Handler For Empty Containers 8-9 Tonnes: Maintenance Manual

Handler for empty containers
8-9 tonnes
Publ. no UDCT01.02GB
Maintenance Manual in original MAINTENANCE MANUAL
DCT 80–90
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DCT 80–90
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A:6
Machine card.............................................................................................. A:7
Function descriptions ................................................................................. A:7
About the documentation .............................................................................. A:10
The documentation's parts ....................................................................... A:10
Ordering of documentation....................................................................... A:10
Feedback .......................................................................................................A:11
Form for copying .......................................................................................A:11
Maintenance Manual DCT 80–90 UDCT01.02GB

A:2
UDCT01.02GB Maintenance Manual DCT 80–90

A Foreword – Foreword A:3
A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.
The maintenance manual contains information about how the machine

should be maintained for maximal operating reliability and service
life as well as troubleshooting information for fast correction of any
malfunctions.
Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.
Cargotec will not accept any responsibility for modifications performed

without permission from Cargotec or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.
Storage
NOTE
The maintenance manual shall be accessible to service personnel.
About the machine version

The information in this publication corresponds to the machine's
design and appearance when delivered from Cargotec. There may be
differences due to customisation of the machine.
Cargotec reserves the right to change specifications and equipment

without prior notification. The information in the manual is valid at the
time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Only used equipment approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Duplication by any means such as copying, printing, etc., is prohibited.

A:4 A Foreword – Reading instructions
Reading instructions
Warning information
Warnings inform of potential hazards that, if warnings are not heeded,
may result in personal injury or product damage.
DANGER
Situation that may lead to severe personal injury or
fatality if the rule is not followed.
WARNING
Situation that may lead to personal injury if the rule is
not followed.
CAUTION
Situation that may lead to product damage if the rule
is not followed.
Important information
Important information is indicated by NOTE, and is provided to
facilitate the work process, handling or increase understanding of the
information.
NOTE
Information that is important without being related to safety.
Read operator's manual

The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
000262
Read the operator's manual
Read maintenance manual

The symbol to the left is used in certain cases on the machine and
001128
refers to important information in the maintenance manual.
Read the maintenance manual

A Foreword – Reading instructions A:5
Maintenance manual's content

The information in the maintenance manual is divided into function
groups (0-12) to facilitate searching for information. The manual is
divided in 20 sections A-C, 0-12, D-G. The sections with letters contain
specific information that applies to several function groups and is not
bound to a function, e.g., section "F Technical data". This is described
in greater detail in the table below.
For more information about function groups, see Function group

structure, page A:6.
A Foreword General information about the maintenance manual's purpose, content and
reading instructions as well as survey for feedback of views and eventual
inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
Technical description, description of the machine's functions with schematic
5 Steering drawings and explanatory texts for the included components.
6 Suspension Overviews with the components' position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
9 Frame, body, cab and
accessories
11 Common electrics
12 Common pneumatics
D Error codes Error code information is found in the Workshop manual and Operator's manual.
E Diagrams Wiring diagrams and hydraulic diagrams are found in the Workshop manual.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations
that may appear in the manual, index for headings in the manual.

Function group structure

The information in the manual is divided in a structure of functions
at different levels, based on the machine's design and use, called
function groups.
The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
done at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.
The idea is that the function groups are intended to work as a search
term to find different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.
The maintenance manual and workshop manual contain different

information. The maintenance manual only includes information
needed for preventive maintenance as well as simpler troubleshooting.
The workshop manual includes more in-depth information and repair
instructions.
References between sections in the same manual are indicated with

section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g., "see Sensor fuel level, description page 24".
References are not given between Maintenance manual and Workshop

manual. If more information is desired for a function group, the primary
recommendation is to search under the same function group in the
other manual.
Product alternatives and optional equipment

The information in the manual is divided in modules. For product
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.
Special equipment is not described in the manual. If you're uncertain

about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:7.
Product alternatives
Product alternatives
000264
Product alternatives are such options that exclude certain standard

Symbol indicating optional equipment equipment (e.g., engine alternative).
Equivalent information for different product alternatives is described

in separate sections following each other under the same function
group. To indicate that there are different alternatives, the supplement
"Product alternative" is used in the heading together with a simple
description of which alternative is described, e.g., "(Product alternative
Climate control unit ECC)". In addition, alternatives that are optional
are marked with the symbol for optional equipment.

