which the display scrolls when using comes due.
quired language and then press key 4 to select it.
truck status display screen in the graph display
Pressing key 5 returns the user to the main SET-
mode.
TINGS menu.

BLEEP selects whether each key press is acknowl-

edged with an audible bleep. Note that, even with
BLEEP switched off, the audible alarm will still sound
if an alarm condition occurs.
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47
OPERATION
Driving
WARNING
Exercise care when operating your ma-
chine in wind velocities of 6 (24 knots/28 mph
or 45 km/h) or greater, handling characteris-
tics may be affected, specifically, high lifting
and lowering operations. Further information
should be sought from the manufacturer, your
authorised distributor, or local statutory author-
ities
CAUTION
Travel on slopes over 15% is not allowed
as a rule due to the prescribed minimum
brake applications and truck stability char-
acteristics. 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 differ-
ences in level.
48
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 driv-
ing, 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 pos-
sible, 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 ade-
quate sight, then training should be given for
driving with these aids. Reversing with a mirror
for example, shall be exercised with particular
care.
- Start the engine.
F
N
R
DRIVING
Gear shift control
The gear control (APC 200) is an electronically controlled
system which detects truck speed through the transmis-
sion and selects the appropriate gear for a driving condi-
tion.
The system will default to second gear start (as factory
setting, first gear start is available). The anti-reverse facil-
ity prevents the transmission from engaging reverse di-
rection drive until the truck is stopped.
The operating lever is fitted to the left of the steering
column and has a dual function control lever (1),
(direction and gear selector).
The control lever has three movements, two of
which select the drive direction (fore / aft), with the
third selecting gears (rotate).
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 DRIVING OPERATION
Selecting the travel direction Moving off
Forward travel - Gently depress the accelerator pedal (3) to pre- At the preset speed the transmission will automat-
- Push the electronic gear shift control lever (1) vent jerky starting. ically select 3rd gear. Also, at the preset speed the
forward. transmission will automatically select 4th gear.
The transmission will shift into 2nd forward gear. The truck will move in the selected direction of
travel.

Reversing
- Pull the electronic gear shift control lever (1)
back.
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F
N
R
2

49
DRIVING
Slowing down and stopping
- Release the accelerator pedal (2).
- Operate brake pedal (3).
- Controlled transmission drive dump will take
place during the depression of brake pedal (3),
when the accelerator pedal (2) is depressed.
- Transmission drive is re-engaged upon depres-
sion of accelerator pedal (2).
ATTENTION:
Allow the engine to idle before releasing
the brake pedals (3). Danger of damage
to the transmission if engaged at high en-
gine speed.
At preset speed the transmission will automatically
select 2nd gear. 1st gear can only be selected
manually.
Gear selected is displayed on the MDM display
Manual 1st gear selection when stopped
when
To select forward 1st gear
- Push the electronic gear shift control lever (4) for-
(4)for-
ward.
- Rotate the gear selector knob clockwise.
Gear selection will be displayed on the MDM
display screen.
To select reverse 1st gear
- Pull the electronic gear shift control lever (4) to
the rear.
- Rotate the gear selector knob clockwise.
Gear selection will be displayed on the MDM
display screen.
When the truck is moved after manual selection of 1st
gear, the transmission will automatically shift into 2nd, 3rd
and 4th gear.
OPERATION
Preselection of 1st gear when travelling
NOTE
1st gear can be preselected for manoeuvring and on
the approach to steep gradients when travelling.
CAUTION
Do not hold the gear change lever (4) in
the rotated position after selecting the
gear. Danger of incorrect transmission
operation causing severe damage.
To preselect 1st gear
From 4th gear - Rotate the gear selector lever (4)
clockwise three times.
From 3rd gear - Rotate the gear selector lever (4)
clockwise twice.
From 2nd gear - Rotate the gear lever (4) clockwise
once.

357 804 25 01 GB 0104

screen (1). NOTE
After preselection of 1st gear the transmission
- Depress the brake pedal further to slowly stop will remain in 1st gear until speed increases
the truck. above the preset speed or until the truck is
stopped and NEUTRAL is selected. On rever-
sion to automatic gear change, 1st gear is
available only by manual selection or
Up

Dn
preselection.
F1 F2 F3 Esc

F
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3 2

50
 OPERATION
Stopping the truck
- Release the accelerator pedal (2).
- Depress the brake pedal (3) to slowly brake the
truck to a standstill.
- Press the parking brake button (3) before releas-
ing the brake pedal.
- Move the electronic gear shift control lever (4) to
NEUTRAL.
NOTE
The transmission will automatically disengage gear
when brake pedal (3) is depressed.
- Lower the handler and ground any load.
- Allow the engine to idle for at least two minutes to
stabilise the turbocharger, lubricating oil and coolant
temperatures.
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Operating the transmission dump
Operating either brake pedal (3) disconnects the
transmission from the drive and applies the brakes
in a controlled sequence.
ATTENTION:
Allow the engine to idle before releasing brake
pedal (3). Danger of damage to the trans-
mission if engaged at high engine speed.
NOTE
Active steering system is installed which
varies steering resistance dependant upon
the operation of the machine.
DRIVING, STEERING
Steering
- Start the engine and drive the truck.
- Turn the steering wheel to the left and right
through the full cycle.
Turning radius Wa .............................................. 8605 mm
NOTE
Very little effort is required to turn the steering
wheel. This is especially beneficial when op-
erating in narrow aisles. To avoid unneces-
sary tyre wear, turn the steering only when the
truck is moving.
WARNING
Contact your authorised dealer if steering re-
quires too much effort or if there is too much
play in the steering.

- Stop the engine.

- Remove the ignition key (1).

4
1

F
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3 2

51
BRAKING SYSTEM
Service brake
To operate the service brake:
- Release accelerator pedal ((22 ) and allow it to
return to its rest position.
Parking brake
The parking brake button (1) for applying the park-
ing brake is mounted in the driver's control centre
located to the right of the seat.
This is illuminated for low light recognition.
OPERATION
- During operation, should the truck become
stationary for 30 seconds or more while in gear
(forward or reverse gear selected), the parking
brake will automatically switch on.

- Depress either brake pedal ((3

3 ). - To release the parking brake, depress the park- - To release the parking brake gently depress the
ing brake button (1). Warning light (4) in RHP will accelerator pedal (2). Warning light (4) in RHP
extinguish. will extinguish

- To apply the parking brake manually, depress the

parking brake button (1) again. The warning light WARNING
(4) on the RHP will illuminate. If the braking system is becoming faulty
or worn, contact your authorised dealer.
- During operation, should the truck become Do not drive your truck with faulty brakes.
stationary for 4 seconds or more in neutral (no
gear is selected), the parking brake will automat-
ically switch on.

357 804 25 01 GB 0104

- To release the parking brake depress the parking
brake button (1). Warning light (4) in RHP will
extinguish.

F
N
R

1 4

3 2

52
 OPERATION
Turning on the lights
The light switch (2 and 3
3)) is located on the left -hand
left-hand
panel (1).
To illuminate the side marker lights:
- Push the light switch (2) to the first position.
To illuminate the side marker lights and dip beam head-
lights:
- Push the light switch (2) 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.
LIGHTING, TURN INDICATOR LIGHTS
Turning on the main beam headlights
- Push the multiple function electrical lever (6)
away from the steering wheel to illuminate the
main beam headlights permanently.
The headlight main beam indicator light (5) will
be illuminate.
- Pull multiple function electrical lever (6) towards
the steering wheel to flash the headlights
headlights..
NOTE
The main beam headlight can only be turned on
permanently when switch (2) is turned on.
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 forward.
The turn indicator warning light (4) will flash.
- For right turn indication pull the multiple function
electrical control lever (6) on the right-hand side
of the steering column to the rear.
The turn indicator warning light (4) will flash.
NOTE
To stop turn indicator lights flashing multiple
function electrical lever must be returned to its
central position manually.

To illuminate the working lights* on the handler and boom:

- Depress light switch ((3 3 ) fully.
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* Option

1
6
6

5
O I II

O I II
4

3
2

53
HORN, FRONT WIPER AND WASHER
Operating the horn
The horn is used as a warning signal at e. g. blind corners
and junctions.
- To sound the horn, press the horn button (2) at the end
of the multiple function electrical control lever (1).
Turning on the front windscreen wiper
The front windscreen wiper switch (3) is part of the multiple
function electrical control lever (1).
- For slow wiping: Turn the switch (3) from the zero
position one step back to position (5).
OPERATION
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 the switch (2).

- For fast wiping: Turn the switch (3) from the zero NOTE
position back two steps to position (4). The washer stops automatically when the switch is
released.
- For intermittent wiping turn the switch (3) from the zero
position one step forward to position (2).

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

357 804 25 01 GB 0104

2 2 3
1 1 1
2
O I II
O I II

O I II
5 4

54
 OPERATION REAR AND TOP SCREEN WIPER AND WASHER, VENTILATION AND HEATING
To Operate Rear Screen Wiper and To Operate Top Screen Wiper and To Operate the Cab Pre-heater System*
Washer Washer The cab pre-heater (1) is fitted in the cab rear right
The rear screen wiper/washer switch (2) is fitted in The top screen wiper/washer switch (3) is fitted in corner. The heater operates for 120 minutes (de-
the drivers central control panel (1). the drivers central control panel (1). fault setting).

To operate the wiper. To operate the wiper. 1 Cab pre-heater

- Push switch (2) to the first position.
To operate the wiper and washer.
- Push switch (2) all the way down and hold.
NOTE:
The washer stops automatically when switch is
released. The wiper continues to operate until the
switch is returned to the starting position.
NOTE
The wiper motor is fitted with a thermal cut-
out which, during operation, will switch off the
357 804 25 01 GB 0104
- Push switch (3) to the first position. 2 Temperature controller (rotate to increase/
decrease cab temperature)
To operate the wiper and washer. 3 Forward
- Push switch (3) all the way down and hold. 4 Backward
5 Heating (depress to activate/ deactivate heat-
NOTE: ing)
The washer stops automatically when switch is 6 Pre-selection
released. The wiper continues to operate until the 7 Clock time
switch is returned to the starting position.
NOTE
NOTE
The wiper motor is fitted with a thermal cut- The cab pre-heater must not be used indoors.
out which, during operation, will switch off the
NOTE

wipers to prevent overheating of the motor, wipers to prevent overheating of the motor,
Always shut off the heater when re-fuelling the
when the windscreen is dry. when the windscreen is dry.
truck.
*option

1
1
2
P
2
3 7 6 5 4 3

55
AIR CONDITIONING, FUSES
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.
- Switch the fan on and select required fan speed by ro-
tating switch (2).
NOTE:
The indicator display shows the current cab temper-
ature in normal operating mode.
- Temperature can be adjusted using the up/down buttons
(4).
- If cooling is required, then the air conditioning must also
be engaged by depressing the ON/OFF switch (5).
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.
OPERATION
Fuses
The truck and handler electrical circuits are protect-
ed by fuses in the fuse box (1) located in the cab.
WARNING
If fuses fail continuously, stop the truck,
ground the load and stop the engine. Do
not continue to operate with faulty elec-
trical circuits. Contact your authorised
dealer. Danger of fire and severe dam-
age to equipment.
To check the fuses, open the fuse box (1) and take
off the fuse box covers (2).
The fuses protect the following circuits:

- The display will revert to the current cab temperature,

but the controller will adjust the heating to match the

357 804 25 01 GB 0606

selected temperature.

* Optional

1
1 2 3

56
 OPERATION
Operating the hazard warning lights
The hazard warning light switch (2) is located in the driv-
er's central control panel (1).
- Push button (2) to operate the hazard warning lights.
- Push the button (2) again to turn the hazard warning
lights off.
NOTE
The indicator light in RHP illuminates.
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HAZARD WARNING LIGHTS, BOOM AND HANDLER CONTROLS
Boom and handler controls
The standard control for boom and handler is the
central control lever ((3
3 ) (joystick).
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.
Central control lever (joystick)
CAUTIO
CAUTION N Operating the accelerator pedal (1) for higher speeds
Use the reach stacker only for authorised
applications. The operator must be trained in
the handling of containers, the boom and
handler.
NOTE
The central control lever has been calibrated
The central control lever ((2 2 ) is mounted on the
driver's control centre to the right of the seat.
Always shift the control lever gently and slowly.
The control lever returns to its initial position auto-
matically when released.
NOTE
When operating the central control lever (1), the
engine speed will increase automatically to
the power required for operating the rotation,
sideshifting and telescoping the handler.
does not have any effect on the speed of these work
cycles.
The central control lever (2) is provided for lifting
and lowering, extending and retracting the boom.
The twistlocks are operated with switch (3).

to allow 5% movement in all directions before

function is activated.

1 1 3

2 3

57
OPERATING THE BOOM, SIDESHIFT
Lifting the boom
- Pull the central control lever (1) back.
Lowering the boom
- Push the central control lever (1) forward.
NOTE
Dual functions can be accessed by positioning le-
ver (1) in the mid-way position.
NOTE
The central control lever has been calibrated
to allow 5% movement in all directions before
function is activated.
Extending the boom
- Push the central control lever (1) to the right.
Retracting the boom
- Push the central control lever (1) to the left.
OPERATION
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.
- If necessary, raise the load slightly.
NOTE
The handler beam centre line is indicated by a white
fluorescent marking on the REAR face. When the
beam is central, the line coincides with a white
fluorescent centering mark on the rear face of the
rotator.
To sideshift left
- Press and hold the button (2) on the central con-
trol lever (1).

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To sideshift right
- Press and hold the button (3) on the central con-
trol lever (1).

3
2
1 1 1

58
 OPERATION ROTATING THE HANDLER
Rotating the handler Rotating the handler clockwise
CAUTION - Press and hold button (2) on the central control lever
Do not slew the handler if fouling of the load can (1).
occur. Danger of severe damage to the han-
dler.
Rotating the handler anticlockwise
- Press and hold button (3) on the central control lever
(1).

NOTE
The front face of the handler is identified by yellow
and black high visibility markings on the sideshift
bearing mountings.
The rear face of the handler is identified by white
fluorescent markings and the beam sideshift
centring marks.
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1 2
3

59
SPREADER OPERATION
Operating the beam spreader Opening the beam locks* Setting the spreader to container width 40 ft
The beam spreader opens and closes to 20 ft and 40 ft for The beamlocks close automatically at the end of a beam - Open the beam locks.
standard containers. spread operation.
- Press and hold the front of switch ((X
X ) on the
ATTENTION - Push down and hold the front of switch ((X
X) on the driver's control centre ((X
X ).
The beam spreader can not be set to intermedi- X ).
driver's control centre ((X
ate positions without beam locks. Setting the spreader to container width 35 ft*
CAUTION
Opening/closing the beam Do not attempt to open or close the beam with - Open the beam locks.
the beam locks closed.
To open the beam - Press and hold the rear of switch ((X
X ) on the
Closing the beam locks* X ).
driver's control centre ((X
- Depress and hold button (2) on central control lever (1).
- Push down and hold the rear of switch ((X
X) on the Setting the spreader to container width 30 ft*
To close the beam X ).
driver's control centre ((X
- Open the beam locks.
- Depress and hold button (3) on central control
lever (1). - Press and hold the front of switch ((X
X ) on the
driver's control centre ((X
X ).

357 804 25 01 GB 0104

Setting the spreader to container width 20 ft
*Optional TL models
* option - Open the beam locks.

- Press and hold the rear of switch ((X

X ) on the
driver's control centre ((X
X ).

2
1 3
* option

60
 OPERATION
Operating the twistlocks
The four twistlocks have electrical control circuit and me-
chanical safety features which indicate successful locking
and prevent continued operation of the handler unless all
locks function correctly.
TWISTLOCKS
When illuminated, the lamps indicate the following lock
states:
Red indicator lamps (1, 2) illuminated:
- No flags (3) set, twistlocks not seated, not locked.

There are two mechanical safety features, indicator flags Red and yellow indicator lamps (1, 2) illuminated:
(3) fitted to the lock mechanism to show if the two twist- - No flags (3) set, twistlocks seated, not locked.
locks on the rear of the handler are open or closed.
Green and yellow indicator lamps (1, 2) illuminated:
The four twistlocks are connected in series electrically by - Flags (3) visible, twistlocks seated and locked.
switches fitted on the mechanism. If any switch or combi-
nation of switches does not close when loading, the han- Green indicator lamps (1, 2) illuminated:
dler lift circuit is locked out, preventing any further move- - Flags (3) visible, load lifted (no load on SEATED sensor).
ment until the twistlocks are operated correctly. Visual in-
dication of locking is given by three indicator lamps fitted
on the handler beam (2) and in the cabin (1).
357 804 25 01 GB 0104

Up

Dn

F1 F2 F3 Esc

2
1

3
2

CH

61
TWISTLOCKS
Locking the twistlocks
- Position the handler over the corner castings of
the container.
- Slowly lower the handler so that the twistlocks are seat-
ed in the corner castings.
The yellow (7) and red (8) indicator lamps on the
handler and in the cabin illuminate.
- Depress and hold the twistlock switch (2) on the
driver's control centre (1). This will lock the twist-
locks and the indicator flags (9) will become vis-
ible.
- Simultaneously the red indicator lamps (8) will
extinguish.
- The green indicator lamps (6) will illuminate in
addition to the yellow indicator lamps (7) (7)..
The container can now be picked up with the handler and
taken to its new place. When the container is lifted, the yel-
low indicator lamps ((7 7 ) are extinguished.
OPERATION
Unlocking the twistlocks
ATTENTION The green indicator lamps (6) will extinguish. The
Do not unlock the twistlocks unless they are twistlocks are unlocked and the indicator flags
seated in the corner castings without a load and (9) are no longer visible.
if the yellow ((77 ) and green ((6 6 ) indicator - Slowly raise the handler until the twistlocks are
lamps in the cabin and on the handler are lifted out of the corner castings. The yellow indi-
illuminated. cator lamps (7) will extinguish.
- The red indicator lamps (3) will remain on.
CAUTION
Before depositing the container, make sure that
no person is standing directly in the area.
- Position the container over the place of storage.
- Slowly lower the handler so that the container is seated.
- The yellow ((77 ) and green ((6 6 ) indicator lamps on
the handler and in the cabin are illuminated.
- Depress and hold the twistlock switch (2) on the driver's
control centre until the red indicator lamps ((8 8)
and yellow indicator lamps ((7 7 ) are illuminated.

357 804 25 01 GB 0104

1
Up

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F1 F2 F3 Esc

9
6 7 8

TI

62
 OPERATION
Operating the twistlock override
WARNING
If the twistlocks cannot be unlocked due
to a malfunction, overriding is possible.
For this procedure a key (3) is required
which may only be used by authorised per-
sons.
CAUTION
Before depositing the container, make
sure that the container landing point is
clear of all personnel.
- Lower the container to the ground or onto anoth-
er container. Slowly lower the handler until the
twistlocks are loose in the corner castings.
- Insert the key (3) into the switch (4) on the left
side of the handler indicator panel (5).
357 804 25 01 GB 0104
TWISTLOCKS
Traversing the cab*
- Turn the key clockwise and hold it in this posi-
tion. The yellow indicator lamps (7) should illu- WARNING
minate in addition to the green indicator lamps The cab traverse switch (1) is located on
(6). DCC1 (1) to the right of the driver.
Simultaneously depress switch (2) on the driver's To move the cab forward
control centre (1) until the red indicator lamps
(8) illuminate in addition to the yellow indicator - Push the cab traverse switch (1) to the first posi-
lamps (6). tion.
The twistlocks are now unlocked and the indica- To move the cab backwards
tor flags (9) are no longer visible.
- Push the cab traverse switch (1) to the second
position.
- The green indicator lamps ((6
6 ) extinguish.
NOTE
Switch (1) is sprung and will return to the
- Raise the handler slowly out of the container. Do not
neutral position when released.
continue to lift if a twistlock is still closed.
CAUTION:
Exept in cases of emergency exit, move the cab
- Remove the key (3).
to the fully rearward position before exiting.

Walkways, steps and handrails should be

used whenever possible.

*option TL model

Up
Up

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F1 F2 F3
Dn

Esc
1
F1 F2 F3 Esc

3 4 5
1 2 9
6 7 8

TI

63
RAISING AND LOWERING THE ATTACHMENT LEGS
Raising and lowering the attachment legs
ATTENTION:
When operated, legs must not touch the truck
or the ground.
OPERATION
Lowering the front legs Clamping and unclamping the legs
- Push switch (3) forward, keep pressed until the lamp (5) WARNING
on the CHI (4) illuminates to indicate front legs down. Before deposting the container, make sure that
the container landing point is clear of all
Raising the front legs personnel.

The rocker switches (2,3) for raising and lowering the - Push switch (3) backward, keep pressed until the lamp The switch (2) for clamping and unclamping the legs is
attachment legs are located on DCC 1 (1). (6) on the CHI (4) illuminates to indicate front legs up. located on DCC (1).

Lowering the back legs To clamp the legs

- Push switch (2) forward, keep pressed until the legs are - Push the clamp/unclamp legs switch ((2 2) to the first posi-
fully down. tion, keep pressed until indicators - legs clamped (5) are
illuminated on the CHI (3).
Raising the back legs
ATTENTION:
- Push switch (2) backward, keep pressed until the back
Indicators (4,5) must be illuminated on the CHI
legs are fully up.
(3) before the container can be lifted.

357 804 25 01 GB 0104

To unclamp the legs
- Push the clamp/unclamp legs switch ((2 2) to the second
position, keep pressed until indicators - legs clamped
back (4) and legs clamped front (5) extiguish on the CHI
(3).

2
5
4 6
1

64
 OPERATION BEFORE LIFTING A LOAD
Before lifting a load Load safety indication and warnings
To slope pyle the spreader
WARNING All Reach stackers are fitted with a load safety warn-
The switch (2
(2)) for sloping the spreader left and right is Exercise care when operating your machine in ing system. This system gives the driver visual indi-
located on DCC (1). wind velocities of 6 (24 knots/28 mph or cation of the stability of the truck and its load at any
45 km/h) or greater, handling characteristics point during operation.
To slope pyle the spreader left may be affected, specifically, high lifting and Operational travel speed is restricted when:
lowering operations. Further information - The load being handled is 70% or more of the
- Push switch ((2
2) forward, keep pressed until the desired should be sought from the manufacturer, your capacity of the truck.
angle is reached. authorised distributor, or local statutory - The boom is extended more than 930 cms.
authorities.
To slope pyle the spreader right Before lifting a load, check the load capacity diagram be- Normal driving speeds are restored when the load
low. is less than 70% of the truck capacity, and when the
- Push switch ((2
2) backward, keep pressed until the desired
boom is retracted less than 930cm.
angle is reached.
WARNING
The values stated on the load capacity diagram
and the handler apply for standard containers
and towed loads. These values must not be
exceeded as this will reduce the stability
357 804 25 01 GB 0104

of the truck and the strength of the han-

dler.
Maximum capacity is governed by the height of lift and the
load centre distance.

000.000.00.00 Up

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F1 F2 F3 Esc

Machine Serial Number

CC

65
LOAD DIAGRAMS TL MODELS OPERATION

TL4 TL5
9'6" 8'6" 9'6" 8'6"
27t
37t 37t
25t 37t
42t
30t 42t 16t 30t 42t
C 4230 TL 16t 30t 42t
30t 42t 30t 42t 16t 30t 42t
16t 30t 42t
16t 30t 42t 16t 30t 42t 16t 30t 42t
16t 30t 42t
16t 30t 42t 16t 30t 42t 16t 30t 42t 16t 30t 42t

8'6"

357 804 25 01 GB 0104

9'6" 8'6" 9'6" 27t
37t 35t
29t 37t
42t 34t 42t
C 4234 TL 34t 42t
16t 34t 42t
34t 42t 34t 42t 16t 34t 42t 16t 34t 42t
16t 34t 42t 16t 34t 42t 16t 34t 42t 16t 34t 42t
16t 34t 42t 16t 34t 42t 16t 34t 42t
16t 34t 42t

8'6" 9'6" 8'6" 30t

9'6"
40t 35t
30t 40t
45t
C 4535 TL 35t 45t 19t 35t 45t
19t 35t 45t
35t 45t 19t 35t 45t
35t 45t 19t 35t 45t
19t 35t 45t 19t 35t 45t 19t 35t 45t
19t 35t 45t
19t 35t 45t 19t 35t 45t 19t 35t 45t
19t 35t 45t

66
 OPERATION LOAD DIAGRAMS CH MODELS

CH4 CH5

9'6" 9'6"
8'6" 33t 8'6" 21t 33t
C 4026 CH
37t 26t 40t 26t 37t 12t 26t 37t

26t 40t 26t 40t 12t 26t 40t 12t 26t 40t

12t 26t 40t 12t 26t 40t 12t 26t 40t 12t 26t 40t

12t 26t 40t 12t 26t 40t 12t 26t 40t 12t 26t 40t

9'6" 9'6"
8'6" 8'6"
357 804 25 01 GB 0104

33t 25t 33t

C 4030 CH
37t 29t 40t 30t 37t 12t 30t 37t

29t 40t 30t 40t 14t 30t 40t 14t 30t 40t

14t 30t 40t 14t 30t 40t 14t 30t 40t 14t 30t 40t

14t 30t 40t 14t 30t 40t 14t 30t 40t 14t 30t 40t

8'6" 9'6"
9'6" 31t 8'6" 26t 36t

C 4531 CH 41t 31t 41t 31t 41t 15t 31t 41t

31t 45t 31t 45t 15t 31t 45t 15t 31t 45t

15t 31t 45t 15t 31t 45t 15t 31t 45t 15t 31t 45t

15t 31t 45t 15t 31t 45t 15t 31t 45t 15t 31t 45t

67
PICKING UP A CONTAINER
Picking up a container TL model
WARNING
Do not attempt to lift a load or continue to lift if
the twist locks do not seat and lock correctly.
WARNING
No person is allowed to stand underneath the
elevated load.
- The twistlocks must be unlocked and the red indicator
lamps must be illuminated.
- Approach the container to be lifted as carefully and
accurately as possible.
- Raise and extend the boom sufficiently to allow the
handler to clear the load and intervening stacks.
- Stop the truck centred and as close as possible to the
OPERATION
- Apply the parking brake.
- Elevate the boom until the container is clear of
- Lower the handler over the load using the side-
the ground or transport vehicle.
shift and boom raise/lower and extend/retract to
land the handler on the load and position the
CAUTION
twistlocks.
The load being lifted may be unevenly
balanced, in this case use the sideshift
NOTE
function to stabilise the load.
The levelling system will automatically set the
Re-position the truck where the unbal-
handler with a 5° tilt up. As the handler is lowered on
anced load is within a stack.
the container, the levelling cylinders reset allowing
the twistlocks to enter into the front container
- Release the parking brake.
pockets first.
- Move the truck and rotate the load as necessary until it
- Lock the twistlocks.
is free of obstructions.
- Raise or lower the load to travelling height.

357 804 25 01 GB 0104

container.

20'

40'

68
 PICKING UP A CONTAINER
Picking up a container CH model
WARNING
No person is allowed to stand underneath the
elevated load.
WARNING
When operated, legs must not foul truck or
ground.
WARNING:
Do not attempt to continue to lift a load if the
legs are not seated properly (Indicators (2), (3),
(4) and (5) illuminated on the CHI (1)).
- Approach the container to be lifted as carefully and
accurately as possible.
- Raise and extend the boom sufficiently to allow the
handler to clear the load and intervening stacks.
357 804 25 01 GB 0104
- 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.
- For sloping trailers, use Slope Pyle to compen-
sate*.
NOTE
The levelling system will automatically set the
handler with a 5° tilt up. As the handler is lowered on
the container, the levelling cylinders reset allowing
the twistlocks to enter into the front container
pockets first.
NOTE
When the Container handler legs are activated the
handler is set horizontal automatically.
OPERATION
- Raise the load slightly, indicators (2,3,4,and 5)
illuminate on the CHI (1) to indicate that all legs
are seated correctly.
CAUTION
The load being lifted may be unevenly
balanced, in this case use the sideshift
function to stabilise the load.
Re-position the truck where the unbal-
anced 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 lift truck in reverse and rotate the load

- Lower the front legs. Indicator (8) illuminates,

- Stop the truck centred and as close as possible to the indicator (9) extinguishes on the CHI (1). as necessary until it is free of obstructions.
container.
- Clamp the legs. Indicators (6 and 7) illuminate - Raise or lower the load to travelling height.
on the CHI (1).

CHI

A
1 2 3 4 56 78

20'

40'

69
OPERATION
Travelling with loads
CAUTION
The reachstacker is designed for operation
on firm level ground. The stacking of contain-
ers on sloping ground is not approved.
The transport of loads along slopes is only allowed where
the machine is moving from one level stacking area to
another.
- Travel with the container centred (no sideshift).
- Transport the load as low as possible whilst maintain-
ing forward visibility.
- Always travel with the load uphill on upgrades and
downgrades, never travel or turn across a slope.
- Work with a guide if visibility is reduced.
- Operate the truck in reverse if the container being
transported obstructs forward visibility.
70
TRAVELLING WITH LOADS, DEPOSITING THE LOAD
Depositing the load
WARNING
No person is allowed to stand underneath the
elevated load.
- 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.
- Apply the parking brake.
- Lower the load onto the stack using the sideshift and
rotate for final positioning.
- Slowly lower the handler until the twistlocks are loose
in the load, the yellow indicator lamps illuminate in
addition to green.
- Unlock the twistlocks.
- For sloping trailers use Slope Pyle to compensate*.
- Lift the handler up out of the corner castings.
- Slowly lower the handler until the legs are no longer
seated. Indicators (2,3,4, and 5) extinguish on CHI (1)*.
- Unclamp the legs. Indicators (6) and (7) extiguish on
CHI (1)*.
- Raise the front legs. Indicator (8) extinguishes and
indicator (9) illuminates on CHI (1)*.
- Raise the back legs*, and reverse the truck away from
the stack.
- Lower the handler to driving height.
357 804 25 01 GB 0104
WARNING:
Do not leave the truck unattended with the
load elevated.
* CH models
 PARKING THE TRUCK, TRAILER COUPLING, JACK LOCATIONS
Parking the truck
- Lower the boom and ground the load.
- Apply the parking brake.
NOTE
The parking brake will be applied automati-
cally if neutral is selected and after the truck
has been stationary for 4 seconds.
- Stop the engine and remove the ignition key from
the keyswitch.
- Lock the cabin door and remove the door key.
CAUTION
When parking the CH model take care not to
damage the front and rear legs on the
container handler.
357 804 25 01 GB 0104
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 the tow pin (1).
- Place the tow bar in coupling recess in the lower retain-
ing hole.
- Push the tow pin (1) down to engage the drawbar.
1 1
OPERATION
Jack locations for changing wheels
CAUTION
Only use a jack with sufficient lifting capacity
(25,000 kg minimum).
CAUTION
The truck should only be lifted at these posi-
tions. When jacking up the front of the truck,
chock the rear wheels. When working under
the truck secure the chassis with wooden
blocks, do not rely just on the jack.
- To raise the truck at the front, place a jack under drive
axle mounting plate (1).
- To raise the truck up at the rear, place a jack under the
main plate (2) of the steer axle.
1
71
OPERATION WHEEL CHANGE
Wheel change Drive axle inner wheel
Changing wheels is a two man operation which requires - Remove the inner spacer band (6) from the hub (7).
the use of a slave truck fitted with a wheel support (1). - Support the weight of the inner wheel (8) with the forks
of the slave truck.
- Lean the inner wheel (8) against the wheel support (1)
Removing the drive wheels and secure.
WARNING - Carefully reverse the slave truck clear and unload the
Before removing a wheel on the drive axle, de- inner wheel (8).
flate the tyre to under 5 bar pressure. Danger of
damage or injury through wheel rims.

Drive axle outer wheel

- Remove wheel nuts (2) and lugs (3).
- Remove the outer wedge band (4) from the wheel (5).
Loosen by striking the rim using a hammer and drift.
- Carefully drive slave truck into place.
- Lean the outer wheel (5) against the wheel support (1)
and secure.

357 804 25 01 GB 0104

- Carefully reverse the slave truck clear and unload the
outer wheel (5).

1
4

6
5

72
 WHEEL CHANGE
Fitting the drive wheels
CAUTION
When a wheel has been removed and replaced,
the wheel nuts must be checked before use
and daily for two weeks.
Inner drive wheel
- Load the inner wheel (8) onto the slave truck and se-
cure.
- Carefully drive the slave truck into place and position
inner wheel (8) over the drive axle hub (7).
- Remove securing restraint from wheel support (1) and
inner wheel (8), push inner wheel (8) upright.
- Lower the slave truck forks until inner wheel (8) is seat-
ed onto hub (7).
- Carefully reverse slave truck clear.
- Fit inner spacer band (6) onto hub (7).
357 804 25 01 GB 0104
6
OPERATION
Outer drive wheel Removing the steer wheels
- Load outer wheel (5) onto the slave truck and secure. This procedure is the same as removing the outer drive
- Carefully drive slave truck into place and position outer wheel.
wheel (5) over hub (7). Ensure that the tyre inflation
valve extension is positioned correctly in the hub cut-
out.
- Remove securing restraint from wheel support (1) and Fitting the steer wheels
outer wheel (5) and push outer wheel (5) upright.
- Fit the outer wheel (5) onto hub (7). This procedure is the same as fitting the outer drive wheel.
- Fit the outer wedge band (4).
- Fit the wheel lugs (3) and wheel nuts (2). Tighten the
nuts.
NOTE: Wheel nut torque = 350 Nm (260 lb ft).
- Inflate tyres to 10 bar (145 psi).
1
4
3
5
73
OPERATION
Towing
CAUTION
Check the truck unloaded weighweightt (see
page 75 ). The truck must only be towed
75).
with a rigid towbar and by a vehicle with
sufficient tractive braking power to stop
both vehicles.
NOTE
With the engine stopped, the truck can still be steered,
although with much increased effort at the steering
wheel because of lack of hydraulic power.
Towing procedure
- Lower and release the load.
- Attach the towing vehicle to the towing pin with a rigid
tow bar (tractive and braking power are sufficient).
TOWING INSTRUCTIONS
Releasing the parking brake CAUTION
Tow the truck only with great caution and
- Remove the cover (5) from the brake calliper (7). at a speed of not over 3-5 kph.
Because of a lack of hydraulic power
- Turn bolt (6) anticlockwise to release the brake until the during towing, increased effort is re-
brake disc is clear. quired at the steering.
CAUTION After towing
The truck can not be braked now.
- Chock the wheels.
Removing the propeller shaft - Reset the parking brake.
- Remove the bolts (1) and nuts (2) on the coupling joints. Resetting the parking brake
- Take off the propeller shaft (4) and suspend it with a - Turn bolt (6) clockwise to reset the brake until
chain, for example, to prevent it from touching the the brake disc is tight again.
ground during towing.
- Fit the cover (5) to the brake calliper (7).

357 804 25 01 GB 0104

Refitting the propeller shaft
- Chock the drive axle wheels.
- Detach the propeller shaft, position it and fit the
axle.

- Fit the bolts (1) and nuts (2)on the coupling

joints.
7
- Tighten the bolts.
6
Torque..................................................80 Nm.

ATTENTION
Bolts may be used 2 times maximum.

CHECK THE
Check FUNCTION
the OF THE
function of BRAKES AFTER after
the brakes
CARRYING OUT REPAIRS
5
2

4
1

74
 HOISTING THE TRUCK, HANDLER REMOVAL MAINTENANCE

DANGER Handler removal

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!
Hoisting the truck
CAUTION
The weight of the unladen reach stacker is
approximately 68 - 79 tonnes (see chart).
Only use a crane and slinging gear with suffi-
cient lifting capacity.
Attach the lifting slings at the four points shown.
ATTENTION
- Attach two lifting hooks to the rear sling points (2) in
This work may only be performed by
qualified staff. Please contact your
front of the boom bearings.
authorised dealer
- Attach two lifting hooks to the front sling points (1) in
front of the boom cylinders.
- Attach the slings to the crane hook (4).

CAUTION
The safety lock (3) must close after attaching
the slings to the lifting hook (4). When the truck
is hoisted, the lifting sling must not rub against
357 804 25 01 GB 0104

any part of the cabin and any attachments

fitted.

Table of Weights
3
C4230TL 70400Kg
C42434TL 73200Kg
C4535TL 76300kg
4 C4026CH 73950Kg
C4030CH 76700kg
C4531CH4 81250Kg
C4531CH5 81250Kg

2
1

75
MAINTENANCE
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 op-
eration
- Thoroughly clean the truck.
- Elevate the handler several times as far as possible,
extend and retract the boom several times.
- Check the hydraulic oil level and add oil, if needed.
- Add diesel fuel.
- Apply a thin film of oil or grease on all unpainted
mechanical parts.
- Lubricate the vehicle.
- Check the condition and electrolyte level of the battery.
Coat the battery terminals with non-acidic grease.
TAKING THE TRUCK OUT OF OPERATION
- 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 meas-
ures.
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 qualified author-
ised personnel. This work can be carried out by your
authorised distributor under a service contract.
We recommend reserving a special service area for the
reach stacker with a container or support onto which the
handler can be lowered to gain easy and safe access to the
service points.
If you wish to do the work yourself, we recommend that the
Work on the boom and the front part of the
truck
CAUTION
Do not carry out any work on the boom, the
handler or the front part of the truck with the
boom lifted without securing the boom as de-
scribed below!
These safety precautions are only sufficient
for the general servicing of the truck (inspec-
tions and lubrication).
When carrying out repairs (e.g. boom cylinder
removal), additional safety precautions are re-
quired. Please contact your authorised distrib-
utor.
- Park the truck on firm level ground and chock the
wheels.
- Support the boom (on container).