Optional equipment
Optional equipment are options that can be added to the standard

equipment to obtain additional or improved functions.
Information for optional equipment is described in separate sections

with the standard equipment as starting point. Description of the
optional equipment describes how the standard function is affected by
the option as well as which additional components are added.
Machine card
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
The machine card indicates of which drawings the machine consists,

in many cases these can be associated to options and product
alternatives. For more information on handling product alternatives and
optional equipment, see Product alternatives and optional equipment,
page A:6. The machine card is supplied with the spare parts catalogue
and should be in the cab.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the first and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.
If the information on the machine card does not help, contact Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.
Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.
The function descriptions describe the function in a logical flow from

input signal to desired output signal. Most functions require that
pre-determined conditions are fulfilled for that function to be activated.
In these cases the conditions are listed above the figure.
Function descriptions use symbols to illustrate components such as

valves, sensors, etc.

4:10 4 Bromsar – Parkeringsbromssystem
4.5 Parkeringsbromssy stem

Parkeringsbromssys tem, funktionsbeskrivning
Parkeringsbromsen best å r av hydrauloljetank, Hydrauloljepump broms
och styrning, Ventilblock ackumulatorladdnings - och prioriteringsventil,
Ventilblock bromssystem, tryckgivare och parkeringsbromsenhe t.
Hydrauloljepump broms och styrning (frå n tanken). Ventilblock

ackumulatorladdnings - och prioriteringsventil styr tryck till
ackumulatorerna som lagrar trycket. Parkeringsbromsenhe ten lossas
med tryck frå n ackumulatorerna genom att parkeringsbromsventile n i
Ventilblock bromssystem trycks ä tter parkeringsbromsoket. Slutkontakt
parkeringsbroms ger signal s å att Indikeringslampa parkeringsbroms
tä nds nä r parkeringsbromsen ä r ansatt.
D
12 1
1
2 11
D790-1 D790-2
8 D797-1 2
3 D
7 D 8
4 10
C 7
Pa GHB 3
6 C
ACK M P HB
T
P 9
5
6
5 4
P 014645
1. Str ömst ä llare parkeringsbroms (S107) 7. Brytkontakt parkeringsbroms (S200)

2. Reglerenhet hytt (D790 -1) 8. Ackumulatorer
3. Reglerenhet ram (D797 –1) 9. Ventilblock bromssystem
4. Magnetventil parkeringsbroms (Y642) 10. Parkeringsbromsok
5. Hydrauloljepump broms och styrning 11. Reglerenhet KIT (D790 -2)
014684
6. Ventilblock ackumulatorladdnings - och 12. Indikeringslampa parkeringsbroms

prioriteringsventil
Example of function description
1. Electric power (solid single line) 6. Flag pressure check connection (Check point),
indicates that there is pressure check connection for
2. Hydraulic force (solid double line)
checking pressure signal
3. Illustration of function, (applied brake)
7. Flag diagnostic test, indicates that the signal can be
4. Component list checked with diagnostic test, see section 8 Control
system, group 8.4 Diagnostics
5. Position number in illustration, reference to
component list 8. Electric signal (dashed single line)

Symbol explanation function descriptions

Symbol explanation function descriptions
1 2
The following symbols are used in function descriptions, the symbols
3 4 are based on standard symbols used in wiring and hydraulic diagrams.
1. Electric control signal
2. Electric force
5 6
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic motor
7 8 M 6. Hydraulic oil pump with variable displacement
7. Hydraulic oil pump with fixed displacement
8. Electric motor
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12 12. Radiator
13. Bulb
D790-1 14. Control system, two control units with CAN-bus
13 14 15. Restriction
D797-F 16. Adjustable restriction
17. Inductive position sensor
15 16 18. Electrically controlled servo valve
19. Thermal bypass valve
17 18 20. Temperature-controlled switch
21. Temperature sensor
19 °C 20 °C
22. Pressure sensor
°C Pa
23. Pressure-controlled switch
21 22
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
23 Pa 24
26. Spring brake cylinder
27. Valve block
25 28. Shuttle valve
29. Non-return valve
26 27
28 29
014726

A:10 A Foreword – About the documentation
About the documentation

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
delivered to the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual
• Supplier documentation for engine, transmission and drive axle.
Ordering of documentation
The documentation is ordered from the dealer for Cargotec.
Always specify publication number when ordering.
For publication number, see the machine card.

A Foreword – Feedback A:11
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To: Cargotec Sweden AB

Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
Date: .................................... - .................. - ..................

Manual in-
formation
Name / Publication number: .............................................................................................................................
Section / page number: ......................................................................................................................................

Sugges-
tions,
.............................................................................................................................................................................
views, re-
marks,
etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................