357 804 25 01 GB 0104

(Follow the instructions of the battery manufacturer.)
- Spray all open electrical contacts with a suitable con-
tact spray.
ATTENTION
Block up the truck so that all wheels are clear
of the ground. This will prevent tyre deforma-
tion.
NOTE
Do not use plastic foil to cover the truck 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-acidic grease.
- Check the condition of the battery.
- Check the engine oil for condensation water and change
the oil, if necessary.
- Check the hydraulic oil for condensation water and
change the oil, if necessary.
- Perform the same services as for commissioning.
76
first three customer service checks be carried out by your
distributor’s mechanic in the presence of the responsible - Turn the ignition key to the zero position and remove it.
mechanic in your workshop, so that your staff can receive
the appropriate instruction. - Lock all cab doors and remove the key.
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 boom elevated, secure
it against inadvertent lowering.
For work on the front end of the truck, fully lower the boom.
No changes, particularly no modifications and additions,
may be made to the truck without the approval of the
manufacturer.
Perform a functional check and trial run after every ser-
vicing.
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.
ATTENTION
Follow the precautions for handling fluids and
lubricants.
 INSPECTION AND MAINTENANCE CHART MAINTENANCE
Services Before initial Daily checks As required Every 500
operation hours
(Description of the services can be located in the index)
For services refer to page 21 .................................................................................................... •
Check tyre condition and inflation pressure .................................................................................................. •
Check the working hydraulic system oil level ................................................................................................ •
Check the brake hydraulic system oil level .................................................................................................... •
Check coolant level in radiator header tank .................................................................................................. •
Check the engine oil level ................................................................................................................................... •
Check windscreen washer reservoir fluid level ............................................................................................. •
Check the fuel level ............................................................................................................................................... •
Check the transmission oil level ....................................................................................................................... •
Check the handler for visible damage ............................................................................................................. •
Check the twistlocks and warning lights for proper operation ................................................................. •
Adjusting the driver’s seat ................................................................................................................................... •
Clean the truck .................................................................................................................................................................................. •
Tighten the wheel nuts (after 100 hours minimum) ............................................................................................................... •
Check the tyres for damage and foreign objects ..................................................................................................................... •
357 804 25 01 GB 0104

Drain the fuel filter ........................................................................................................................................................................... •

Prime the fuel system ...................................................................................................................................................................... •
Check the battery condition ........................................................................................................................................................... •
Clean and check the air filter ........................................................................................................................................................ •
Clean and check the climate control filter ................................................................................................................................. •
Clean the radiator and oil cooler ................................................................................................................................................. •
Check the steering lock .................................................................................................................................................................. •
Check the central lubrication lubricating points* .................................................................................................................... •
Fill central lubrication canister with grease* ............................................................................................................................ •
Clean and lubricate steer axle, check the drive axle mounting ........................................................................................................................................ •
Check and lubricate the drive shaft ....................................................................................................................................................................................... •
Check the drive axle centre and hub differential oil level ................................................................................................................................................. •
Check the hydraulic system, pumps, valves and lines ........................................................................................................................................................ •
Change transmission oil filter canisters .................................................................................................................................................................................. •
Change the engine oil and the engine oil filter canisters ................................................................................................................................................... •
Change the fuel pre-filter .......................................................................................................................................................................................................... •
Renew the fuel filter canister ................................................................................................................................................................................................... •
Check mounting of turbocharger intake pipe ........................................................................................................................................................................ •
Check the front and rear cab mountings ............................................................................................................................................................................... •
Check and lubricate the handler sliding bearings ................................................................................................................................................................ •
Lubricate locking cylinder pin on the handler ...................................................................................................................................................................... •
Check and lubricate boom cylinders, boom pivot and sideshift sliding bearings ........................................................................................................... •
Lubricate the sideshift cylinder bearings ............................................................................................................................................................................... •
Check and tension drive belts ................................................................................................................................................................................................. •
* Option

77
MAINTENANCE INSPECTION AND MAINTENANCE CHART
Services Every 500 Every 1000 Every 2000 Every 3000 Every 5000 Every 6000
hours hours hours hours hours hours
(Description of the services can be located in the index)
Renew hydraulic tank air filter .......................................................................................................................... •
Check electric cables, connectors and connections for condition and tightness .................................. •
Renew the working hydraulic return line filters ..................................................................................................................... •
Renew the brake hydraulic system oil suction filter ............................................................................................................. •
Change the air filter element ..................................................................................................................................................... •
Renew the brake hydraulic system oil pressure filter ........................................................................................................... •
Renew the transmission oil and clean the filter screen ....................................................................................................... •
Check valve clearances ............................................................................................................................................................ •
Check the engine mountings ..................................................................................................................................................... •
Check transmission mountings .................................................................................................................................................. •
Check the cooling system for leaks and tightness ............................................................................................................... •
Check the parking brake condition and mounting ................................................................................................................ •
Lubricate handler extension cylinder bearing pads .............................................................................................................. •
Check the intake and exhaust systems for leaks and tightness ........................................................................................ •
Change the drive axle centre differential oil and drive axle hub differential oil ............................................................. •

357 804 25 01 GB 0104

Renew engine coolant and coolant filter ....................................................................................................................................................... •
Check and adjust hub bearings ....................................................................................................................................................................... •
Renew the brake hydraulic system oil ............................................................................................................................................................ •
Renew the fuel tank breather filter ................................................................................................................................................................. •
Clean the hydraulic tank pre-filter ................................................................................................................................................................................................. •
Check the condition of boom mountings ..................................................................................................................................................................................... •
Renew handler slewing gearbox and brake oil ........................................................................................................................................................................... •
Check, renew hydraulic oil of working hydraulic system .......................................................................................................................................................... •
Replace the air filter safety element ............................................................................................................................................................................................ •
General overall check ..................................................................................................................................................................................................................... •
Check handler extension cylinder bearing pads ................................................................................................................................................................................................ •
Renew the twistlocks ............................................................................................................................................................................................................................................. •
Check the vibration damper ............................................................................................................................................................................................................................................ •
Check the fan drive idler pulley assy and belt .............................................................................................................................................................................................................. •
Flush the cooling system ................................................................................................................................................................................................................................................................. •
Check the turbocharger ................................................................................................................................................................................................................................................... •
Renew the lift chains (at least every 3 years) ............................................................................................................................................................................................................................ •

78
 AFTER FIRST 50 HOURS, ROUTINE MAINTENANCE MAINTENANCE
Checks and maintenance work after the Routine maintenance
first 50 service hours
Every 100 hours
NOTE
- Lubricate slewing ring bearing and gear.
A description of the maintenance activities can also
- Check and lubricate the twistlocks.
be found by using the index.
- Check the slewing brake and gearbox oil level.
- Tighten the wheel mounting nuts
- Check the tyre inflation pressure
- Check the tyres for damage and foreign objects
- Clean the steer axle, check mounting
- Check the mounting of the drive axle
- Renew the working hydraulics suction filter
- Renew the brake hydraulics suction filter
- Inspect the air filter
- Check the condition of the battery
- Drain the water separators in the fuel system
- Renew the engine oil filters
- Renew the engine oil
357 804 25 01 GB 0104

- Renew the transmission oil filter

- Check the drive axle oil
- Check the pilot circuit oil filter
- Renew the hydraulic tank air filter
- Renew the fuel tank air breather filter
- Check the engine and transmission mounting for secu-
rity
- Check, tension V-belt drives
- Check the security of the cabin
- Check the air intake system for leaks and tightness
- Check the exhaust system for leaks and tightness
- Clean the coolant radiator and oil cooler
- Check, lubricate the boom cylinder, boom pivot and
sliding bearings
- Check the handler hydraulic system and electrical
lines
- Renew handler slewing gearbox and brake oil level
- Lubricate slewing ring bearing and gear
- Check the parking brake
- Check the boom for condition and tightness
- Check electric cables and connectors for condition and
tightness
- Check the central lubrication* lubricating points
- Check the steering stop

* optional

79
MAINTENANCE
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.
ATTENTION
Follow the precautions for handling lubricants
and fluids.
Use hot steam or intensive degreasing solu-
tions with the utmost care. The grease in sealed-
for-life bearings may dissolve and leak out.
Since re-greasing is not possible, this will re-
sult in damage to the bearing.
ATTENTION
When cleaning with a pressure washer,
do not expose electrical components or
INSPECTION AND MAINTENANCE AS REQUIRED
Tighten the wheel nuts
CAUTION
On new trucks, or if a wheel has been
removed and replaced, check the wheel
nuts before use and daily for two weeks
thereafter.
Check the wheel nuts at least every 100
hours.
Torque.....................................350 Nm (250 lb. ft.)
You need a socket spanner with extension to tight-
en the front wheel nuts.
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.

357 804 25 01 GB 0104

air filter intake lines to the direct jet,
cover them first.
Wear protective clothing and eye protec-
tors.

Before lubrication, clean the grease nipples, oil

filler openings and surrounding areas.
Remove stubborn dirt with a cold cleaner when
cleaning with an air jet.

NOTE
If the truck is cleaned frequently, increase
lubrication intervals accordingly.

When cleaning with degreasing cleaning solutions, allow

sufficient time for the cleaner to soak in and then flush with
a strong water jet.
After cleaning the engine, allow it to run warm to dry it in
order to prevent any malfunctions due to the ingress of
water.

80
 MAINTENANCE INSPECTION AND MAINTENANCE AS REQUIRED
Drain the fuel filter Prime the fuel system Check the battery condition.
ATTENTION: ATTENTION: CAUTION
Follow the precautions for handling flu- Follow the precautions for handling flu- Battery electrolyte is very caustic. Avoid any
ids and lubricants. ids and lubricants. contact with battery electrolyte. If electrolyte
comes into contact with clothing, skin or eyes,
The fuel filter is located in the air filter/battery com- CAUTION: flush the areas in question immediately with
partment on the left-hand side of the chassis The engine may be at operating temper- water. In case of eye contact see a doctor at
ature. Danger of scalds and burns. once! Neutralize any spilled battery acid
- Visual check for any water in the water separator, immediately!
drain if required. - Remove filler cap from the top of the fuel pump
(1). The battery is fitted in the air filter/battery compartment on
- Place a catch tray of approximately 5 L capacity the left-hand side of the truck.
under the sediment bowl (1). - Fill the pump with clean fuel.

- Release the drain screw (2) and drain the sedi- - Re-fit filler cap (1). - Check the battery for cracks in the casing, and leaked
ment/water. electrolyte.

- Tighten the screw as soon as clean fuel flows. - Remove any corrosion on the battery terminals and
check the connections for tight seating.
357 804 25 01 GB 0104

- Tighten the terminals and coat with non-acidic grease.

1
1

81
MAINTENANCE
Check the air filter
NOTE:
This service is only required once after the first 50
service hours. Further service intervals as required.
WARNING:
Stop the engine before servicing the air intake
system. Do not start the engine with the filter
element removed.
Wear a protective mask for all services on the air intake
system.
CAUTION:
Clean the filter casing with a damp cloth. Do
not clean the filter element.
The use of wet cleaning agents will destroy the filter ele-
ment. Follow the precautions for handling fluids and lubri-
cants.
If the air filter restriction indicator illuminates on
the truck status display screen (1), stop the engine
at once and renew the air filter.
RHP
1
82
INSPECTION AND MAINTENANCE AS REQUIRED
ATTENTION: Before installing a new filter element, examine it for dam-
A dirty filter element decreases engine per- age with an inspection lamp held inside the element.
formance. Careful filter servicing is essential
for the engine. - Examine the seals for damage.
- Renew the filter or seals if damaged.
- Open the air filter/battery compartment door. - Examine the safety element (7). Renew if damaged.
- Unscrew nut (1) and remove the filter end cover (2). - Install the filter element (5) into the filter casing (6) and
- Empty the dust collected in the cover and wipe it with a secure it with the wing nut (4).
clean damp cloth. - Refit the end cover (2), ensuring that the dust valve (3)
- Squeeze the dust valve (3) to remove any collected dust. is positioned through the deck plate, and secure with
If necessary, clean the dust valve with a damp cloth. the wing nut.
- Replace the dust valve if split or torn. - Close the air filter/battery compartment door.
- Unscrew the wing nut (4) and carefully remove the filter
element (5).
- Wipe the inside of the filter casing (6) using a damp cloth.
- Examine the filter.
- Replace the filter element if it is damaged, after 1000
service hours or at least every 12 months.
357 804 25 01 GB 0104
2
1
3
6
 INSPECTION AND MAINTENANCE AS REQUIRED MAINTENANCE
Renew the safety element Check and clean the climate control filter Clean the radiator and oil cooler, check for
The safety element (7) must be changed: element
element** leaks
After 3000 hours of service. NOTE CAUTION
If the element is defective This service interval is as required according Clean the radiator only when the engine is
to environment. stopped and cool.
- Remove the filter element.
- Remove the nut (8) and withdraw the safety element (7). - Access the filter element by opening rear cab door CAUTION
locks (1 and 2) and lifting door (3). Follow the precautions for the use of com-
Before installing a new safety element, examine for - Lock door in the open position by ensuring lock- pressed air.
damage. ing arm (5) is fully engaged.
- Carefully pinch the top left corner of filter (4), and ATTENTION
- Insert a new safety element (7), fasten with the nut (8). pull out from securing frame. Follow the precautions for handling fluids and
- Refit the filter element. - Wash filter (4) with clean water and dry before re- lubricants.
fitting.
ATTENTION: - If the filter (4) is damaged, replace it. - Remove the radiator grille and clear the radiator and oil
Do not clean or re-use the safety element. - Close door (5) and lock using locks (1 and 2). cooler of any debris.
- Clean the radiator and oil cooler fins with compressed
air or use a cold cleaner or steam jet if necessary.
* Optional
357 804 25 01 GB 0104

ATTENTION
Do not allow water to enter the alternator.

- Start the engine and let it idle to allow water to evapo-

1 rate quickly.
- Check the cooling system for leaks with the engine at
2 operating temperature.
- Install the radiator grille.
3
7

8
4

83
MAINTENANCE INSPECTION AND MAINTENANCE AS REQUIRED
Check the steering lock Check the central lubrication* lubricating Fill central lubrication* canister with grease
- Rotate the steer wheel fully to the left and fully to points NOTE
the right to ensure that full steering lock is NOTE The central lubrication canister is located behind
maintained. This check is required only once after the first 50 the battery/air filter cover on the left-hand side of
service hours. the truck.

- Check that enough grease is emerging at all central
lubrication lubricating points.
- If there is not enough or too much grease, please
contact your authorised dealer in this regard.
- See page 12 for lubrication points.
- Open the battery/air filter cover.
- Remove the dust cap (1) on the canister filler nipple.
- Clean the filler nipple and install the filler tube of the
grease gun.
- Fill grease up to the high mark or about 2 cm from top
edge of the canister.
- Remove the filler tube and fit the dust cap.

NOTE
If filling is difficult, clean the filter in the canister.

357 804 25 01 GB 0104

- Close the battery / air filter cover.

* Option

F
N
R

84
 ROUTINE MAINTENANCE
Lubricate slewing ring bearing and gear
ATTENTION
Follow the precautions for handling fluids and
lubricants.
CAUTION
Work on the truck on level ground. Retract and
lower the boom, 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.
- Lubricate the bearing grease points (1) (4 points).
- For lubrication use a grease gun until fresh grease
357 804 25 01 GB 0104
emerges at the bearings.
- Using a brush, apply grease to the ring gear (2).
2 2
MAINTENANCE
Check and lubricate the twistlocks
CAUTION - Lubricate the grease nipples (1 and 3) (3 on each end
Work on the truck on level ground. Retract and beam).
lower the boom, stop the engine and put the
parking brake on when working. - Press the grease gun until clean lubricating grease
emerges at the bearings.
WARNING
The twistlocks (2) are wearing parts. These
must be inspected regularly for damage, cor-
rect operation and wear. Do not operate the
truck if damage, malfunctions and heavy wear
are evident.
- Check the twistlocks (2) in area (4) by measuring.
The wear in areas (4) on the twistlocks must not exceed
26 mm.
- Renew twistlocks if the wear limit is exceeded.
Please contact your authorised dealer.
3
85
MAINTENANCE
Check the slewing gearbox and brake oil
level
ATTENTION
Follow the precautions for handling fluids and
lubricants.
CAUTION
Work on the truck on level ground. Retract and
lower the boom, 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.
- Remove the level/filler plug (1).
- The hydraulic oil level must be at the lower edge of the
filler hole (1).
- If necessary, fill hydraulic oil to the base of the
hole.
- Fit the level/filler plug (1).
1 2
86
ROUTINE MAINTENANCE
Check and lubricate the leg folding group Check and lubricate feet at the bottom of
each leg
ATTENTION
Work on the truck on level ground. Retract and ATTENTION
lower the boom, stop the engine and put the Work on the truck on level ground. Retract and
parking brake on when working. lower the boom, stop the engine and put the
parking brake on when working.
CAUTION
Follow the precautions for handling fluids and CAUTION
lubricants. Follow the precautions for handling fluids and
lubricants.
- Lubricate the fold/clamp cylinder bearings (1) (2 points).
- Lubricate the leg pivot pin (2). - Lubricate the nipple in the centre shaft (1).
- Lubricate the leg raise cylinder top bearing (3). - Lubricate the nipples at the rear of each foot (2)
- Lubricate the shoulder pivot pin (4). (3 points).
- For lubrication use a grease gun until fresh grease - For lubrication use a grease gun until fresh grease
emerges at the bearings. emerges at the bearings.
357 804 25 01 GB 0104
3
1 2
1 4
 ROUTINE MAINTENANCE MAINTENANCE
Clean and lubricate steer axle, check the Check the steer axle hub oil level Check and lubricate the drive shaft
mounting ATTENTION CAUTION
Follow the precautions for fluids and lubri- Work on the truck on level ground. Retract and
ATTENTION
cants. lower the boom, stop the engine and put the
Follow the precautions for fluids and lubri-
cants. parking brake on when working.
CAUTION
Work on the truck on level ground. Retract and CAUTION
CAUTION
lower the boom, stop the engine and put the Engine and transmission may be at operating
Work on the truck on level ground. Retract and
parking brake on when working. temperature. Danger of burns.
lower the boom, stop the engine and put the
parking brake on when working. - Ensure that oil filler plug (1) is in the 2-o-clock
position and drain plug (2) is in the 6-o-clock - Open the transmission cover.
- Clean the steer axle. position. - Examine the drive shaft coupling bolts (1) for damage or
- Check the steer axle mounting bolts (3) for damage and signs of fretting.
- Remove oil filler plug (1).
wear. - Check bolt torque loading.
- Check the nut (2) torque loading. - Check oil is visible at the base of the hub filler hole (1).
Torque ................................................. 80 Nm (60 lb. ft.)
Torque................................2300 Nm (1700 lb. ft.)
- If required, replenish oil to the base of the filler hole (1). - Lubricate the drive shaft grease points (2) (3 points).
- Lubricate the king pin grease points (1,5) (4 po-
sitions). - Replace oil filler plug (1). - For lubrication use a grease gun until fresh grease
357 804 25 01 GB 0104

- Lubricate the drag link grease points (4) (4 posi- emerges at the bearings.
tions).
- For lubrication use a grease gun until fresh grease
emerges at the bearings.

1
1

4
1
3
2
5
2

4
5 2

87
MAINTENANCE
Check and lubricate boom cylinder, boom
pivot and sliding bearings
CAUTION
Work on the truck on level ground. Retract and
lower the boom, 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.
ROUTINE MAINTENANCE
- Check that all stop plates (4) on the inner and outer
boom are fitted and tight (4 plates).
- 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 grease
emerges at the bearings.

A 3
1 2 5

357 804 25 01 GB 0104

A
6

2
2

88
 500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check the drive axle mounting Check the drive axle centre differential oil Check the drive axle hub oil level
CAUTION level CAUTION
Work on the truck on level ground. Retract and CAUTION Work on the truck on level ground. Retract and
lower the boom, stop the engine and put the Work on the truck on level ground. Retract and lower the boom, stop the engine and put the
parking brake on when working. lower the boom, stop the engine and put the parking brake on when working.
parking brake on when working.
- Tighten the drive axle securing bolts (2) and nuts (1), ATTENTION
and check for damage or signs of fretting. ATTENTION Follow the precautions for handling fluids and
Follow the precautions for handling fluids and lubricants.
- Check the torque loading of bolts. lubricants.
Torque ........................................ 2300 Nm (1680 lb. ft.) - Position the truck so that the drive axle hub level
- Remove the differential level/filler plug (1). indicator mark (1) is horizontal.
- Remove the level/filler plug (2).
- Check that the oil is visible at the base of the filler hole. - Check that the oil is visible at the base of the hub filler
hole.
- If required, replenish with oil to the base of the filler hole. - If required, replenish with oil to the base of the filler hole.
- Fit the level/filler plug. - Fit the level/filler plug.
357 804 25 01 GB 0104

- Repeat for the other hub.

1
1
OIL

89
MAINTENANCE
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 boom, levelling and steer cylinders for leaks.
- Renew cracked hoses.
- Check the hoses for damage and chafing, renew if
necessary.
Check electric cables, connectors and con-
nections for condition and tightness
- Examine cable connections for looseness and corro-
sion.
- Inspect the earth lead for loose connection.
- Examine the electrical wiring for chafing and loose
connections.
NOTE
Corroded connections and cracked cables lead to a
drop in voltages, thus creating starting difficulties.
- Remove corrosion and replace cracked cables.
90
500-HOUR INSPECTION AND MAINTENANCE
Change transmission oil filter canisters
ATTENTION
Follow the instructions for handling fluids and
lubricants.
CAUTION
The filter canisters and oil may be hot. Danger
of burns and scalding.
- Open the engine compartment front cover.
- Place a catch tray of at least 5 L capacity under the filter
canisters (1).
- Loosen the canisters (1) using a filter wrench
and remove by hand.
- Clean the filter heads (3).
- Fill the new filters with hydraulic oil.
- Lubricate the filter seals (2) with hydraulic oil.
- Install new filter canisters and tighten it by hand
only.
- Start the engine and check for leaks at the seal faces.
- Check the transmission oil level and replenish oil if
necessary.
- Close the engine compartment front cove coverr.
3
3
2
1
Change the pilot circuit oil filter
ATTENTION
Follow the instructions for handling fluids and
lubricants.
CAUTION
The filter canister and oil may be hot. Danger of
burns and scalding.
- Place a catch tray of at least 5 L capacity under the filter
canister (1), situated beneath the valve tray.
- Loosen the canister (1) using a filter wrench and re-
move by hand.
- Clean the filter head.
- Lubricate the filter seal with hydraulic oil.
- Install a new filter canister (1).
- Start the engine and check for leaks at the seal faces.
357 804 25 01 GB 0104
1
 500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Change the engine oil Change the engine oil filter canister
ATTENTION - Torque drain plug (1) to 60 Nm (45 lb. ft.). ATTENTION
Follow the precautions for handling fluids and Follow the precautions for handling fluids and
lubricants. - Remove the oil filler cap (2) on the filler neck. lubricants.

CAUTION - Fill engine oil. CAUTION

Engine and engine oil may be at operating Engine and engine oil may be at operating
temperature. Danger of burning. Capacity (with oil filter change) ................................... 35 L temperature. Danger of burning.

NOTE - Check the engine oil level with the dipstick (3). The oil - Open the bonnet.
Change the oil when the engine is at operating level should be between the high and low marks. The oil
temperature. level must NOT exceed the high mark. - Put a catch tray with a capacity of at least 10 li-
NOTE tres under the oil filter (2).
Oil change intervals must not exceed a time period - Start the engine and check drain plug (1) for leakage.
of 12 months - Loosen the filters using a filter wrench and re-
- Stop the engine and wait at least 5 minutes for the oil move by hand.
- Open the engine cover. level to stabilise.
- Put a catch tray with a capacity of at least 35 L under the - Clean the filter housing (1).
- Check the oil level again and replenish engine oil, if
357 804 25 01 GB 0104

drain plug (1).

necessary.
- Remove oil drain plug (1) and drain engine oil.
- Clean drain plug (1) and re-install with a new washer. - Replace filler cap (2).

1
2

91
MAINTENANCE
- Check filter seal rings (3) in new engine oil filter
for proper seating.
- Fill the new filler canister slowly with oil.
- Lubricate the seal rings (3) of the new filter can-
isters with engine oil.
- Install the filter canister by hand until the seal
rings mate with the filter head, then tighten by
quarter turns using a filter wrench with tighten-
ing band.
- Start the engine and check the seal faces for leak-
age.
- Stop the engine and wait for at least 5 minutes
for the engine oil level to stabilise.
500-HOUR INSPECTION AND MAINTENANCE
Change the Fuel pre-filter with water
monitor
- Clean the area around the fuel filter.
- Disconnect the water monitor(1).
- Drain the fuel filter, see ”Fuel system, draining”.
- Remove the fuel filter using an appropriate filter wrench.
NOTE
If the entire filter unit with the water separator
is not going to be changed the water monitor
should be moved to the new fuel filter.
- Clean the filter’s sealing surface on the filter housing.
- Spread a thin layer of oil on the sealing ring and mount
the new fuel filter according to the instructions on the
filter.
- Connect the water monitor (1).
- Start the engine and check for leaks.
Fuel pre-filter, draining of condensation
water
CAUTION
Wait a few hours after the engine has been
turned off before draining the filter.
- Open the drain nipple (2) in the bottom of the fuel pre-
filter and let the condensation water run out.
NOTE
Place a container under the fuel pre-filter to catch
the condensation water and fuel.
- Close the drain nipple (2) when water-free fuel comes
out.
- Start the engine and let the engine fill the water separator.
Let the engine idle for 10 minutes to remove the air from
the fuel system.

357 804 25 01 GB 0104

- Shut off the engine and check for leaks.
- Check the engine oil level and replenish engine
oil if necessary.

2 2

92
 500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check mounting of turbocharger intake Check the front cab mountings Check the rear cab mountings
pipe NOTE NOTE
CAUTION Access to front cab mounting bolts (1) is from Access to rear cab mounting bolts (1, 2) is
Engine and turbocharger may be at oper- u n d e r the cab floor mat. from under the cab behind the cab rear com-
ating temperature. Danger of burns. partment door.
- Check that the front cab mounting bolts (1) are
- Check the mounting of the turbocharger intake secure; tighten to 115 Nm (85 lb. ft.) if required. - Check that the cab mounting bolts (1) are secure;
hose (2) for leaks. tighten to 115 Nm (85 lb.ft.) if required.
NOTE
- Check the nuts (1) for correct torque loading. Access to front mounting bolts (2) is through - Check that the cab mounting bolts (2) are secure;
T o r q u e ........................................... 90 Nm (66 lb. ft.) the engine compartment front cover. tighten to 56 Nm (41 lb.ft.) if required.

- Check that the front cab mounting bolts (2) are

secure; tighten to 56 Nm (41 lb. ft.) if required.
357 804 25 01 GB 0104

2
1
1

93
MAINTENANCE
Check and lubricate the handler sliding
bearings
CAUTION
Work on the truck on level ground. Retract
and lower the boom, 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.
- Check all stop plates (1 and 2) for completeness and
security (24 plates).
- Examine the sliding bearings (3) for wear. The plates
must be renewed if the thickness is under 8 mm (24
plates).
- Lubricate all grease points (4) with a grease gun until
fresh grease is visible (24 grease points).
3
2
94
500-HOUR INSPECTION AND MAINTENANCE
Check and lubricate sideshift sliding bear-
ings
CAUTION
Work on the truck on level ground. Retract
and lower the boom, 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.
- Check all stop plates (2) for completeness and secu-
rity (8 plates).
- Examine the sliding bearings (1) for wear. The plates
must be renewed if the thickness is under 8 mm (8
357 804 25 01 GB 0104
plates).
- Lubricate all grease points (3) with a grease gun until
fresh grease is visible (8 grease points).
4
4
 MAINTENANCE
Lubricate locking cylinder pin on the han-
dler*
CAUTION
Work on the truck on level ground. Retract
and lower the boom, 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.
- Using a grease gun, lubricate all grease nipples
(1) on the locking cylinder until fresh grease
emerges (2 grease points).
357 804 25 01 GB 0104
* option on TL models
500-HOUR INSPECTION AND MAINTENANCE
Lubricate the sideshift cylinder bearings
CAUTION
Work on the truck on level ground. Retract
and lower the boom, 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.
- Using a grease gun, lubricate all grease nipples
(1) on the sideshift cylinder bearings until fresh
grease emerges (8 grease points).
1 1
95
500-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check and tension belt drives
WARNING
The engine and radiator may be at oper- - Use a belt tension gauge to measure the belt
ating temperature. Danger of burns. tension, this should be approximately 75 Nm.
Examine the drive belt for excessive wear, cracks - If adjustment is required, turn screw (1) clock-
and traces of oil. Renew damaged belts. wise to increase tension, and anticlockwise to
reduce tension.
- This belt drive system is equipped with an auto-
matic belt tensioner which CANNOT be adjusted. - If necessary, renew the belt.
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.

- If required change the drive belt.

357 804 25 01 GB 0104

1

96
 MAINTENANCE
Renew hydraulic tank air filter
- De-pressurise the tank by rotating the air filter
cap slowly until air is heard escaping from the
tank. Wait until the tank is completely
de-pressurised and no more escaping air is
heard.
- Remove and discard breather filter cap (1).
- Replace breather filter cap (1).
357 804 25 01 GB 0104
500-HOUR INSPECTION AND MAINTENANCE
EDC system check with diagnosis tool
- Every 1000 operating hours arrange for a full
system diagnosis test to ensure engine efficien-
cy is maximised.
NOTE
Licensed software, along with technical skill
and knowledge are required for this proce-
dure. Please contact your authorised dealer.
97
1000-HOUR INSPECTION AND MAINTENANCE
Renew the main hydraulic system oil re-
turn line filters
CAUTION
Follow the procedure for handling flu-
ids and lubricants. The oil tank, filter
and hydraulic oil may be at operating
temperature. Danger of burns.
MAINTENANCE
- Press retainer down, rotate through 90° and
lift out to allow removal and replacement of
filters (4).
- Lift out filters (4).

- De-pressurise the tank by rotating the filler cap - Replace filters (4).
slowly until air is heard escaping from the tank,
keep rotating the filler cap until no more air is - Remove and retain cap (5), taking care to retain
heard. spring.
WARNING
The hydraulic tank accumulates stored - Lift out filter (6).
pressure, take care when removing the
filler cap. - Replace filter and seals, re-fit spring and cap (5).

- Remove nuts (1) from the top of each housing (2), - Check oil level and replenish, if required.

357 804 25 01 GB 0104

remove this to expose filter element retainer.
- Dispose of used filters according to local author-
ity guidelines.

2
1

1 2
4
5
3
6
2

98
 MAINTENANCE
Renew the brake hydraulic system suction
and in line filters
CAUTION
Follow the procedure for handling flu-
ids and lubricants. The oil tank, filter
and hydraulic oil may be at operating
temperature. Danger of burns.
- Brake oil filtration consists of a suction strainer
in the brake oil tank, and an in-line pressure
filter (10). The in-line filter (10) is situated on the
left hand side of the chassis near the transmission.
1000-HOUR INSPECTION AND MAINTENANCE
- Fit seal ring (11) to filter casing (12).
- Check that the seal ring (11) is correctly seated
and lubricated with hydraulic oil.
- Prime new filter casing (12) with new oil.
- Engage the filter case (12) into the filter head
(10) and tighten.
- To replace suction strainer (3), remove and re-
tain union nuts (2).
- Lift filter cover (1) and filter case (4) from tank.
- The strainer can be cleaned using compressed
a i r unless damaged, in which case it can be
removed by unscrewing by hand and replaced by
repeating the above procedure.
- Check oil level and replenish, if required.

- Chock the wheels of the truck and deplete any

stored pressure in the brake circuit.

- Unscrew filter case (12).

- Remove and discard filter element and seal ring

357 804 25 01 GB 0104

(11).

3
4
1

10
11 2
3
12 3

99
1000-HOUR INSPECTION AND
Change the air filter element, Check the
vacuum switch
CAUTION
Work on the truck on level ground. Retract
and lower the boom, stop the engine and
put the parking brake on when working.
CAUTION
Stop engine before servicing the air in-
take system. Do not start the engine with
the filter element removed.
Wear a protective mask for all services on
the air intake system.
CAUTION
Clean the filter case with a damp cloth.
Do not clean the filter element.
- Unscrew nut (1) and remove the filter end cover
(2).
100
- Empty the dust collected in the cover and wipe
clean with a damp cloth.
- Remove the dust valve (3) and clean with a damp
cloth.
- Renew the dust valve if damaged.
- Unscrew the wing nut (4), remove the element
(5) and discard it.
- Wipe the filter casing (6) with a damp cloth.
Mark the filter element service hours on the end
cover.
- Examine the new filter element for damage be-
fore installation.
- Install the filter element (5) into the filter casing
(6) and secure with the wing nut (4).
MAINTENANCE
- Refit the end cover (2) and secure with nut (1).
Ensure that the dust valve (3) is positioned
through the casing hole.
- The dust valve (3) must show down.
- Ensure that the dust valve (3) Is pointing down-
wards.
- Remove the intake hose from the air filter intake.
- Close the air filter Intake when the engine is run-
ning.
The air filter restriction indicator should illuminate.
- Refit the intake hose.
- Close the air filter/battery compartment door.
357 804 25 01 GB 0104
 MAINTENANCE 1000-HOUR INSPECTION AND MAINTENANCE
Renew the brake hydraulic system oil pres- Renew the transmission oil and clean the
sure filter filter screen
CAUTION - Check that the seal ring (2) in the new filter ATTENTION
Work on the truck on level ground. Retract element is fitted correctly and lubricate with Follow the precautions for fluids and lu-
and lower the boom, stop the engine and hydraulic oil. bricants.
put the parking brake on when working.
- Fit a new seal ring (4) to the filter case and
lubricate with hydraulic oil. CAUTION
ATTENTION Oil filter and hydraulic oil may be at
Follow the precautions for fluids and lu- - Fit the filter element to the filter head. operating temperature. Danger of burns
bricants. and scalding.
- Engage the filter case in the filter head and
tighten.
CAUTION - Open the engine compartment front cover.
Oil filter and hydraulic oil may be at - Start the engine and check the joint for leakage,
operating temperature. Danger of burns tightening the filter case if necessary. - Remove the engine compartment front under-
and scalding.
- Stop the engine and check the brake system trays.
hydraulic oil level, replenishing hydraulic oil if
The filter is fitted under the cab on the left side.
necessary. - Place a catch tray of at least 60 L capacity under
the transmission.
- Place a catch tray of at least 2 L capacity under
357 804 25 01 GB 0104

the filter assembly.

- Remove the transmission drain plug (1) and
- Unscrew the filter case (3). allow the oil to drain. Remove and discard the
- Remove and discard the filter element (1) and plug seal ring.
seal ring (4).

2
1

4 2

101
1000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Renew the transmission oil and clean the Check the engine mountings
filter screen continued CAUTION
- Replace the transmission filler cap (3). Engine and transmission may be at oper-
- Remove the plug (2) from the transmission hous-
ating temperature. Danger of burns and
ing with the filter screen attached. - Start the engine and check for leaks at the seal scalding.
faces.
- Remove and discard the seal ring on the plug.
- Check the transmission oil level, using dipstick Check the engine mountings and spherelastic
(4), replenishing oil if required. mounts for condition. Renew the rubber mounts, if
- Wash the screen assembly in paraffin derivatives
damaged.
such as benzine and dry with compressed air - Fit the engine compartment front undertrays.
(max. 5 bar).
- Close the engine compartment front cover. - Check mounting bolt (1).
T o r q u e ........................................
............................................. ... 68 Nm (50 lb. ft.)
- Fit a new seal ring to the drain plug (1).
- Check mounting bolt (2).
- Install the screen assembly and the plug (2) with T o r q u e ........................................... 195 Nm (145 lb. ft.)
the new seal ring, torque to 13 - 20 Nm (10 - 15
lb.ft.).
- Remove the transmission filler cap (3) and fill

357 804 25 01 GB 0104

transmission oil.
Capacity ..................................................................... 6 0 L

1
2

2
1
3 1
1
1 2
4 1

1
2

102
 MAINTENANCE 1000-HOUR INSPECTION AND MAINTENANCE
Check transmission mountings Check the cooling system for leaks and Check the parking brake condition and
CAUTION
tightness mounting
Work on the truck on level ground. Re- CAUTION CAUTION
tract and lower the boom, stop the engine Work on the truck on level ground. Retract Work on the truck on level ground. Retract
and put the parking brake on when work- and lower the boom, stop the engine and and lower the boom, stop the engine and
ing. put the parking brake on when working. put the parking brake on when working.

CAUTION CAUTION - Examine the brake disc (3) for wear and damage.
Engine and transmission may be at oper- Engine and oil cooler may be at operating
ating temperature. Danger of burns and temperature. Danger of burns. - Check the thickness of lining material on the
scalding. brake pads (2). Renew pads if thickness is under
- Check the condition of the radiator top hose (1), 2 mm.
Check the condition of the rubber mounts. Renew replace if deteriorated.
the rubber mounts, if damaged. - Examine the calliper bolts (1) for wear, renew if
- Check that the hose clamps (2) are secure. required. Check that the nuts and split pins are
- Check mounting bolts (1). secure.
T o r q u e ............................................ 100 Nm (75 lb. ft.) - Check the condition of the bottom radiator hose
(3), replace if deteriorated.
357 804 25 01 GB 0104

- Check mounting bolts (2).

T o r q u e ........................................... 195 Nm (145 lb. ft.)

- Check mounting bolts (3).

T o r q u e ........................................... 250 Nm (185 lb. ft.)

2 1

1
1

2
2

3 3 3

103
1000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Lubricate handler extension cylinder bear- Check the intake and exhaust systems for
ing pads leaks and tightness
CAUTION CAUTION
Work on the truck on level ground. Retract Work on the truck on level ground. Retract - Check the overall condition of the exhaust sys-
and lower the boom, stop the engine and and lower the boom, stop the engine and tem, replace any pipes or the silencer if badly
put the parking brake on when working. put the parking brake on when working. corroded.

- Lubricate the bearing pads (3) and tracks (1) with - Inspect the air intake hoses (1), renew if dam- - Check that the exhaust mounting clamp (4) is
grease. aged. tight.

- Extend and retract the handler several times.
- Inspect hose clips (2) for security, tighten if
necessary.
- Check that the exhaust clamps (3) are tight.
- Check that the silencer mountings (5) are se-
cure.
T o r q u e ........................................... 56 Nm (41 lb. ft.)

- Check that the tail pipe mounting bolts (6) are

secure.

357 804 25 01 GB 0104

T o r q u e ........................................... 56 Nm (41 lb. ft.)