A:12

B:1
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under machine ............................................................................. B:9
Lifting heavy components .......................................................................... B:9
Vibrations ................................................................................................... B:9
Noise .........................................................................................................B:11
Solvents ....................................................................................................B:11
Fire and explosion risks............................................................................ B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:15
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:16
Tensioned springs .................................................................................... B:17
Electric motors ......................................................................................... B:17
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:18
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:19
Non-ionised radiation ............................................................................... B:19
Environment.................................................................................................. B:21
General .................................................................................................... B:21

B:2

B Safety – Safety B:3
B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions in this manual must
make absolutely sure that the work is performed without risks of
personal injury, without risks of machine damage, or property damage!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and be careful. Do not take any risks!
Cargotec has in this publication documented and warned for situations

and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.
Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.
A near accident is a warning!

An incident is an unforeseen event where neither a person, the
machine, nor property is damaged. However, incidents indicate that
there is a risk of injury and actions must be taken to avoid injury risks.

B:4 B Safety – Safety instructions
Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position, page B:4
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• Clothing, etc., page B:8
• Several mechanics on the same machine, page B:8
• Working under machine, page B:9
• Lifting heavy components, page B:9
• Vibrations, page B:9
• Noise, page B:11
• Solvents, page B:11
• Fire and explosion risks, page B:12
• Fluid or gas under pressure, page B:14
• Coolant, page B:15
• Refrigerant, page B:15
• Air pollution, page B:16
• Tensioned springs, page B:17
• Electric motors, page B:17
• Rotating components and tools, page B:17
• Tyres and rims, page B:18
• Lifting equipment, page B:18
• Spare parts, page B:19
• Non-ionised radiation, page B:19
Service position
General
General
Service position is used for service, maintenance and other situations

when the machine needs to be secured.
Service position means:

• Machine parked, that is, applied parking brake.
• Trolley and attachment in completely lowered position.
• Mast fully tilted forward.
• Engine off.
• System voltage off (with battery disconnector).
009797
Machine with trolley and attachment in completely

lowered position

B Safety – Safety instructions B:5
Hydraulic and brake systems, depressurising

1 Machine in service position, see Service position, page B:4.
2 Depressurise the hydraulic system.

Turn on the system voltage and turn the start key to position I.
Repeatedly activate the load handling functions.
3 Turn the start key to position 0 and turn off the system voltage.
4 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
014618

5 Depressurise the attachment.

Open relief valve top lift.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to fine filter hydraulic oil.
Check that relief valve attachment is closed before the
engine is started.
014620
The figure above shows open valve.
Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! Oil may
also be corrosive to mucous membranes in, e.g., eyes,
skin, and throat.
IMPORTANT
Always clean the area around components and
connections before loosening them. Dirt in oil systems
causes increased wear, which results in material
damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also start fires. Waste oils/fluids shall always
be handled and taken care of by companies that are
authorised for this work.

Fuel system
The following safety instructions shall be followed for work when
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces and
may ignite.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.

IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised for
this work.
Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
Remove jewellery as it may conduct electricity and get caught in

moving parts.
Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.
Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
Movements performed from the operator's station, e.g., all movement

of lifting equipment, may cause severe personal injuries.
Safety actions
• Make sure that the machine's lifting equipment is completely
lowered or secured in another way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you're working with.
• Do not work with drive wheels on the machine's both sides at the
same time.

Working under machine
Working under frame
A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
• Use axle stands and supports that stand securely.
• Lifting tools should be inspected and type approved for use.
Lifting heavy components
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to
move heavy components. Make sure that the device
is sturdy and intact.
Risks
Unsuitable lift slings, straps, etc. may break or glide.
The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.
A component lifted with lifting equipment can start to turn if the centre
of gravity changes.
A component lifted using an overhead crane may start to swing

back and forth, which can cause severe crushing injuries or material
damage.
Safety actions
Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs. See the workshop
manual for methods.
If lifting must be performed without lifting device:

• Lift near the body.
• Keep your back vertical. Raise and lower with your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.
Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.

Safety actions
• Use heavy gloves to protect against the cold and transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.

Noise
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) is more damaging than low tones at the
same sound level. Noise in the form of impulse sounds may also be
damaging, e.g., hammer blows.
Risks
Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.
Safety actions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.
Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are flammable.
Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the central nervous

system may be injured. This manifests itself as trouble sleeping,
depressions, nervousness, poor memory, and general tiredness.
Continuous inhalation of gasoline and diesel vapours is suspected
of causing cancer.
Safety actions
• Avoid inhaling solvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a solvent container without tight-sealing lid.
• Use solvents with a low content of aromatic compounds. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are solvent-resistant.