3 3 4
5
1

3
6
3
3
2 2
3

104
 MAINTENANCE
Change the drive axle centre differential oil
ATTENTION
Follow the precautions for fluids and lubri-
cants.
CAUTION
Work on the truck on level ground. Retract and
lower the boom, stop the engine and put the
parking brake on when working.
- Place a catch tray of at least 75 L capacity under the
centre differential.
- Remove the level/filler plug (1).
- Remove the drain plug (2) and allow the oil to drain.
- Remove and discard the seal rings on plug (1) and (2).
- Install and tighten drain plug (2) with a new seal ring.
- Fill the differential with gear oil to the base of the filler
hole.
- Fit the filler plug (1) with a new sealing ring.
357 804 25 01 GB 0104
NOTE
Maximum oil capacity ........................................ 75 L
1 OIL
1000-HOUR INSPECTION AND MAINTENANCE
Change drive axle hub oil
ATTENTION - Repeat for the other hub.
Follow the precautions for fluids and lubri-
cants. NOTE
Maximum oil capacity ................................... 7 L
CAUTION
Work on the truck on level ground. Retract and
Change steer axle hub oil
lower the boom, stop the engine and put the - Position the truck so that the drive axle hub level
parking brake on when working. indicator mark (1) is in the 2 o clock position and the
drain plug (2) is in the 6 o clock position.
- Position the truck so that the drive axle hub level
- Place a catch tray of at least 5 L capacity under the hub.
indicator mark (2) is horizontal and the drain plug (3) is
down. - Remove filler plug (1) and drain plug (2) and allow the oil
to drain completely.
- Place a catch tray of at least 7 L capacity under the hub.
- Remove and discard plug seal ring.
- Remove filler plug (1) and drain plug (3) and allow oil to
drain completely. - Fit drain plug (2) with a new seal ring.
- Remove and discard the plug seal rings. - Fill the hub with gear oil to the base of the filler hole.
- Fit drain plug (3) with a new seal ring. - Fit filler plug (1) with a new seal ring.
- Fill hub with gear oil to the base of filler hole. - Repeat for the other hub.
- Fit filler plug (1) with a new seal ring.
1 2
1
3
105
2000-HOUR INSPECTION AND MAINTENANCE
Renew engine coolant
ATTENTION
Follow the precautions for fluids and lubri-
cants.
CAUTION
Do not remove the radiator cap or drain plugs
when the radiator is hot or with the engine
running. Danger of scalds and burns.
CAUTION
Work on the truck on level ground. Retract and
lower the boom, stop the engine and put the
parking brake on when working.
The radiator drain plug is fitted at the base of the radiator.
It is reached from under the truck through an access hole
immediately in front of the steer axle.
- Remove the engine undertray.
- Place a container of at least 45 L capacity under the
engine drain plugs (3).
- Remove the drain plugs and allow the coolant to drain.
- Flush out the radiator through the filler cap aperture.
- Refit the radiator drain plug (2).
- Refit the engine drain plug (3).
- Fill the cooling system with a water-antifreeze mixture.
- Refit the radiator cap (1).
- Run the engine for 5 minutes.
- Check the coolant level, replenishing coolant if re-
quired.
- Check the cooling system for leaks.
- Fit the undertray.
NOTE
Capacity of cooling system ............................. 44 L
MAINTENANCE
Change the coolant filter
ATTENTION
Follow the precautions for handling fluids and
lubricants.
CAUTION
Engine and engine oil may be at operating
temperature. Danger of burning.
- Turn the valve (1), 90° to stop the flow through the coolant
filter.
- Remove the coolant filter using an appropriate filter
wrench. Make sure that no residue from the old gasket
remains on the housing.
- Spread a thin layer of engine oil on the new coolant filter’s
gasket. Tighten the coolant filter by hand until the rubber
seal contacts the sealing surface on the filter bracket.
- Tighten the coolant filter ½ turn.
- Turn the valve (1) 90° to start the flow through the coolant

357 804 25 01 GB 0104

- Remove the radiator cap (1). filter again.
- Place a container of at least 45 L capacity under the - Start the engine and check for leaks.
radiator drain plug (2). - Shut-off the engine and check the coolant level, top up if
required.

1
1

2 3
2

106
 MAINTENANCE
Check the condition of structured compo-
nents
CAUTION
Work on the truck on level ground. Retract and
lower the boom, 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,
particularly at changes of section, bolted interfaces and
357 804 25 01 GB 0104
sliding pad pressure points.
- Examine the boom lift and extension 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.
2000-HOUR INSPECTION AND MAINTENANCE
Check Valve Clearances
CAUTION
Retract and lower the boom, stop the engine
and put the parking brake on when working.
CAUTION
Engine and radiator may be at operating tem-
perature. Danger of scalds and burns.
- Isolate the battery.
- Remove the rocker arm cover, nuts and seal rings.
- Remove the rocker arm covers, with gaskets.
- Turn the crankshaft in the normal direction of rotation
until the inlet valve of cylinder 6 is just open and the
exhaust valve has not yet fully closed.
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
The engine is marked with numbers (1–6) for valves
and unit injectors (cylinder no. 6 is nearest the flywheel).
Each number applies to the adjustment of inlet valves,
exhaust valves and unit injectors for the respective
cylinders.
NOTE:
When adjusting, it is important to ensure that
the line marked on the camshaft is midway
between the marks on the bearing cap.
NOTE:
Exhaust valves, inlet valves and unit injectors
are to be adjusted at the same time for each
cylinder.
5
5
107
2000-HOUR INSPECTION AND MAINTENANCE
Renew the brake hydraulic system oil
Valves and unit injectors should be adjusted in the order ATTENTION
as marked on the camshaft when the engine is turned Follow the precautions for handling fluids and
over in the direction of rotation. lubricants.
By following this order, the crankshaft need not be
CAUTION
rotated more than two revolutions for the adjustment of Hydraulic oil and hydraulic oil tank may be at
all valves and unit injectors. operating temperature. Danger of scalds and
burns.
A colored pencil can be used to mark the rocker arms
that have been checked or adjusted. CAUTION
Work on the truck on level ground. Retract and
There is a special tool (1) available, shown below, to be lower the boom, stop the engine and put the
used when rotating the engine during this procedure parking brake on when working.
(please contact your authorised Linde dealer).
ATTENTION
Note the addition of pre-mixed L ubrizol to the
Lubrizol
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
108
MAINTENANCE
wheel. The drain plug for the hydraulic braking system is
located behind the drain plug for the working hydraulics.
- Place a catch tray of at least 100 L capacity 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.
- Fill hydraulic oil into the tank checking the sight glass
(1), frequently to check the oil level.
Capacity ..................................................................... 100 L
- Start the engine and carry out a functional test of the
braking system hydraulics.
357 804 25 01 GB 0104
- Stop the engine and check the oil level of the hydraulic
oil tank at the sight glass (1). If required, fill clean
hydraulic oil as far as between the HIGH and LOW
marks on the dipstick.
 MAINTENANCE
Renew the fuel tank breather filter
ATTENTION
Follow the precautions for handling fluids and
lubricants.
- Clean the area around the filter.
- Remove filter cap (1) from pipe (2) taking care not to
loosen fitting and washer (3,4).
- Dispose of filter as per local regulations,
- Clean the filter’s sealing surface on the filter housing,
and the filter cap (1).
- Fit new filter cap (1)
357 804 25 01 GB 0104
2000, 3000-HOUR INSPECTION AND MAINTENANCE
Clean the hydraulic tank pre-filter
ATTENTION
Follow the precautions for handling fluids and
lubricants.
- Remove nuts (1) from the top of each housing to
expose filter element retainer (2).
- Lift out filter housing (2).
- Clean filter pre-filter (3).
- Replace filter housing (2).
- Check oil level and replenish, if required.
Renew handler slewing gearbox and brake
oil
ATTENTION
Follow the precautions for handling fluids and
lubricants.
CAUTION
Work on the truck on level ground. Retract and
lower the boom, 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.
- Position a catch tray of at least 5 L capacity under drain
plug (2).

- Remove drain plug (2) and filler plug (1) and allow the oil
to drain.

1 2
1
1
2

3
4

3
2

109
3000-HOUR INSPECTION AND MAINTENANCE
Check, renew hydraulic oil of working
- Refit drain plug (2). hydraulic system
ATTENTION
- Fill gear oil through filler plug hole (1) up to the base of Follow the precautions for handling fluids and
the hole. lubricants.
- Refit filler plug (1).
CAUTION
Hydraulic oil and oil tank may be at operating
- Repeat for the second gearbox. temperature. Danger of scalds and burns.
CAUTION
Work on the truck on level ground. Retract and
lower the boom, stop the engine and put the
parking brake on when working.
NOTE
The operator can have the hydraulic oil analysed
MAINTENANCE
Replacing the air filter safety element
WARNING:
Stop the engine before servicing the air intake
system.
WARNING:
Under no circumstances must the safety ele-
ment be cleaned, or an attempt made to start
the truck with the safety element removed.
CAUTION:
Clean the filter casing with a damp cloth. Do
not clean the filter element.
The use of cleaning agents will destroy the filter element.
Follow the precautions for handling fluids and lubricants
- Unscrew nut (1) and remove filter end cover (2).
- Empty the dust collected in the cover and wipe clean

357 804 25 01 GB 0104

after about 2750 servi ce hours to determine if the
servic
hydraulic oil must be changed at 3000 service with a damp cloth.
hours, (refer to analyis of hydraulic oil). - Remove the dust valve (3) and clean with a damp cloth.
- Renew the dust valve if damaged.
NOTE
Technical skill and knowledge are required for this
procedure. Please send contact your authorised
dealer.

7
6

5
4
1
3

110
 MAINTENANCE 3000-HOUR INSPECTION AND MAINTENANCE
Replacing the air filter safety element General overall check
cont. Examine the mast, chassis and all welds for signs
- Refit dust valve (3). of damage, deformation, metal fatigue etc.
In case of doubt, contact your authorised dealer.
- Unscrew wing nut (4) and remove the main air filter
element (5). Inspect and renew if damaged.

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

- Examine the new safety element for signs of damage,

before installation.

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

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

- Refit end cover (2) and secure with nut (1). Ensure that
357 804 25 01 GB 0104

dust valve (3) is positioned through casing hole (9).

111
5000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Renew the twistlocks Check the handler extension cylinder
WARNING bearing pads
The twistlocks are wearing parts and must be
CAUTION
replaced for safety reasons after maximum
Work on the truck on level ground. Retract and
5000 service hours.
lower the boom, stop the engine and put the
parking brake on when working.
Contact your authorised dealer for renewal of the twist-
locks.
- Extend the handler to 40' and lock the boom extensions.

- Check that the bearing retaining nuts (2) are fitted and
tight.

- Check the bearing pad (3) thickness, minimum

thickness 8 mm.

357 804 25 01 GB 0104

1

2
3

112
 MAINTENANCE 6000-HOUR INSPECTION AND MAINTENANCE
Check the vibration damper Check the fan drive idler pulley assembly
NOTE: - Remove the fan drive belt (1). - Measure the idler pulley end clearance.
Silicone fluid inside the vibration damper will
Min...................................................................0.025mm
become solid after extensive service, which
Max..................................................................0.250mm
makes the vibration damper inoperative. This
could cause major engine or driveline
- If end clearances are not within these measure-
problems.
ments, contact your authorised dealer.
- Check the vibration damper for evidence of loss
o f fluid, 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.
357 804 25 01 GB 0104

- Inspect the idler pulley for:

Freedom of rotation,
Damaged or broken pulley groove.

113
6000-HOUR INSPECTION AND MAINTENANCE
Fan hub, belt driven
- Remove the fan drive belt (1).
- Inspect the fan hub for:
Freedom of rotation,
Cracks,
Grease seal leakage.
114
MAINTENANCE
Flush the cooling system
- Measure the fan hub end clearance.
CAUTION
Min...................................................................0.08mm
Do not remove the pressure cap, while the
Max..................................................................0.41mm
engine is hot. Wait until the coolant tem-
perature is below 50°C before removing
- If end clearances are not within these measure-
the pressure cap. Danger of scalds or
ments, contact your authorised dealer.
burns.
357 804 25 01 GB 0104
CAUTION
Coolant is toxic. Keep away from children
and animals. Dispose of waste coolant ac-
cording to local regulations.
- Drain the cooling system, do not allow the cool-
ing system to dry out.
- Do not remove the coolant filter.
 MAINTENANCE
Flush the cooling system, continued
- Use cooling system cleaner to flush the cooling
system.
- Operate the engine at normal operating temper-
atures 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.
- 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 page 97 for recommended
357 804 25 01 GB 0104
coolant.
6000-HOUR INSPECTION AND MAINTENANCE
Check the turbocharger
- Remove the air intake and exhaust piping.
- Check the turbcharger 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.
Check the radial bearing clearance.
- Remove the intake and exhaust piping from the
turbocharger.
- 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.
- 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.
115
6000-HOUR INSPECTION AND MAINTENANCE MAINTENANCE
Check the Axial clearance Renewing the lift chains
- Subtract the smaller clearance from the larger - Use a dial depth gauge. (at least every 3 years)
clearance, this is the radial bearing clearance.
Min...................................................................0.15mm - Push the rotor assembly away from the gauge. NOTE:
Max..................................................................0.64mm Please contact your authorised dealer for
- Set the gauge to zero. renewal of the lift chains.
- If end clearances are not within these measure-
ments, contact your authorised dealer. - 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-fit the intake and exhaust piping.

357 804 25 01 GB 0104

116
 MAINTENANCE INSPECTION AND MAINTENANCE DATA
No. Assembly Aids/Oils and Lubrication Filling Capacity/Rated Values

1 Engine Engine oil approx. 35 lts.

2 Fuel tank Diesel approx. 450 lts.

3 Cooling system Water and antifreeze mixture approx. 44 lts.

4 Working hydraulic system oil tank Hydraulic oil approx. 800 lts.

5 Braking system oil tank Hydraulic oil approx. 100 lts.

6 Brake relay hydraulic system Hydraulic oil as required

7 Drive axle differential Gear oil approx. 75 lts.

8 Drive axle hub Gear oil approx. 7 lts.

9 Steer axle hub Gear oil approx. 4 lts.

357 804 25 01 GB 0104

10 Transmission Transmission oil approx. 6 0 lts.

11 Battery Distilled water as required

12 Tyres Air 10 bar

13 Wheel mounting nuts 350 Nm

14 Grease points on boom, Lubricating grease as required

handler and chassis

15 Handler rotator gear Molybdenum lubricating grease as required

16 Temperature switch Oil Engine oil temperature 130 °C

17 Valve clearances Inlet 0.2 mm

Exhaust 0.5 mm

18 Fuel injection nozzle Diesel Operating pressure 246 bar

Pressure setting 264 bar

19 Drive belt tension

- Fan-alternator Belt deflection approx. 10 mm

117
FUEL AND OIL RECOMMENDATIONS
Engine oils Gear oil Electrical contact grease
API classification: CCMC D5, API-CE MIL-L2104C-class 10 For use on all electrical connections.
API CD/SE or CD/SF grade 10 Part number: 733.950.00.20
Oil grades
Transmission oil
Engine oils of API classification CD or less are not recom- Multipurpose grease
mended due to the extended drain cycle given for this Only Dexron III oil is approved for use.
engine application. Penetration stage 2 to ASTM 26-295 1/0 mm

During engine operation, part of the oil serving as a lubri- Handler slew gearbox and brake
cant for the piston is combusted (“consumed”). The prod- Handler ring gear grease
SAE 90 Gear oil to with additives to specification
ucts of combustion and the high temperatures combined
J306a. Linde heavy duty grease lithium based with EP and
lead to “wear”, particularly of the chemical oil additives.
e.g. Esso compressor oil G150 MOS2 additives.
For this reason the oil must be changed at certain inter-
e.g. Mobil Glygoyle 22
vals. Designation acc. to DIN 51825-KPF 2N-20 (see the Parts
Since this oil wear depends on the operating conditions Catalogue for order number).
Hydraulic oil for working hydraulics
and the quality of the oil (oil performance) and fuel used, Do not mix with grease types other than lithium-based
oil change intervals of different lengths result. ISO VG 46 (factory filling) greases.
Oil additives of any kind must not be used with any of the

357 804 25 01 GB 0104

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.
Hydraulic oil analysis General lubricating oil
The working hydraulic system has a capacity of 800 lts. To General penetration oils
reduce the high level of expenditure required if the oil is
renewed at the 3000 hour service, the operator may use Battery grease
a reputable oil analysis company to determine the state of
the hydraulic oil. This analysis should be made between Non-acidic grease (terminal grease).
2750 and 3000 hours run.
The results of the analysis should be recorded to Central lubrication
support any warrant claim which may arise from
The grease must be an EP grade NLGI-0 grease with a
defects in the working hydraulic system subsequent
lithium/calcium base. It must not contain any additives
to the analysis.
such as graphite or PTFE.
Where oil analysis is not available, the recommend-
A grease from Greenlube is recommended. If difficult to
ed 3000 hour oil renewal is mandatory.
obtain, please contact your authorised dealer.

Hydraulic oil (brake system, brake cylin-

der)
ISO VG 46 (factory filling)

Hydraulic oil additives (brake system)

Use only pre-mixed Lubrizol solution,
(part number 7 329 400 116).

118
 FUEL AND OIL RECOMMENDATIONS
Coolant Diesel fuel
Only use coolants with a monoethylene glycol base Use only Diesel fuel to DIN EN 590 with a cetane number not In winter, fill only winter diesel fuel to prevent any clogging
and containing a rust inhibitor. lower than 45. caused by paraffin precipitation. At very low temperatures
you must reckon with disturbing precipitations even if
Do not mix with antifreeze containing ethanolamine. The sulphur content should not exceed 0.5 %. If the sulphur
winter diesel fuel is used.
Mixing ratio for lower temperatures: content is 0.5 to 1%, the oil change intervals must be
halved.
NOTE
Temperature Antifreeze Mixture ratio If the values are higher, contact the manufacturer of the lift These are only recommendations. In case of doubt
down to % water:antifreeze truck or the supplier of the lubricant. we recommend you contact your authorised dealer.

-12°C 25 1:3 NOTE

-18°C 33 1:2 As the ambient temperature decreases, so does the
-22°C 40 1:1.5
-37°C 50 1:1 fluidity of Diesel fuel due to the precipitation of
-60°C 66 2:1 paraffin. 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 -15°C is
357 804 25 01 GB 0104

available in the cold season of the year.

The addition of any form of additive will invalidate the

engine manufacturer's warranty.

119
TROUBLESHOOTING GUIDE (DIESEL ENGINE)
Trouble Possible Cause Correction See Page
Engine will not start Fuel tank empty. Refill the tank. 30

Fuel filter clogged, in winter by paraffin deposits. Renew the fuel filter, use winter fuel. 83, 104

Water in fuel system filter. Drain, clean the fuel filter. 72

Fuel shut off solenoid fails to open. 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 fittings.

Battery charging indicator light not illuminated
although lamp is okay.
Preheating system defective.
Tighten terminal clamps at battery, check cable connections. 72
Check the power supply. Check the cables and connections
at the preheat/starting switch. If the fault can not be remedied,
contact your authorised dealer.

357 804 25 01 GB 0104

These faults should always be checked and corrected by
Fuel pump defective. skilled staff.
Injection nozzles defective. Please contact your authorised dealer.
Injection pump defective.
Engine idling speed incorrect.

Engine starting performance Battery power is too low. Battery terminal Check battery, clean battery terminals, tighten clamps and 72
is poor loose or oxidized, causing the starter to turn cover with non-acidic grease.
only slowly.

Fuel supply insufficient. Renew the fuel filter. Check the fuel line connections for 84
Restriction or air in fuel system due to paraffin leaks and tighten fittings.
deposits in winter. Use winter fuel in the cold season. 104

Particularly in winter:
Filled engine oil viscosity too high. Use engine oil appropriate for the ambient temperature. 104

Engine running and buzzer Oil pressure in hydraulic braking system below Let engine continue to run until minimum pressure is 38
sounding operating pressure. reached.

120

Trouble
Engine running unevenly
with poor performance
Excessive exhaust smoke
Idle running trouble
357 804 25 01 GB 0104
Engine overheating, red
warning light in instrument
panel illuminated. Stop the en-
gine immediately.
Engine oil pressure too low.
Stop the engine immediately.
Battery charging indicator
light illuminated during op-
eration
TROUBLESHOOTING GUIDE (DIESEL ENGINE)
Possible Cause Correction See Page
Fuel supply insufficient. Renew the fuel filter. Check the fuel line connections for 84
Restriction or air in fuel system due to paraffin leaks and tighten fittings.
deposits in winter. Use winter fuel in the cold season. 104
Injection pump overflow valve not functioning Contact your authorised dealer.
correctly.
Valve clearances not as specified. Adjust valve clearances. 97
Injection nozzles defective. Contact your authorised dealer.
Engine oil level too high. Drain oil to the high mark on the dipstick. 82
Poor compression due to burned-in or broken Adjust valve clearances. 97
piston rings or incorrect valve clearances. Contact your authorised dealer.
Fuel system not in order. Clean and inspect fuel filter and fuel filter, renew if neces- 72, 84
sary. 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 author-
ised dealer.
Coolant level low. Check cooling system for leaks, seal if necessary. 28, 94
Add coolant.
Fan V-belt either slack or broken. Tighten or renew the V-belt. 88
Radiator fins restricted due to dirt or foreign Clean the radiator. 74
objects.
Injection system setting incorrect. Contact your authorised dealer.
Leaks in the lubricating system. Contact your authorised dealer.
29, 82
Oil level too low. Add lubricating oil.
88
Alternator RPM too low. Check V-belt tension.
Alternator not charging the battery because Contact your authorised dealer.
alternator or relay defective.
121
TROUBLESHOOTING GUIDE (HYDRAULIC SYSTEM)

Trouble Possible Cause Correction See Page

Abnormal noise Suction filter restricted. Renew the suction filter. 99
Suction hoses leaking, oil foaming. Tighten lines. Check oil level, top up if necessary. 27, 91
Hydraulic pump or motor failure, seals defective, Have hydraulic unit inspected by your authorised
causing air intake. dealer.
Incorrect oil viscosity, low oil level in tank or in Change oil, be sure to use the correct viscosity, 27, 109, 103
hydraulic pump. replenish oil.

No or too low pressure in sys-
tem
Pump suction defective, noise. Change oil, replenish oil. 27, 109
Pump failure, leakages, pressure valves do not Contact your authorised dealer.
close, valve seat damage.
Pipe broken or leaky. Replace or tighten line. 91
Oil of low viscosity, causing high leakage losses. Change oil, be sure to use oil of correct viscosity. 109, 103
Oil temperature warning lamp illuminated. Check oil level, clean oil cooler.

357 804 25 01 GB 0104

Oil pressure fluctuating
Cause as under abnormal noise. See under abnormal noise.
Pressure relief valves or boost pressure valves Contact your authorised dealer.
sticking.
Lift and tilt cylinders have tight spots. Contact your authorised dealer.
Boom does not extend completely or retracts slightly Replenish hydraulic oil. 27
after being extended.

No oil flow or low oil flow
Suction filter restricted (if accompanied by noise).
Pump faulty, leakage, pressure relief valves do not
close, valve seat damaged.
Pipe broken or leaky.
Valves restricted.
Hydraulic system overheating.
Clean or replace suction filter. 99
Contact your authorised dealer.
Replace or tighten line. 91
Contact your authorised dealer.
Check oil level, use specified oil, clean oil cooler, if needed. 27, 90, 103

Hydraulic oil temperature too Pump failure, valves leaky. Contact your authorised dealer.
high Oil level too low or oil cooler defective. Check oil level, if necessary top up oil. Clean cooler and 27, 90, 103
check for leaks. If defective, contact your authorised dealer.

122
 ELECTRICAL CIRCUIT DIAGRAM

916
PG 6
:30 5/6/504 :30 B+ :30 B+
:15 IGN 4/10/123 :15 IGN

F:MAIN 1
120 AMP
F12 F13 F1 F2 F3 F4 F16

5
3 AMP
6/504
20 AMP 5 AMP 10 AMP 10 AMP 5 AMP 5 AMP
K1

124

497
F27:IGN Pg1:27

29

25
X10:4

496

409
110

7
161

13
X10:20 X10:21 X10:18 X10:3 X10:2
30

K15 S1
H1 24V
58

12V
B1 19
17
X1:7 X1:8 X1:5 X1:2 X1:1
50a

S2 X1:3
15/54 I,0
III
II I

13a

497
496

409
474

40-0

29

25
916b

16
916

79
357 804 25 01 GB 0104

X1:6
Pg1:42

110
124
125
F:MAIN 2

Radio
7 8 17 18 28 38
0.1A

Coolant Level Switch

474

BAT1 BAT2 IGN

122

B2 Pg2:87 463 5

D
IQAN-XS
S3 464 7 A1 S2

79a

C
CUMMINS QSM11 BAT IGN
412 19 ENGINE DANA CLARK

A B
411 6
B3 TE27 TRANS.

79
114
24V
exitation K1 4
29 30 39 40 37 A3 B4 S3
G2

129b
129d
129e

129a

129c
M1 G1

115

137
P
S4

40
506

150

129
:31 :31

:115/129/137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

c 16/12/03 PRH DESIGN UPDATE B16069

Safed on: LL-BL ACAD

b 13.05.03 RHP POST PROTO ISSUE FOR TRAINING B15826

a 26.09.02 PAULY FIRST ISSUE B 15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 26.09.02 PAULY Title 357 MARK3 none
Checked ELECTIC SCHEMATIC
Linde CAN-BUS GENERATION sheet: 1
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

123
 ELECTRICAL CIRCUIT DIAGRAM

:30 B+ :30 :30

:15 IGN :15 4/10/123 :15
:15 EMER 658 :15 EMER
:02 RPM :02 RPM
Page 13
F14 28-0
40 AMP Page 10 F33
5 AMP

28-0b

28-0c
446 :15 GEAR SELECT ROTATOR :15

640
659
S6
S5

28-0f
Page 10
658
640a

446
KICK DOWN

IGN KEY

Pg1:22
START
F R
N

1st GEAR
2nd GEAR
KD

4th GEAR
:J :53 :53b :31b F R
35-0

3rd GEAR

11-0
09-0

10-0

22-0
13-0
12-0

23-0

40-0
SPREADER
28-0

DINI:XS0:25

XS0:11
red lights

XS0:10

XS0:12

XS0:13

+BATA
DOUTC

XS0:22

XS0:23

XS0:28
DIND

DING
DINA

DINC
XS0:9

DINB

DINE

DINF
XS0:35

DINO:XS0:40

357 804 25 01 GB 0104

DINJ:XS0:26 yel. lights

DINK:XS0:27 gre. lights

Parker IQAN XS:ADD0 CAB FRONT/FLOOR
B5

DOUTA
DOUTB
XS0:14

DINM
XS0:38

XS0:39
XS0:15

XS0:21

DINN
XS0:20
XS0:16

XS0:37
XS0:1

XS0:2

XS0:3

XS0:4

XS0:5

DINL
VIND

-BAT
VINA

VINC
VINB

+VRef
VINE
-VRef

16-0
5-0

38-0

39-0
4-0
1-0

3-0
2-0

20-0
21-0
14-0
01-0b

01-0d

01-0e
01-0c
01-0a

moving cab swwitch

15-0
BRAKE PEDAL
3 3
K2

br
THROTTLE PEDAL

S7

central warning light

service brake
supply presure

pressure

brake cooler relay

2 2
brake pedal

P P
H2
1 1
15-0c
15-0a
15-0b

R3 R2

215
R1

904
:31 :31

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

c 16/12/03 PRH DESIGN UPDATE B16069

Safed on: LL-BL ACAD

b 13.05.03 RHP POST PROTO ISSUE FOR TRAINING B15826

a 26.09.02 PAULY Production issue B 15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 26.09.02 PAULY
Title 357 MARK3 none
Checked ELECTIC SCHEMATIC
Linde CAN-BUS GENERATION sheet: 2
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

124
 ELECTRICAL CIRCUIT DIAGRAM

:30 :30 :30

:15 :15 4/10/123 :15
:15 EMER 658 :15 EMER :15 EMER

F34
5AMP

28-1e
28-1d

28-1c
28-1

7 S9 S10

28-1g
28-1f/g
R4
Joystick

Override key
:58 :49a/+
handbrake switch

:31 :L/S1
15 8 1 14 5 4 3 11 10 9 S11
Pg 10

15-1a

1-1a

23-1
S8
28-1b

1-1

3-1
22-1
S34

12-1

13-1
11-1
10-1

2-1
15-1
175

9-1
357 804 25 01 GB 0104

XS1:10

XS1:12

XS1:22

XS1:2

XS1:3
DIND
DINB

DINF

VINA

VINB

XS1:22

XS1:16

XS1:17
XS1:28

XS1:23
XS1:4

DING
DINA
XS1:9

XS1:5
+BAT

VIND
VINC

VINE

VINF
XS1:15

VINC
DOUTA

XS1:1
XS0:20

XS1:11

XS1:13

+VRef
DINC

-VRef
DINE
14-1 -BAT
XS1:14
Parker IQAN XS:ADD1 CAB ARMREST/REAR/LHS
B6

DOUTD
DOUTA

DOUTC
DOUTB

XS1:27

XS1:25

XS1:26
XS1:21
XS1:20

XS1:35

XS1:36

DINK

DINJ
DINI
25-1

26-1
185

36-1
21-1

35-1
20-1

B7 B8 8
1 7 2 10
warning buzzer

rocker swich
alarm buzzer

handbrake light

moving cab
H4
Low fuel warning

3 4 9
H3
S12

903
28-1a

905
901
906

902

:31 :31

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150

c 16/12/03 PRH DESIGN UPDATE B16069

Safed on: LL-BL ACAD

b 13.05.03 RHP POST PROTO ISSUE FOR TRAINING B15826

a 26.09.02 PAULY Production issue B 15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 26.09.02 PAULY
Title 357 MARK3 none
Checked
ELECTIC SCHEMATIC
Linde CAN-BUS GENERATION sheet: 3
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

125
 ELECTRICAL CIRCUIT DIAGRAM

:30 BAT+ :30

:15 IGN :15
:15 IGN:Emer :658

F35 F37
20AMP
3AMP
X10:23 INPUTS 0-28
X5:1 OUTPUTS

666
0-28a 0-42

0-28d
0-28g

0-28b
0-28h
0-28e
0-28f

0-28c
0-12 666a/b
+Vref, Pos12 IQAN MDM

+Bat: Pin28

666c
+Bat: Pin42
c PG6:295

S13 S14 B9
p p
B10
0-21 VinA:Pin21
0-32 X11:4 X5:4 X10:26

0-22
Cret-A+:Pin32 LED LOAD
R12 1 VinB:Pin22 0-31 X11:5 X5:5 X10:25
R4 R5 Cout-A:Pin31 INDICATOR
3 0-39 VinJ:Pin39
R11 1 P
120 Ohm

120 Ohm

Chassis LHS, Add:0

DoutE:Pin6 0-6
3 2 0-24 VinD:Pin24

Parker IQAN XT2

R10 1 P
0-2
DoutA:Pin2
0-25 VinE:Pin25

0-6b
3 2 0-2c

0-6a
P

357 804 25 01 GB 0104

Brake Lights
R9 1 0-3

0-2b
DoutB:Pin3

0-2a
3 2 0-35 VinF:Pin35
R8 1 P 0-4
DoutC:Pin4
3 2 0-36 VinG:Pin36 E1 E2 E3 E4
P DoutD:Pin5 0-5 B11
2
Y1 Y2 Y3
0-37

Reverse Lights
VinH:Pin37

Reverse Buzzer
-GND: Pin15
-GND: Pin29

forward
Moving cab
DoutF:Pin7

handbrake
reverse

solenoid
0-38 VinI:Pin38

R6 R7
0-13d

0-13e
0-13c

0-13g
0-13f

0-13

115
128
0-29

171

180

183

343

344
24

42
K15
0-13a 0-13b -Vref, Pos13
Pg1:8

0-15

130
:31 :31

151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200
brake temp

bottom RHS

bottom LHS
fuel level

handbrake
top side No.1

filter switch
top side No.2

lift cylinder

lift cylinder

pilot pressure
sender

lift cylinder
lift cylinder

warning

Relay by Start
sender

brake oil

Engine Start

c 16/12/03 PRH DESIGN UPDATE B16069

Safed on: LL-BL ACAD

b 13.05.03 RHP POST PROTO ISSUE FOR TRAINING B15826

a 26.09.02 PAULY Production issue B 15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 26.09.02 PAULY
Title 357 MARK3 none
Checked
ELECTRIC SCHEMATIC
Linde CAN-BUS GEENERATION sheet: 4
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

126
 357 804 25 01 GB 0104

Safed on: LL-BL ACAD

201
S15

1-28d

202
1-13h P
3
4

:31

203
LS

Y11
Electric 1-39
2

204
PWM-A:Pin2 Vin-J:Pin39
Steering Right 1-28c
1-13g

205
P
3
4

spare
P

206
S16
2

1-38

207
Electric Vin-I:Pin38
Steering Left PWM-B:Pin3

208
1-12

Y12
+Vref.Pin12

209
1-13a

1:18

210
1-13
1-12a

Cret-A+:Pin18
-Vref.Pin13

211
Lift Prop.
1:17 1-13b 1-12b

Y5
Valve Cout-A:Pin17

212
:15 EME (F14)

Vin-A:Pin21 1-21

213
Boom
ELECTRICAL CIRCUIT DIAGRAM

length

214
R13

1:31

Y6
Lower Prop. Cout-A:Pin31 1-13c 1-12c

215
Volve 1-22
1:32

216
Cret-A-:Pin32 Vin-B:Pin22

217
1:20 Cret-B+:Pin20

218
Ext. Prop.
1:19 1-13d 1-12d

Y7
Valve Cout-B:Pin19

219
1-23
Vin-C:Pin23

220
658

angle
Boom

221
R14

1:33 Cout-B:Pin33
Retr. Prop.
Y8

222
1-13e 1-12e
Volve
1-24

223
1:34 Cret-B-:Pin34 Vin-D:Pin24

224
225
Y9

PILOT
644
spare

WDO

226
B12
angle

ADD:01
Steering

R15

227
IQAN-XT2

LS
228
:15 EME (F14)

1:05
WDO Dout-D:Pin5
229
spare

230

Vin-E:Pin25
1:06
231

Steering Dout-E:Pin6
angle

WDO
232
Steering

R16

233

Moving 215 1:07 Dout-F:Pin7

234

Cab Supply
Y10

235

1:15 Vin-F:Pin35
-BAT:Pin15
236

a
b
c

1:29
237

-BAT:Pin29 1-13i
Drawn
Checked
Date
238
Y4

120 Ohm
c
R18

Vin-G:Pin36
13.05.03
26.09.02
16/12/03
239

PWM CEB14 126b 1-02 Hydr. Temp.

Dout-A:Pin2
26.09.02

Heavy Truck
Linde
240

1-28a
Protection under DIN 34

PUMP CONTROL
Division Ltd.
RHP

BAT+:Pin28
PRH

PAULY

Date Name
Checked Alteration
241

VING 1-42
Vin-H:Pin37 BAT+:Pin42
PAULY
242
R17
1:37

243

repl.
Title
DESIGN UPDATE
244

Hydr. Tank
Production issue

Dr. No.:

Oil Level
245

4K7Ohm
change no fit Toler.

617
S

632
246
5 sec
:15 EME (F14)

POST PROTO ISSUE FOR TRAINING

:31

1-28
247

631 1-28b
S17

248
X5:2
X11:2

CAN-BUS GENERATION
357 MARK3
249
20AMP

X10:24

ELECTRIC SCHEMATIC
F36

250

Orig.
357 802 0131
B15826
B16069

B15374

of:
scale

sheet:
none

17
5

127
 ELECTRICAL CIRCUIT DIAGRAM
pg 1
916
:30 6/504 :30
:15 4/10/123 :15
:15 EMER 4/10/123 :15 EMER

RHS CHASSIS LHS CHASSIS CAB FRONT CAB REAR TOP

F17
ADDRH ADDRH 3AMP
IQAN XT2 XT2:0:1 IQAN XT2 IQAN XS CAN1:3 IQAN XS IQAN MDM
:Add1 ADDRL B9 :Add0 B5 :Add0 ADDRL
B6 :Add1 B13
XT2:0:14 CAN1:4

CAN:5, +bat

CAN:3 -BAT
B12

CAN:6 IGN
XT2:01:01

XT2:01;14

916A

CAN:4 H
CAN:1 L
CAN2H

CAN1:2

CAN1:6

CAN2:2

CAN2:6

CAN1:2

CAN1:6

CAN2:2

CAN2:6
CAN2L
XT2:16

XT2:26

XT2:40
XT2:41

XT2:27

XT2:41
XT2:30

XT2:27
CANH
CANH

CANH

CANH
CANL

CANL
CANL
R20

0-27b
0-41b
666a
R19 X3:5 F37
0:16 0:41a 0:41b
0:27 Pg4:199
0:30 0:41 0:27a 0:27b

X3:4
188

357 804 25 01 GB 0104

R21 666b

0:40

0:26

37 46

TRANSMISION ENGINE MAIN SCREEN MODEM

B4 B3 B15 B14

CAB BOTTOM CAB TOP

REAR
:31 :31

251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300

b 05.06.03 RHP DESIGN UPDATE B15826

Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name
Drawn 26.09.02 PAULY
Title 357 MARK3 scale
none
Checked ELECTRIC SCHEMATIC
Linde CAN-BUS GENERATION sheet: 6
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

128
 ELECTRICAL CIRCUIT DIAGRAM

6/504 :30 :30

4/10/123 :15 :15

30 AMP
F27
:217 (F27) :217 (F27)
Pg 1:15

F23 F25 F24 10 amp

10 amp 15 amp 240

54
152
52

8
153
S20A/B :J
Rear Top 43 :H WIPE
0
wash S18 wash S19 HORN 1 J
:2 :9 :2 :9 2
wipe wipe wipe wipe
2 2

WASH

8
357 804 25 01 GB 0104

:7 :5 :6 :3 :1 :7 :5 :6 :3 :1
:31b :53b :53 :15 :53c
229

88
87

227

329
226
228
X15:1 X15:2 X14:1 X14:4
225 B16
X15:3
I S 31b 15 86

354
136

55

51
57

58
56
86
71

84
85
135
53

47
48

50

X21:2 X21:6 X21:5 X21:3 X14:2

M4

113
M5
M6 M7 M8
X15:4 X14:3 X14:3 K4 X21:1 M3

75

82
67
75
66

146/65

75

X14:3
31

241
:31 :31
301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350

b 05.06.03 RHP DESIGN UPDATE B15826

Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 07.04.00 PAULY
Title 357 MARK3 none
Checked

Linde electric circuit sheet: 7

Heavy Truck
Division Ltd. Dr. No.: 357 803 0131 of: 17
Protection under DIN 34
repl. Orig.