Fire and explosion risks
DANGER
The operator's safety may not be jeopardised in case
of fire.
If possible, take the following actions at the slightest
sign of fire:
1. Stop the machine and turn the start key to stop
position.
2. Leave the cab.
3. Turn off the system voltage with the battery
disconnector.
4. Call the fire department.
5. Try to put out the fire.
If this is not possible, leave the machine and the
danger area.
DANGER
Smoke from a fire may be very toxic.
Smoke anesthetises, suffocates, and kills! Smoke
from fires, even small amounts, can damage lungs and
respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
fire and working with burnt materials.
Examples of flammable and explosive substances are oils, gasoline,

diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.
Risks
Examples of causes of ignition are welding, cutting with a welding

torch, smoking, sparks from grinding machines, contact between
hot machine parts and flammable materials, heat generation in rag
drenched with oil or paint (linseed oil), and oxygen. Oxygen cylinders,
lines, and valves shall be kept free from oil and grease.
Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding flames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.

Special cases
Gas oil with added gasoline has a reduced flash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,

keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive fires.
When a battery is being charged, the battery electrolyte's water is

divided into oxygen and hydrogen gas. This mixture is very explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge device is used since this increases the risk of sparks.
In today's machines there are a lot of electronics. When welding,

all control units must be unplugged and the electric power must be
turned off with the battery disconnector. Powerful welding currents may
otherwise short-circuit the electronics, destroy expensive equipment,
and may cause an explosion or fire.
Never weld on painted surfaces (remove paint, preferably by blasting at

least 10 cm around the welding or cutting point). Use gloves, breathing
protection, and protective safety glasses. Also, never weld near plastic
or rubber materials without first protecting them from the heat. Paint,
plastic, and rubber generate many substances when heated, and these
may be hazardous to health. Be careful with machines that have been
exposed to intense heat or fire.
Safety actions
DANGER
Remains of fuel, oils, grease, and other flammable
materials on the engine or in the engine compartment
are fire hazards.
Risk of fire!
Remove remains of flammable materials from the
engine compartment as soon as they are discovered,
be extra thorough with hot surfaces such as the
exhaust system, manifold, or turbo. If leaks of oil, fuel,
or coolant are detected, find the cause and solve the
problem before starting the engine.
• Make a habit of performing a visual check of the engine and engine

compartment before starting the engine and after operation, when
the engine has been stopped. This ensures fast detection if
anything abnormal has happened or is about to occur. Pay special
attention to oil, fuel, or coolant leaks, loose bolts, worn or poorly
tensioned drive belts, loose connections, damaged hoses, and
electrical cables. The inspection only takes a few minutes and may
prevent serious problems and expensive repairs.
• Store hazardous substance in approved and sealed container.
• Make sure that there is no ignition source near flammable or
explosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.

Fluid or gas under pressure

Lines with high pressure may be damaged during work and fluid or
gas may jet out.
There may be high pressure in a line even if the pump has stopped,
therefore gas or fluid may leak out when the connection for the hose
is loosened.
A gas cylinder exposed to outside forces may explode, e.g., if it falls on

a hard surface. Gas may flow out from damaged valves.
Risks
Risk of damage/injuries in connection with work on:

• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
• Cooling system.
Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall first be drained of pressure
and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.
• Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
• First open the cooling system's cap for the filling point, to release
the high pressure. Hot steam and coolant may otherwise jet out.

Coolant
The coolant in the machine’s cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous

and hazardous to health.
Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
Refrigerant is used in the machine’s air conditioning system.
Work on the air conditioning system must be performed by

accredited/authorised and trained personnel according to national
legislation and local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant

can cause frostbite injuries.
Refrigerant that is heated (e.g., when repairing leaking climate/AC

system), generates gases that are very dangerous to inhale.
Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).

Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
The following health-hazardous air pollution is especially prominent in

workshops:
• Carbon monoxide (fumes) is found in exhaust gases. Odourless
and therefore extremely dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.

(Generated when heating certain plastics and paints.)
Isocyanates may be released in the form of vapour, dust (or may

be found in aerosol) when cutting, grinding, or welding. May cause
mucous membrane irritation with asthma-like symptoms and impaired
lung function. Even brief exposures to high concentrations may cause
problems with persistent hypersensitivity.
Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.

Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines
Risks
Rotating components, e.g., fans or shafts, can cause severe injuries

if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in
the machine.