129
 ELECTRICAL CIRCUIT DIAGRAM

:30 6/504 :30 :30

:15 4/10/123 :15 :15
:02
217 (F27)

F22 F9
F8 F19 F20 F21 15AMP 15AMP
3AMP 5AMP 20AMP 20AMP

311

302
S21

305
S20C

480

307
27

14
12
9

26
:9 :1 :2 :56 :15/1

190

30
:10 :3 :6 :8
S23 S22

345
:5 :6 :9 :5 :6 :9
312
:56a :56b

346
316
:1 :2 :10 :1 :2 :10
F39 F40

357 804 25 01 GB 0104

S24
1AMP 1AMP

317
F43
189

X4:8 X4:9

194
193
59

111

345L
310

345R
5AMP
X10:1
482 X10:14 X10:15 F41 F44
X40:7 X40:8 5AMP F42 5AMP

317R
317L
346L

346R
5AMP
X4:2
X4:13 X4:12 X4:14 X4:11

308
X4:3

309
X10:5

316
X10:6 X10:16 X10:17
270

X10:10 X10:11

X35L:1
X38:19

X35R:1
X35R:3 X35L:3
CABIN INTERIOR LIGHT

X38:20
ROTATING BEACON BOOM

X35R:2 X35L:2

DIP LIGHT

DIP LIGHT
SIDE LIGHTS
ROTATING BEACON CAB

E10 E11 E12 E13

SPREADER LIGHTS

BOOM LIGHTS

HEAD

HEAD
E6 H6

X35L:5
X35R:5
E5 E8 E9 E14 X35L:5 E15 X35R:5
140
193/65

343

328
200

344
334/339
75

333/339

333/339
334/339
E7
:31 :31

351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400
b 05.06.03 RHP DESIGN UPDATE B15826
Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 26.09.02 PAULY
Title 357 MARK3 none
Checked
ELECTIC SCHEMATIC
Linde CAN-BUS GENERATION sheet: 8
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

130
 ELECTRICAL CIRCUIT DIAGRAM

:30 6/504 6/504

:15 4/10/123 4/10/123
:02

F18 F6 F7
5AMP 5AMP 20AMP

303
304
S25

:15 :+ :30

222
H5

:31 :L :R :49A :49

318
330
326 321

H7

319
324

325
357 804 25 01 GB 0104

:49A K2
322 323 Pg 2:81

X4:11 X4:12
X17:7 S20D X17:8

210
335

320

327
321
325
326

324

K5
X35R:4 X35L:4

E16 E17 E18 E19 M9

X35R:6 X35L:6
343
337

344

332
340

:31 :31

401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450

b 05.06.03 RHP DESIGN UPDATE B15826

Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B 15374
Date Checked Alteration change no fit Toler.
Date Name scale
Drawn 26.09.02 PAULY
Title 357 MARK3 none
Checked
ELEECTIC SCHEMATIC
Linde CAN BUS GENERATION sheet: 9
Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

131
 ELECTRICAL CIRCUIT DIAGRAM

:15 :15
:15 (F30)
217 (F27) 217 (F27)
677
F26

677
510

201
714
713

712

714

715

718

733
201
S27 S28 S30 S31 S32 S33 S34 S35
4
S29 4
9 3 9 3
701

S26
10 1 7 2 8 10 1 7 2 8
3xPG8:395

726
209

723
208
729

730

734

735

719

720

727

728

723

726

657

735

736
655 708

654 706

653 704
739 739
X37:8

X37:7

X37:6

357 804 25 01 GB 0104

740

640
X38:12; X41:12

X38:13; X41:13

X38:16; X41:16

X38:15; X41:23

X38:10; X41:10

X38:11; X41:11
X38:14 X41:22
X39:1; X41:17
X39:2; X41:18
X38:8; X41:8
X38:9; X41:9

X38:4; X38:4

X38:3: X41:3
707

704
703

708
705

706

Pg 3:130
X41:5

X36:4
X4:16
X41:6

X41:7

XS1-22
Page 2: 54
1

640
659
S5

NO. 3/+
NO. 4/+
NO. 8/LOCK
NO. 9/UNLOCK

NO.11: RETRACT
NO. 16/ROT. CW

NO. 11/RETR. 20'

NO. 17/ROT. CCW

NO. 10/EXT. 40'

NO.10 EXTEND
NO. 18 SPR, HYDR.

NO. 13/SIDESH. RH
NO. 6/RED LIGHT

NO. 12/SIDESH. LH
NO. 7/YEL. LIGHT
NO. 5/GREEN LIGHT

658
640a
POWER

NO. 1/GND
NO. 2/GND
Page 2: 54

ELME SPREADER
X42:1

X42:2

X42:3

H8 H9 H10 Y3

X41:2
X41:1
H10A H9A H8A

641
709

709

709

451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500

b 05.06.03 RHP DESIGN UPDATE B15826

Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 25.10.00 PAULY
Title 357 MARK3 none
Checked

Linde electric circuit sheet: 10

Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

132
 133
11
of: 17
none
sheet:
scale

Box on -
1,2
1
rotator Box on spreader
2 PCB 3 1,2
11 38
-
3 3,4
+24 V
12 39
4
B15374

9 36
Print no. 757 324A
B15826

10 37
Controlbox PCB 2 35 + +
Orig.

L6 - 1 - S36 Locked LH side

- - -
in cab Locked 757 815 41 + +
357 MARK3

H1
+ 2 - S37 Locked RH side
Locked 3 + - -
357 802 0131

3
5 2 1 28 5 3
electric circuit

36 + +
- S38 Not Locked LH side
- -
Not Locked
POST PROTO ISSUE FOR TRAINING

42 + +
Not Locked H2 1 - S39 Not Locked RH side
1
- -
change no fit Toler.

6 3 2 29 6 4
37 + +
- S40
Dr. No.:

Seated LH side, front

Production issue

- -
DESIGN UPDATE

+ +
Title

4 -
38
S41
repl.

- Seated LH side, rear

4 - -
43 + +
7 - S42
- - Seated RH side, front
Seated
44 + +
H3
PAULY

Seated 2 - S43 Seated RH side, rear

2
- -
Checked Alteration

4
Date Name

3 30 7 5
Ind. Seated
PAULY
RHP
RHP

Division Ltd.
Protection under DIN 34
Linde
Heavy Truck
07.04.00

Cable to indicator -
box in cab
05.06.03

18 16
13.05.03
26.09.02

6 33 22
+
Date

Checked
Drawn
b
a

-
1
8 13 40 8 8 47 Y14
Twistlocks Lock LH
55 Y15
759 575 Twistlocks Lock RH
PCB 4
9 14 41 9 9 48 Y16
Twistlocks Unlock LH
501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550

A
B
+ 56 Y17
- Twistlocks Unlock RH
10 1 K1
- -
9 1 15 42 10 10 49 Y18
+ Extension LH
57 Y19
Extension RH
11 2 K2
-
10 2 16 43 11 11 50 Y20
+ Retraction LH
12 58 Y21
3
- Retraction RH
11 3 19 46 12 14 63 Y22
+ Sideshift left
13 4 15 64 Y23
- Sideshift left
12 4 20 47 13 16 65 Y24
+ Sideshift right
17 66 Y25
Sideshift right
14 17 44 14 12 51 Y26
Stops Lock LH (option)
15 15
18 45 13 59 Y27
Stops Lock RH (option)
19 7 34 17 20
20 8 35 18 21 52 Y28
Stops Unlock LH (option)
60 Y29
18 Stops Unlock RH (option)
32 E20
Working light (option)
+ 34
Working light (option)
PCB 4 27 E21
16 5 54 + +
- S44 Stopswitch clockwise
- -
+ 13 5 24 58 Y30
Rotation clockwise
17 6 55 + +
- S45 Stopswitch anticlockwise
- -
ELECTRICAL CIRCUIT DIAGRAM

14 6 25 59 Y31
+ Rotation anti-clockwise
60
Y32
Brake release
22 7
- t=1,5s 61 Y33

Working light RH (option)

Working light LH (option)
+ High speed rotation
15 7 22
+
23 8 52
Y34
- Tilt LH down (option)
16 8 23 53 Y35
+ Tilt RH down (option)
21 26
Only without 45˚rotationstop

E20
E21
2

-
To Spb8
To PCB2
To Spb3
To Spb4
To Spb5
To Spb6

1
1
+
+

+
+
+
+

11
12
13
14
1
2
3
4
5
6

-
-
-
+
+
+

-
-

F10
F1

F2

F3

F4

F5

F6

F7

F8

F9
Print nr 772 236
PCB 1
Box on spreader

10
+
+
+
+
+
+
+
+
+

7
8
9
-
-
-
-
-

18

17
1
3

2
4
rotator
Box on
Safed on: LL-BL ACAD
357 804 25 01 GB 0104
 ELECTRICAL CIRCUIT DIAGRAM

U2.1

5
6
7
8
1,65m 24 6,5m

+
1
2
3
4
U2.2

Cable type A Cable type A

5
6
7
8
Electric box on spreader (L1)

+
1,2

14

13
10

15
12

16
17
18

11
4
3

3
4
1
2
6

9
5
+
-
Cable type C

+ + + + + + + + + 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
771 306 (1,0m)
Cable type B, 2x6,0 m

4,0m
+ -
+ + + 1 2 3 4 5 6 - + - +

10
ELME 772 236 ELME 757 324A

8
7
6
5
4

1
3
2
10
11
14
15
12
13

5
6

2
3

4
3
4

8
9

1
10

1
2
9
77 76 75 74 73 72 71
PCB 1 PCB 2
1 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 16 15 14 13 12 11 10 9

1
1

2
2
1 1,2

4
3

5
2

6
1

16
17
18
5
6
7
2 ELME 757 815 B -
28 29 30 31 32 33 34 35
2 55 56 57 58 59 60 61 62 PCB 3 ELME 759 575
A +

1 2 3 4 5 6 7 8
- - - - - 11 12 13 14 PCB 4

- - - - - 7 8 9 10 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 63 64 65 66 67 68 69 70

24
5
6
7
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 8 7 6 5 4 3 2 1
2
1

4
4

2
3

5
2
3

6
6

1
1
4

4
2
3
2
3

1
1

7
8
5
4

6
1
2

3
19,20

357 804 25 01 GB 0104

23
22
17
16
13
12
11
10
1,2

21
18
14
15
+

-
8
9
3
4
6,2m
0,5m

771 308 (2,5m) 771 316 (6,5m) Electric box on rotator (L4)
Cable type A 2,5m
771 308 (2,0m)
771 041 771 041
U1-B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Cable type B
Connector on rotator
U1-H

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19 Working light (option)
20 Working light (option)
21 Rotation override (option)
22 Tilt LH down (option)
23 Tilt RH down (option)
24 Lift interrupt
771 320 (5,5m) 771 320 (5,5m)

-
-
+
+
Locked
Not Locked
Seated
Lock
Unlock
Extension+
Extension-
Sideshift
Sideshift
Stops Lock
Stops Unlock
Rotation CW
Rotation anti-CW
Pressure
771 316 (6,5m)
E21 Working light LH (option)
E20 Working light RH (option)

771 322 (5,5m) 771 322 (5,5m) 771 308 (2,5m)

+
+ + + +
1 5
1 5 1 5 1 5 1 5
2 6
2 6 2 6 2 6 2 6
3 7
3 7 3 7 3 7 3 7
4 8
4 8 4 8 4 8 4 8

551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600
b 05.06.03 RHP DESIGN UPDATE B15826
Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 07.04.00 PAULY
Title 357 MARK 3 none
Checked

Linde electric circuit sheet: 12

Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

134
 ELECTRICAL CIRCUIT DIAGRAM

:30
:15
:02

258
F45 F46 F28

30 A
40 A

3A

90
X34:10
IGN
K9 K8 K7 K6

CLUTCH
TRINARY

CONDENSER

85
85

85

85
86

86

86

86
87a
87a

87a

87a
87

87

87

87
30

30
30

30
F50 F49 F48 F47
357 804 25 01 GB 0104

25A
3A
10A

10A
LINK SET IN POS.2 close

LINK POS.1 OPEN

CONDENSER 'ON'
TRINARY ' ON'

LP/HP FAIL

CLUTCH 'ON'
H15 H14 H12

POWER
H13 H11

R
G
OB

YB
OB

GW

O
X34:2
X43:3

connected by blower only

257

255

256

253

254

250

X43:1/2
X34:1
X6:9/10
X43:7
X34:7
X6:15

X43:5
X34:4
X6:13

X43:6
X34:5
X6:14

X43:4
X34:3
X6:12

X34:6
X43:4

see Page 12 251/252

601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 634 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650
b 05.06.03 RHP DESIGN UPDATE B15826
Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 07.04.00 PAULY
Title 357 MARK3 none
Checked

Linde electric circuit sheet: 13

Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

135
 ELECTRICAL CIRCUIT DIAGRAM

see Page 11

X34:2
X43:3
257

255

256

253

254

251/252
250

X43:1/2
X34:1
X6:9/10
X43:7
X34:7
X6:15

X43:5
X34:4
X6:13

X43:6
X34:5
X6:14

X43:4
X34:3
X6:12

X34:6
X43:4
GW

FROST STAT

GW

GW
S46
OB

OB

YB

O
BLOWER SWITCH
GW R R
S49

GW
AC 'ON' SWITCH

1
S48

3
2
1
0
250

2
RU
RU
AMBIENT
CONDENSER FANS

357 804 25 01 GB 0104

W
P

S
3 1 COMPRESSOR S47 STAT.
RU

R
CLUTCH
B17

B
3 2 1
PULSE CONTROL

CONTROLLER 12V/24V
RL1
RU

DIGITAL TEMPERATURE
P
ON
MP LP M M B18
Y37 Y M+ RW
+ 24V.

4
YB

+ -
HP M11 M-
M10 - ve B

5
R22

R
7
TRINARY SWITCH S50 4-WAY WATER VALVE
Y36

W
TEMPERATURE PROBE M2
B

B
BLOWER

651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 680 681 682 683 684 685 686 687 688 689 690 691 692 693 694 695 696 697 698 699 700

b 05.06.03 RHP DESIGN UPDATE B15826

Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 07.04.00 PAULY
Title 357 MARK 3 none
Checked

Linde electric circuit sheet: 14

Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

136
 ELECTRICAL CIRCUIT DIAGRAM

F MAIN1 MAIN POWER FUSE (120) 16 F38 FUSE, SPARE -

B1 RADIO VOLTAGE REDUCTION 21
F MAIN2 ECM/RADIO MEMORY (0.1) 3 F39 FUSE, SIDE LGT R (1) 382
B2 RADIO 22
F1 FUSE, IGN (5) 29 F40 FUSE, SIDE LGT L (1) 387
B3 ENGINE ECM 36
F2 FUSE, QSM11 (10) 35 F41 FUSE, DIP BEAM L (5) 394
B4 TRANSMISSION MODULE 44
F3 FUSE, QSM11 (10) 37 F42 FUSE, MAIN BEAM L (5) 395
B5 IQAN XS:ADDO 70
F4 FUSE, TE27 MODULE (5) 43 F43 FUSE, DIP BEAM R (5) 398
B6 IQAN XS:ADD1 130
F5 FUSE, SPARE - F44 FUSE, MAIN BEAM R (5) 399
B7 WARNING BUZZER 115
F6 FUSE, HAZZARD (5) 408 F45 FUSE, A/C MAIN POWER (40) 637
B8 ALARM BUZZER 119
F7 FUSE, OIL COOLER MOTOR (20) 438 F46 FUSE, A/C RELAY POWER (3) 641
B9 IQAN XT2:ADD0 177
F8 FUSE, CABIN INT LIGHT (3) 353 F47 FUSE, A/C CONTROL POWER(25) 639
B10 LED LOAD INDICATOR 200
F9 FUSE, S20 LIGHTS (15) 399 F48 FUSE, A/C CLUTCH POWER (3) 632
B11 REVERSE WARNING BUZZER 194
F10 FUSE, SPARE - F49 FUSE, A/C,COND POWER(10) 623
B12 IQAN XT2:ADD1 238
F11 FUSE, SPARE - F50 FUSE, A/C,TRINARY POWER(10) 614
B13 IQAN MDM 294
F12 FUSE, ALTERNATOR EXCITE (3) 18
B14 MODEM 291
F13 FUSE, VOLT REDUCE/RADIO (20) 22 G1 ALTERNATOR 13
B15 MAIN SCREEN 282
F14 FUSE, EMERGENCY SWITCH (40) 55 G2 BATTERY 5
B16 HORNS 348
F15 FUSE, SPARE -
B17 A/C DIGITAL CONTROL 388
F16 FUSE, TRANS MODULE (5) 45 H1 LAMP, ALTERNATOR 13
B18 A/C PULSE CONTROL 679
357 804 25 01 GB 0104

F17 FUSE, MAIN SCREEN (3) 298 H2 LAMP, CENTRAL WARNING 78

F18 FUSE, INDICATORS (5) 405 H3 LAMP, LOW FUEL 109
E1 LIGHT, REVERSE L 190
F19 FUSE, ROTATE BEACON (5) 357 H4 LAMP, HANDBRAKE 126
E2 LIGHT, REVERSE R 192
F20 FUSE, S23 SPR LGT (20) 362 H5 LAMP, HAZZARD WARN 422
E3 LIGHT, BRAKE L 197
F21 FUSE, S22BOOM LGT,(20) 372 H6 LAMP, MAIN BEAM WARN 391
E4 LIGHT, BRAKE R 199
F22 FUSE, S21 SIDE LGT (20) 384 H7 LAMP, INDICATOR 413
E5 LIGHT, CAB INT 353
F23 FUSE, S18 REAR W/W (10) 304 H8 LAMP, C/H YELLOW IN CAB 461
E6 LIGHT, CAB BEACON 357
F24 FUSE, S20 FRONTW/W,HORN(15) 335 H8A LAMP, C/H YELLOW ON BOOM 451
E7 LIGHT, BOOM BEACON 360
F25 FUSE, S19 TOP W/W (10) 319 H9 LAMP, C/H RED IN CAB 459
E8 LIGHT, SPREADER 363
F26 FUSE, ARMREST SWITCHES (15) 458 H9A LAMP, C/H RED IN CAB 453
E9 LIGHT, BOOM 374
F27 FUSE, SWITCH,LGTS/ALTLGT(30) 303 H10 LAMP, C/H GREEN IN CAB 457
E10 LIGHT, FRONT R 382
F28 FUSE, AIR CON (30) 644 H10A LAMP, C/H GREEN ON BOOM 455
E11 LIGHT, REAR R 383
F29-32 FUSE, SPARE - H11 LAMP, A/C POWER 628
E12 LIGHT, FRONT L 386
F33 FUSE, IQANXS:O/GEAR SELECT(5) 65 H12 LAMP, A/C CLUTCH 629
E13 LIGHT, REAR L 388
F34 FUSE, IQANXS:1/JOSTK-H/BR (5) 102 H13 LAMP, A/C CONDENSER 622
E14 LIGHT, HEADLIGHT R 394
F35 FUSE, IQANXT2:0 (20) 155 H14 LAMP, A/C LP/HP FAIL 623
E15 LIGHT, HEADLIGHT L 399
F36 FUSE, IQANXT2:1/HYDLEVEL(20) 244 H15 LAMP, A/C TRINARY 614
E16 LIGHT, INDICATOR REAR R 408
F37 FUSE, LOAD INDICATOR (3) 197
E17 LIGHT, INDICATOR FRONT R 411
E18 LIGHT, INDICATOR REAR L 416
E19 LIGHT, INDICATOR FRONT L 419
E20 LIGHT, SPOT RH BEAM OPTION 508
E21 LIGHT, SPOT LH BEAM OPTION 508

b 05.06.03 RHP DESIGN UPDATE B15826

Safed on: LL-BL ACAD

a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING

26.09.02 PAULY Production issue B15374
Date Checked Alteration change no fit Toler.

Date Name scale

Drawn 07.04.00 PAULY
Title 357 MARK 3 none
Checked

Linde electric circuit sheet: 15

Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

137
 ELECTRICAL CIRCUIT DIAGRAM

K1 RELAY, MAIN POWER 26 S6 SWITCH, GEAR SELECTOR 75 Y1 SOLENOID, MOVE CAB REV 183
K2 RELAY, BRAKE OIL COOLER 81/435 S7 SWITCH, MOVING CAB 92 Y2 SOLENOID, MOVE CAB FOR 186
K3 RELAY, STARTER 9/179 S8 SWITCH, H/BRAKE 105 Y3 SOLENOID, H/BRAKE 188
K4 RELAY, INTERMITTENT WIPER 330 S9 SWITCH, JOYSTIK BUTT 113 Y4 SOLENOID, CEB 14 192
K5 RELAY, HAZZARD 423 S10 SWITCH, JOYSTIK SW 118 Y5 SOLENOID, LIFT PROP 212
K6 RELAY, A/C IGNITION 636 S11 SWITCH, O/R KEY 145 Y6 SOLENOID, LOWER PROP 215
K7 RELAY, A/C CLUTCH 628 S12 SWITCH, MOVING CAB 144 Y7 SOLENOID, EXTEND PROP 219
K8 RELAY, A/C CONDENSER 619 S13 SWITCH, H/BRAKE WARN 168 Y8 SOLENOID, RETRACT PROP 222
K9 RELAY, A/C TRINARY 610 S14 SWITCH, BRAKE OIL FILTER 170 Y9 SOLENOID, PILOT WDO 225
S15 SWITCH, HYD LS PRESS 202 Y10 SOLENOID, MOVING CAB SUPPLY 233
M1 MOTOR, STARTER 9 S16 SWITCH, HYD PILOT PRESS 206 Y11 SOLENOID, STEERING R 204
M2 MOTOR, BLOWER 693 S17 SWITCH, HYD TANK LEVEL 243 Y12 SOLENOID, STEERING L 208
M3 MOTOR, FRONT WASHER 337 S18 SWITCH, REAR WASH/WIPE 306 Y13 SOLENOID, SPREADER HYDS 499
M4 MOTOR, FRONT WIPER 344 S19 SWITCH, TOP WASH/WIPE 321 Y14 SOLENOID, LOCK LH 535
M5 MOTOR, REAR WIPER 304 S20A SWITCH, FRONT WASH/WIPE 340 Y15 SOLENOID, LOCK RH 534
M6 MOTOR, REAR WASHER 308 S20B SWITCH, HORN 344 Y16 SOLENOID, UNLOCK LH 533
M7 MOTOR, TOP WIPER 316 S20C SWITCH, DIP/MAIN 396 Y17 SOLENOID, UNLOCK RH 532
M8 MOTOR, TOP WASHER 323 S20D SWITCH, INDICATORS 413 Y18 SOLENOID, EXTEND LH 531
M9 MOTOR, BRAKE COOLER 435 S21 SWITCH, SIDE/HEAD 381 Y19 SOLENOID, EXTEND RH 530
M10 MOTOR, A/C CONDENSOR 1 663 S22 SWITCH, BOOM LIGHTS 373 Y20 SOLENOID, RETRACT LH 529
M11 MOTOR, A/C CONDENSOR 2 665 S23 SWITCH, SPREADER LIGHTS 363 Y21 SOLENOID, RETRACT RH 528
S24 SWITCH, CAB INT LIGHT 353