Safety actions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or pant legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
Tyres and rims
DANGER
Tyres are to be considered as pressurised containers.
Handling incorrectly, they are a fatal hazard.
Parts can be thrown with explosive force and may
cause severe injuries.
Never repair damaged tyres, rims, or lock rings. Tyre
changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims, and lock rings may be ejected.
Inflating tyres: Tyres, rims, or lock rings may be ejected.
Safety actions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regards
to securing the mast, carriage and attachment.
Get into the habit of always keeping the carriage lowered to the lowest
position when working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a

risk of crushing.
Risk of crushing is extra high when depressurising the hydraulic

system, see Hydraulic and brake systems, depressurising, page B:5.
Safety actions
Do not start work until the carriage is fully lowered. If the nature of the
work requires the carriage to be raised, it must be secured in some way.

Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
• Brake valve
• Drive axle
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Lift cylinder
• Valve block lift
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Emergency stop
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units
Non-ionised radiation
WARNING
Extra equipment such as two-way radio, telephone, etc.,
may emit non-ionised radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, telephone, etc., when no persons
with active or non-active medical products are nearby.

NOTE
When persons with active or non-active medical products are not
nearby, then telephone and two-way radio may be used in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.

B Safety – Environment B:21
Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.
Still there are no environmentally safe chemicals, e.g., oils and

coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.
By following the simple rules below, you will contribute to protecting

our environment.
Recycling
Well-planned recycling of the machine is the starting point for finishing

the life cycle and making use of materials for re-use in new products.
According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.
Environmentally hazardous waste
Components such as batteries, oils and other chemicals, and other

materials that may constitute environmentally hazardous waste, must
be handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health

and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids
Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorised

disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.
Air conditioning system
The refrigerant in the air conditioning unit for the cab contributes to
the greenhouse effect if it escapes into the open air. Special training
is required for all service work on the air conditioning unit. Many
countries also require certification by an authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area
The machine shall be equipped for work within a contaminated area

(polluted environment or health-hazardous area) before starting the
work. Also, special local instructions apply for handling and service
work on such a machine.

B:22 B Safety – Environment
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and electrical wiring. Some

models have cast lead counterweights.
If the machine is equipped with air conditioning, refrigerant of the type

R134a and an amount between 1-3 kg is used.

C:1
Contents C Preventive maintenance

Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:6
Service schedule............................................................................................. C:8
Washing ........................................................................................................ C:14
Lubrication 500 hours ................................................................................... C:14
Lubrication 1000 hours ................................................................................. C:19
Checking for cracks ..................................................................................... C:22

C:2

C Preventive maintenance – Preventive maintenance C:3
Preventive maintenance, general
It’s very important that preventive maintenance is performed according
to recommended intervals.
Preventive maintenance should be performed by Cargotec, or by a

service organisation authorised by Cargotec.
CAUTION
Service intervals shall be followed.
This is to maintain the machine's safety and to fulfil
warranty and service agreements!
Use spare parts and fluids approved by Cargotec to
fulfil the warranty.
Preventive maintenance, work instructions
1 For a new machine it is very important to check-tighten the wheel

nuts during the first work week until they are seated properly.
This should be done at an interval of 4–5 operating hours (up to
approx. 40–50 operating hours).
2 For a new machine, perform check actions after 50 operating

hours, see 50h-check, page C:6.
Note completed 50h-check in the service log, see Check and
service log, page C:4.
3 Regular service shall be performed according to service schedule,

see Service schedule, page C:8. The service schedule shall be
followed to ensure high machine reliability and safety.
Note completed service in the service log, see Check and service
log, page C:4.

C:4 C Preventive maintenance – Preventive maintenance
Check and service log

Model:
Serial number:
Completed maintenance
Oper-
ating Operating
hours Actions hours Date Signature
50h 50h-check
250h 250h service
500h 500h service
750h 250h service
1000h 1000 service
1250h 250h service
1500h 500h service
1750h 250h service
2000h 2000h service
2250h 250h service
2500h 500h service
2750h 250h service
3000h 1000 service
3250h 250h service
3500h 500h service
3750h 250h service
4000h 2000h service
4250h 250h service
4500h 500h service
4750h 250h service
5000h 1000 service
5250h 250h service
5500h 500h service
5750h 250h service
6000h 2000h service
6250h 250h service
6500h 500h service
6750h 250h service
7000h 1000 service
7250h 250h service
7500h 500h service
7750h 250h service
8000h 2000h service
8250h 250h service
8500h 500h service
8750h 250h service

Completed maintenance
Oper-
ating Operating
hours Actions hours Date Signature
9000h 1000 service
9250h 250h service
9500h 500h service
9750h 250h service
10000h 2000h service