357 804 25 01 GB 0104

Y22 SOLENOID, S/S L 527
R1 RESISTOR, THROTTLE 69 S25 SWITCH, HAZZARD LIGHTS 420 Y23 SOLENOID, S/S L 526
R2 SENDER, SERVICE BRAKE 63 S26 SWITCH, OVERIDE KEY-BEAM 458 Y24 SOLENOID, S/S R 525
R3 SENDER HAND BRAKE 58 S27 SWITCH, TWIST LOCK/ULOCK 464 Y25 SOLENOID, S/S R 524
R4 RESISTOR, 120 OHM 151 S28 SWITCH, SIDESHIFT L 468 Y26 SOLENOID, STOPLOCK L 523
R5 RESISTOR, 120 OHM 153 S29 SWITCH, SIDESHIFT R 469 Y27 SOLENOID, STOPLOCK R 522
R6 SENDER, FUEL 152 S30 SWITCH, ROTATE C/W 473 Y28 SOLENOID, STOP UNLOCK L 521
R7 SENDER, BRAKE TEMP 153 S31 SWITCH, ROTATE AC/W 475 Y29 SOLENOID, STOP UNLOCK R 520
R8 SENDER, LIFT TOP 1 156 S32 SWITCH, EXTEND 479 Y30 SOLENOID, ROTATE C/W 518
R9 SENDER, LIFT TOP 2 158 S33 SWITCH, RETRACT 480 Y31 SOLENOID, ROTATE AC/W 517
R10 SENDER, LIFT BOTTOM 2 160 S34 SWITCH, VERTICAL LIFT 483 Y32 SOLENOID, BRAKE RELEASE 516
R11 SENDER, LIFT BOTTOM 1 162 S35 SWITCH, STOPS LOCK/UNLOCK 487 Y33 SOLENOID, HIGH SPEED ROTATE 513
R12 SENDER, PILOT PRESSURE 165 S36 SWITCH, TWIST LOCKED LH 547 Y34 SOLENOID, TILT DOWN L 512
R13 SENDER, BOOM LENGTH 213 S37 SWITCH, TWIST LOCKED RH 546 Y35 SOLENOID, TILT DOWN R 511
R14 SENDER, BOOM ANGLE 220 S38 SWITCH, TWIST UNLOCKED LH 544 Y36 SOLENOID, 4 WAY H2O VALVE 672
R15 SENDER, STEERING R 229 S39 SWITCH, TWIST UNLOCKED RH 543 Y37 SOLENOID, COMPRESSOR CLUTCH 667
R16 SENDER, STEERING L 233 S40 SWITCH, SEATED LH FRONT 542
R17 RESISTOR, 4K7OHM 242 S41 SWITCH, SEATED LH REAR 541
R18 RESISTOR, 120 OHM 237 S42 SWITCH, SEATED RH FRONT 540
R19 RESISTOR, 768 OHM 255 S43 SWITCH, SEATED RH REAR 539
R20 RESISTOR, 287 OHM 262 S44 SWITCH, ROT STOP C/W 518
R21 RESISTOR, 120 OHM 280 S45 SWITCH, ROT STOP AC/W 517
R22 A/C TEMPERATURE PROBE 682 S46 SWITCH, BLOWER 695
S47 SWITCH, AMBIENT STAT 679
S1 SWITCH, IGNITION 29 S48 SWITCH, A/C ON-OFF 679 b 05.06.03 RHP DESIGN UPDATE B15826
Safed on: LL-BL ACAD

S2 SWITCH, MAIN POWER 5 S49 SWITCH, FROST STAT 674 a 13.05.03 RHP POST PROTO ISSUE FOR TRAINING
Production issue
S3 SWITCH, COOLANT LEVEL 28 S50 SWITCH, TRINARY-LP/HP FAIL 657 26.09.02 PAULY B15374
Date Checked Alteration change no fit Toler.
S4 SWITCH, AIR CLEANER 30 Date Name scale
S5 SWITCH, EMERGENCY 54/497 Drawn 07.04.00 PAULY
Title 357 MARK 3 none
Checked

Linde electric circuit sheet: 16

Heavy Truck
Division Ltd. Dr. No.: 357 802 0131 of: 17
Protection under DIN 34
repl. Orig.

138
357 804 25 01 GB 0104
HYDRAULIC CIRCUIT DIAGRAM

139
 HYDRAULIC CIRCUIT DIAGRAM

357 804 25 01 GB 0104

140
357 804 25 01 GB 0104
ELME SPREADER ELECTRICAL CIRCUIT DIAGRAM

141
 ELME SPREADER ELECTRICAL CIRCUIT DIAGRAM

357 804 25 01 GB 0104

142
357 804 25 01 GB 0104
ELME SPREADER HYDRAULIC CIRCUIT DIAGRAM

143
 BRAKE CIRCUIT

9 14
10 B
16
C
A 15
19
8 1 13 17

8 18
12
6
20
7
11

1 21 A Valve block
B Foot operated brake valve (right)
5 C Foot operated brake valve (left)
D Sliding caliper disc brake (parking brake)

357 804 25 01 GB 0104

E Multi disc brake

4 23 D 22 1. Tank
2. Suction Filter
3. Hydraulic pump 26 cc, transmission results in 1 engine
24 revolution = 33 cc
4. Pressure filter
3 5. Change over valve (130 bar)
6. Change over valve (160 bar)
7. Solenoid valve handbrake
8. Check valves
E 9. Pressure warning switch (buzzer lamp)
10. Accumulator (hand/foot brake)
2 25
26 26 11. Pressure warning switch (handbrake)
25 12. Accumulator (footbrake)
13. Check valve
27 14. Foot brake pedal (right)
15. Control valve
1 1 16. Brake pedal (left)
17. Brake plunger
18. Feeder valve
19. Oil tank
20. Disengaging switch (gearbox)
21. Brake light switch
22. Spring - type cylinder
23. Temperature switch (ventilator)
24. Cooler
25. Foot brake cylinder
26. Multi-disc brakes
27. Temperature pick up (for display)

144
 ALPHABETICAL INDEX
A Clean the truck .................................................. 8 1
After first 50 hours ............................................ 8 0
Air filter ................................................................ 8 3
Air filter element, change ............................. 1 0 1
Air filter safety element, replace ................. 1 1 1
Alphabetical index .......................................... 1 4 6
Alternator drive .................................................. 9 8
Approved applications ........................................ 2
Attachment legs, clamping and unclamping 6 4
Attachment legs, raising and lowering ........ 6 4
Automatic lubrication system ............................ 1 2
B Daily checks and services .............................. 2 1
Battery and air filter compartment door, opening
25
Battery and air filter compartment door, closing closing2
Battery condition ................................................... 8 2
Battery grease .................................................. 1 1 9
357 804 25 01 GB 0104
Beam locks, opening and closing ................ 6 0
Beam spreader .................................................. 6 0
Before lifting a load .......................................... 6 5
Boom and handler controls ............................... 5 7
Boom cylinder, check and lubricate ................ 8 9
Boom, extending and retracting ................... 5 8
Boom, lowering and lifting ............................. 5 8
Brake circuit ......................................................... 1 4 5
Brake hydraulic system oil level ................... 2 7
Brake hydraulic system oil pressure
filter, renew .................................................... 1 0 1
Brake hydraulic system oil, renewal .......... 1 0 9
Brake hydraulic system oil suction filter,
r e n e w a l ............................................................ 1 0 1
Brake hydraulic system oil tank cover ......... 2 4
B r a k e s .................................................................. 1 0
C E n g i n e ................................................................. 1 0
Closing the cabin door ........................................ 2 2
Cab rear bulkhead (CRB) ................................ 1 7
Central control lever ......................................... 5 7
Central lubrication .......................................... 1 1 9
Central lubrication system, filling ................. 8 5
Check and clean the climate control filter ..... 8 4
Check the tyres for damage and
foreign objects ............................................. 8 1
Checks and services prior to
initial operation ........................................... 2 1
Climate control ...................................................... 5 6
Closing the bonnet ........................................... 2 3
Cold start ............................................................. 3 5
Combi-Handler indicator (CHI) ...................... 1 7
Controls and indicators .................................... 1 5
C o o l a n t .............................................................. 1 1 9
Coolant pump drive .............................................. 9 8
Cooling system, check ................................... 1 0 4
D F u s e s ................................................................... 5 6
D r i v i n g ..................................................................... 4 8
Depositing the load .......................................... 7 0
Diesel engine emissions ................................ 2 1
Diesel fuel ........................................................ 1 2 0
25
Drive axle ............................................................ 1 0
Drive axle centre differential oil, change . 1 0 6
Drive axle centre differential oil level ......... 9 0
Drive axle hub oil, check ................................ 9 0
Drive axle mounting, check ............................ 9 0
Drive shaft, lubricate and check ................... 8 8
Driver's control centre 1 (DCC 1) ................. 1 7
Driver’s seat ....................................................... 3 3
Driving cabin controls, switches and
i n s t r u m e n t s ............................................................ 1 0
E Handler slewing gearbox and
Engine control management ............................. 3 4
Electric cables, connectors and connections 9 1
Elecrical circuit diagram .............................. 1 2 4
Electrical system ............................................... 1 2
Gear shift selection .......................................... 4 8
Elme spreader electrical circuit diagram . 1 4 2
Elme spreader hydraulic circuit diagram . 1 4 4
Engine coolant, renewal ............................... 1 0 7
Engine mountings, check ............................. 1 0 3
Engine oil, change ........................................... 9 2
Engine oil filter canisters, change ............... 9 2
Engine oil level ................................................. 2 9
Engine oils ....................................................... 1 1 9
F Hydraulic system, suction filter renewal ...... 9 9
Feet at the bottom of each leg, check
and lubricate .................................................... 8 7
Filling fuel ........................................................... 3 0
Front cab, mounting checks ........................... 9 4
Front windscreen wiper ................................... 5 4
Fuel filter canister, renewal ........................... 9 4
Fuel filter, draining ........................................... 8 2
Fuel filter priming ................................................. 8 2
Fuel level check and filling ............................ 3 0
Fuel pre-filter renewal ........................................ 9 3
Fuel tank air breather renewal ....................... 1 1 0
Fuse box cover, opening and closing .......... 2 6
G
Gauges switches and warning lights ........... 1 6
Gear oil .............................................................. 1 1 9
General lubricating oil ................................... 1 1 9
General view of container handler ................ 1 4
General view of truck ....................................... 1 3
H
H a n d l e r ................................................................ 1 1
Handler checks ................................................. 3 2
Handler extension cylinder bearing pads .... 1 0 5
Handler removal ............................................... 7 6
Handler ring gear grease ............................. 1 1 9
Handler, rotating ............................................... 5 9
Handler slewing brake oil ............................ 1 1 8
brake oil, renewal ..................................... 1 1 0
Handler sliding bearings,
check and lubricate .................................... 9 5
Handling fluids and lubricants .......................... 2 0
Hazard warning lights ..................................... 5 7
H e a t e r .................................................................. 5 5
Hoisting the truck .............................................. 7 6
H o r n ..................................................................... 5 4
Hydraulic circuit diagram ............................... 1 4 0
Hydraulic oil
(brake system, brake cylinder) ............... 1 1 8
Hydraulic oil additives (brake system) ...... 1 1 8
Hydraulic oil analysis ..................................... 1 1 8
Hydraulic oil for working hydraulics ........... 1 1 8
Hydraulic system, pumps, valves and lines 9 1
Hydraulic tank air filter renewal ....................... 9 8
Hydraulic tank pre-filter clean ......................... 1 1 0
145

I Pilot circuit filter renewal ................................... 9 1
Preselection of 1st gear .................................. 5 0
Inspection and maintenance chart ............... 7 8 Prime the fuel system ...................................... 8 2
Inspection and maintenance data .............. 1 1 8 Propeller shaft, refitting .................................. 7 5
Intake and exhaust systems, check ............ 1 0 5 Propeller shaft, removal .................................. 7 5
Isolating the battery ............................................. 2 5
R Table of contents ................................................. 5
J Taking the truck out of operation .................. 7 7
Radiator and oil cooler, cleaning
Jack locations .................................................... 7 1 and checking ................................................ 8 4
Joystick ................................................................ 5 7 R e a c h s t a c k e r ............................................................ 4
Rear cab, mounting checks ........................... 9 4
L Rear compartment door, opening
Left-hand control panel (LHP) ....................... 16 and closing ................................................... 2 4
Leg attachment, check and lubricate .......... 87 Rear screen wiper and washer ..................... 5 5
L i g h t i n g ............................................................... 53 Releasing the parking brake ......................... 7 5
Load diagrams .................................................. 66 Repositioning and securing the cabin ........ 2 3
Load safety indication and warnings ........... 65 Resetting the parking brake ........................... 7 5
Load safety system ........................................... 37 Right-hand control panel (RHP) ................... 1 6
Load safety system panel (LSSP) ................. 17 Routine maintenance ...................................... 8 0
Locking cylinder pin on the Running-in instructions ................................... 2 1
handler, lubricate ........................................ 96
S Transmission oil (drive axle) ....................... 1 1 9
M Safe load system .................................................. 1 1
Safety element, renewal ................................. 8 4
Main beam headlights ..................................... 5 3
Malfunctions during operation ...................... 3 6 Safety rules ......................................................... 2 0
Safety precautions ............................................ 2 0
Manual 1st gear selection when stopped .. 5 0
Moving off ........................................................... 4 9 Safety systems and shut down devices ....... 1 2
Securing the open cabin door ....................... 2 2
Multipurpose grease ...................................... 1 1 9
Service brake ..................................................... 5 2
N Sideshift sliding bearings, lubrication ........ 9 5
Sideshift operation ........................................... 5 8
Normal start ....................................................... 3 4 Sideshift cylinder bearings, lubrication ...... 9 7
Slewing gearbox and brake oil level, check 8 7
O mounting checks ......................................... 9 4
Slewing ring bearing and gear, lubrication 8 6
Oil grades ......................................................... 1 1 9 Slope pyle ........................................................... 6 5
Opening the bonnet .......................................... 2 3 Slope pyle the spreader, left and right ........ 6 5
Opening the cabin door .................................. 2 2 Slowing down and stopping ........................... 5 0
Operation of reach stackers in the Spreader, setting to container width ............ 6 0
plant area ...................................................... 2 0 Steer axle ........................................................... 1 0
Steer axle, clean and lubricate ..................... 8 8
P Steer axle hub oil level check ....................... 8 8
Steer axle, mounting checks ......................... 8 8
Parking brake .................................................... 5 2
Parking brake condition checks .................. 1 0 4 S t e e r i n g ............................................................... 5 1
Steering column (SC) ...................................... 1 6
Parking the truck ............................................... 7 1
Picking up a container ..................................... 6 8 Steering lock, checking ................................... 8 5
146
ALPHABETICAL INDEX
Stopping the engine ......................................... 3 5
Stopping the truck ............................................ 5 1
Stored hydraulic energy ...................................... 2 0
T
Technical data ...................................................... 8
Technical description ....................................... 1 0
Technical note ......................................................... 2
Telescopic boom ............................................... 1 1
Tighten the wheel nuts .................................... 8 1
Top screen wiper .............................................. 5 5
T o w i n g ................................................................. 7 5
Towing procedure ............................................. 7 5
Trailer coupling ................................................. 7 1
T r a n s m i s s i o n ..................................................... 1 0
Transmission cover, closing .......................... 2 3
Transmission cover, opening ........................ 2 3
357 804 25 01 GB 0104
Transmission dump ............................................. 5 1
Transmission mountings, check ................... 9 4
Transmission oil (handler slew gearbox) . 1 1 9
Transmission oil filter canisters, change ... 9 1
Transmission oil level check and fill ........... 3 2
Transmission oil, renew .................................. 9 3
Travel direction selection ............................... 4 9
Travelling with loads ........................................ 7 0
Traversing the cab ............................................ 6 3
Troubleshooting guide diesel engines .... 121
Troubleshooting guide hydraulics .............. 1 2 3
Truck takeover ...................................................... 2
Turbocharger intake pipe,
Turn indicator lights ........................................... 5 3
Twistlock indicators (TI) .................................. 1 7
Twistlock override ............................................. 6 3
Twistlocks operation ........................................ 6 2
Twistlocks and warning lights check ........... 3 2
Twistlocks, locking and unlocking ................ 6 2
Twistlocks, lubrication ..................................... 8 6
Twistlocks, renewal ........................................ 1 1 3
Type Plates ............................................................ 3
Tyre condition and inflation pressure,
c h e c k s ............................................................ 2 6
Tyre specifications ............................................ 2 6
 ALPHABETICAL INDEX
V
Belt drives, tension checks ............................. 9 8
Vacuum switch, check ................................... 1 0 1
Valve clearances ............................................. 1 0 8
Ventilation fan .................................................... 5 5

W
Wheel change .................................................... 7 3
Wind speed ............................................................ 2 0
Windscreen washer reservoir fluid level ..... 2 9
Windscreen wipers ........................................... 5 4
Work on the boom and the front
part of the truck ............................................... 7 7
Working and steering hydraulics .................. 1 1
Working hydraulic system oil level ............... 2 7
Working hydraulic system oil cover .............. 2 4

Y
357 804 25 01 GB 0104

Your type 357 03 Reachstacker ........................... 2

147
Linde Heavy Truck Division Limited
Linde Industrial Park
Merthyr Tydfil
CF48 4LA
Tel: (01443) 624200
Fax: (01443) 624303
Printed in United Kingdom 357 804 25 01 GB 0205