50h-check
On a new machine, the following checks shall be performed after 50
operating hours. The checks are performed to increase reliability and
safety.
1 Engine Reference
Performance and exhaust smoke, check (engine
alternative Yuchai YC6A240-30)
Bolted joints, attachments, mountings, hose clamps,
wear and chafing of hoses, cable harnesses, etc.
Sealing check oil, coolant, exhaust system
Fuel prefilter, draining condensation Section 1 Engine, group 1.2.3 Fuel pre-filter
Air filter indicator, check Section 1 Engine, group 1.6.1 Air cleaning system
Air filter main cartridge, inspection
Air filter safety cartridge, inspection
Drive belt tension, checking Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Engine oil and oil filter, change Section 1 Engine, group 1.8 Lubrication system
Oil pressure
2 Transmission
Leakage check
Oil level, check Section 2 Transmission, group 2.6 Lubrication system
Transmission oil filter, changing Section 2 Transmission, group 2.6 Lubrication system
3 Driveline/Axle
Mounting propeller shaft, check-tightening Section 3 Driveline/Axle, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Driveline/Axle, group 3.3 Drive axle
4 Brakes
Leakage check
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check Section 4 Brakes, group, 4.5.4 Parking brake unit
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Suspension, group 6.3 Tyres and rims
Wheel nuts, check-tightening Section 6 Suspension, group 6.3 Tyres and rims
7 Load handling
Hose connections, check-tightening
Bolted joints, check-tightening
Mast wheel and slide plates, function check
Slide plates and support rollers, function check
Sensors Check that all sensors are undamaged and free of grease.
Attachment Check for damage

Lifting chains, checking and adjusting Section 7 Load handling, group 7.2.9 Mast
Section 7 Load handling, group 7.10.5.1 Spreading
Chain tension spreading, checking and adjusting
8 Control system
Check that there are no active error codes Section 8 Control system, group 8.3 Error codes
No action
Leakage check, check-tightening as required
Hydraulic oil level, check Section 10 Common hydraulics, group 10.6.8 Hydraulic oil
Fine filter hydraulic oil, changing Section 10 Common hydraulics, group 10.6.9 Fine filter hydraulic
oil
11 Common electrics
Batteries, check Section 11 Common electrics, group 11.3.1 Start battery

Service schedule
Service shall be performed every 500 operating hours. Actions are
divided into 250h, 500h, 1000h and 2000h service.
Actions for 250h service are performed between 500h and 1000h
service, which means at 250h, 750h, 1250h, etc.
Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.
Actions for 1000h service are performed at odd thousands of operating

hours: 1000h, 3000h, 5000h, etc.
Actions for 2000h service are performed at even thousands of

operating hours: 2000h, 4000h, 6000h, etc.
After service is performed, make a note in the check and service log,
see Check and service log, page C:4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hours
Object, action Service Comment Reference

250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
h, etc. etc. etc. etc.
0 complete machine
Checking C C C Check for and remove Section B Safety
cleanliness and traces of combustible
leakage materials in the engine
compartment.
Take extra care on hot
surfaces such as exhaust
systems, manifolds or
turbo.
If leaks of oil, fuel, or
coolant are detected, find
the cause and solve the
problem.
Attachments (stub C C Visual check in
axles) connection with greasing.
Lubrication 500 L L L Lubrication 500 hours, page
hours C:14
Lubrication 1000 L L Lubrication 1000 hours, page
hours C:19
Checking for C* C* * Check every 1000h or Checking for cracks , page
cracks every year. C:22
1 Engine (engine alternative Yuchai YC6A240-30)
Engine oil R R R R For volume and quality, Section 1 Engine, group 1.8
see section F F Technical Lubrication system
Engine oil filter R R R R data.
Performance and C C C C
exhaust smoke,
check
Fuel tank C Clean if necessary. Section 1 Engine, group 1.2.1
Fuel tank


250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Fuel prefilter R R R R Incl. draining of Section 1 Engine, group 1.2.3
condensation water. Fuel pre-filter
Shall be done every 50
hours.
Change filter earlier if
error code is displayed.
Fuel filter R R R R Change filter earlier if Section 1 Engine, group 1.2.4
error code is displayed. Fuel filter
Air filter main C/R C/R C/R Checking indicators, Section 1 Engine, group 1.6.1
cartridge change when indicated. Air cleaning system
Air filter safety C C/R C/R Changed every other Section 1 Engine, group 1.6.1
cartridge time main cartridge is Air cleaning system
changed.
Turbo C C C Section 1 Engine, group 1.6.2
Turbo
Exhaust system C C Check sealing and Section 1 Engine, group 1.6.3
suspension. Exhaust system
Intercooler C C Check sealing and Section 1 Engine, group 1.6.4
suspension. Intercooler
Radiator C C C External cleaning. Section 1 Engine, group 1.7.4
Radiator and expansion tank
NOTE
Do not use high
pressure wash.
Drive belt C/R C/R C/R C/R Change when needed. Section 1 Engine, group 1.7.5
Cooling fan
Coolant level C C R R For volume and quality, Section 1 Engine, group 1.7.7
see section F F Technical Coolant
data.
Coolant, freezing C C C For volume and quality, Section 1 Engine, group 1.7.7
point see section F F Technical Coolant
data.
Bolted joints, C C C Checks and
attachments, check-tightening
mountings, etc.
Connector C C C C Visual check for damage
or corrosion.
1 Engine (engine alternative Cummins QSB6.7 )

Exhaust system C C C Sealing check. Section 1 Engine, group 1.6.3
Exhaust system
Charge air hoses C C C Sealing check. Section 1 Engine, group 1.6.4
Intercooler
Engine oil R R R For volume and quality, Section 1 Engine, group 1.8
see section F F Technical Lubrication system
data.
Engine oil filter R R R At every oil change
Fuel tank C C Clean if necessary. Section 1 Engine, group 1.2.1
Fuel tank


250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Fuel prefilter C C/R C/R Incl. draining of Section 1 Engine, group 1.2.3
condensation water. Fuel pre-filter
Shall be done every 50
hours.
Change filter earlier if
error code is displayed.
Fuel filter R R Change filter earlier if Section 1 Engine, group 1.2.4
error code is displayed. Fuel filter
Air filter main C/R C/R C/R Checking indicators, Section 1 Engine, group 1.6.1
cartridge change when indicated. Air cleaning system
Air filter safety C C/R C/R Changed every other
cartridge time main cartridge is
changed.
Radiator C C C External check and Section 1 Engine, group 1.7.4
cleaning. Radiator and expansion tank
NOTE
Do not use high
pressure wash.
Drive belts C/R C/R C/R Change when needed. Section 1 Engine, group 1.7.5
Cooling fan
Drive belt C/R C/R * Check every 1000h or
tensioner every year.
Change when needed.
Fan hub C C * Check every 1000h or
every year.
Coolant level C C C Level check. Section 1 Engine, group 1.7.7
Coolant
The coolant should be
changed after 2000h
and the cooling system
checked/cleaned during
the change.
For volume and quality,
see section F F Technical
data.
Coolant, freezing C C C
point
Coolant quality, C C Check after 1.000h or
checking every year.
Bolted joints, C C C
attachments,
mountings, etc.
Valve clearance C Valve clearance Section 1 Engine, group 1.5.4
checked/adjusted after Valve mechanism
5000h / every 4th year.
Vibration damper, C Check every 2000h or Section 1 Engine, group 1.5.6
rubber every other year. Crank mechanism
2 Transmission
Breather filter C C Clean if necessary Section 2 Transmission, group
2.2 Torque converter


250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Transmission oil R R The transmission oil Section 2 Transmission, group
filter should be changed 2.6 Lubrication system
every 1,000 hours or 1
time/year.
For volume and quality,
data.
Transmission oil R R For volume and quality,
data.
3 Driveline/Axle
Propeller shaft C C C Bolted joints and Section 3 Driveline/Axle,
universal joint. group 3.2 Propeller shaft
Drive axle C C Section 3 Driveline/Axle,
group 3.3 Drive axle
Drive axle oil R R For volume and quality, Section 3 Driveline/Axle,
see section F F Technical group 3.3 Drive axle
data.
Mounting drive C C Section 3 Driveline/Axle,
axle group 3.3 Drive axle
4 Brakes
Brake pedal C C Section 4 Brakes, group 4.1.1
Brake pedal
Hydraulic oil C C C Section 4 Brakes, group 4.3.1
pump brakes and Hydraulic oil pump brakes and
steering steering
Accumulator C C C Section 4 Brakes, group 4.3.4
Accumulator
Parking brake C/R C/R C/R Check pad thickness, Section 4 Brakes, group 4.5.4
change when needed. Parking brake unit
5 Steering
Link arms C/L C/L C/L Check bearings. Lubrication 500 hours, page
C:14
6 Suspension
Wheel spindle, C C Section 6 Suspension, group
check 6.2.2 Wheel spindle
Wheel hub C Check bearing pre-load. Section 6 Suspension, group
steering axle, 6.2.3 Wheel hub
check
Tyres and rims C C C Damage, wear and Section 6 Suspension, group
pressure, change as 6.3 Tyres and rims
needed.
Wheel nuts C C Check-tightening. Section 6 Suspension, group
6.3 Tyres and rims
Rim C* * Checking for cracks, Section 6 Suspension, group
every 2,000 hours and 6.3.2 Rim
in connection with tyre
changes.
7 Load handling


250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Slide plates C C Check wear, change as Section 7 Load handling,
spreader beam needed. group 7.5.4 Spreader beam
Lifting chains C C C Check damage, tension Section 7 Load handling,
chain when needed. group 7.2.9 Mast
Mast suspension C C Checking the wear. Section 7 Load handling,
group 7.2.9 Mast
Slide plates mast C C C Check wear, adjust when Section 7 Load handling,
needed. group 7.2.9 Mast
Slide plates in C C Check wear, adjust when Section 7 Load handling,
trolley needed. group 7.2.11 Trolley
Attachment C C Check for damage.
Slide plates C C Check wear, change as Section 7 Load handling,
spreader beam needed. group 7.5.4 Spreader beam
Tilt cylinder C C C Section 7 Load handling,
group 7.7.7 Tilt cylinder
Twistlocks C/R Check for cracks every Section 7 Load handling,
other year or every 4000 group 7.9.1 Twistlocks
operating hours.
Replace every 10,000
operating hours.
Reset time counter
for twistlocks after
replacement.
8 Control system
Service indicator, C C C Section 8 Control system,
reset group 8.2.4 Service indicator

Instruments and C C C Checking function.
controls
Air conditioning C C C Checking function. Section 9 Frame, body, cab
unit and accessories, group 9.4.
Check/performance test of air
conditioning.
Fresh air filter R R R Dependent on external Section 9 Frame, body, cab
environment, at latest and accessories, group 9.4.1
every 500 h. Fresh air filter
C C C Clean when needed. Section 9 Frame, body, cab
Condenser and accessories, group 9.4.8
Condenser
NOTE
Do not use high
pressure wash.
C/R C/R C/R Checking, change if Section 9 Frame, body, cab

Moisture filter indication is grey. and accessories, group 9.4.9
Moisture filter
Windshield wipers C C C Incl. washer, top up when
needed.
Lighting and C C C
audible signals


250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Roof window C C Check damage, change Section 9 Frame, body, cab,
when needed. and accessories, group 9.9.3
Roof window
Cab frame C C Check rust damage,
deformation or cracks.
Doors C C C Section 9 Frame, body, cab
and accessories, Group 9.10.2
Doors
Cab undercarriage C C Check mountings, Section 9 Frame, body, cab
isolators and bolted and accessories, group 9.10.3
joints. Cab undercarriage
Frame C C Check occurrence of
any deformation and rust
damage as well as cracks
in welded joints.
Counterweights C Check that the
counterweights are
positioned properly and
that the mounts and
welding seams are intact
and free of visible cracks.
Check tightening torque
of bolted joints.
Central lubrication C C C Section 9 Frame, body, cab
and accessories, group 9.14
Central lubrication
Paint/coatings C C Check the machine's
painted surfaces
for stone chips and
scratches.
Safety decals C C C Check that safety decals See Operator's manual DCF
are legible, securely 80–100, section 3 Overview,
fastened, and not group 3.2 Signs
damaged. Clean dirty
decals and replace
decals as needed.
Cooler hydraulic C C External check and
oil cleaning.
NOTE
Do not use high
pressure wash.
Breather filter C/R R R Change at indication. Section 10 Common

hydraulic oil tank hydraulics, group 10.6.6
Breather filter hydraulic oil
tank
Hydraulic oil filter R R Section 10 Common
hydraulics, group 10.6.7
Hydraulic oil filter
Hydraulic oil R For volume and quality, Section 10 Common
see section F F Technical hydraulics, group 10.6.8
data. Hydraulic oil


250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Fine filter hydraulic R R R Section 10 Common
oil hydraulics, group 10.6.9
Fine filter hydraulic oil
11 Common electrics
Fuses C C C Check that fuses are Section 11 Common electrics,
intact, change if needed. group 11.2.2 Fuses
Batteries C C C Section 11 Common electrics,
group 11.3.1 Start battery
Battery cable C C C Section 11 Common electrics,
group 11.3.1 Start battery
Position sensors C C C Should be free from
grease and dirt, clean as
needed.
Test-run Test-run the machine and check:
• Instruments
• Brakes
• Gearshifting
• All load handling functions
• Steering
• Any noise
After test-run Check the following after test-run:
• Sealing (no leakage)
• Fluid levels
Washing
CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,
battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.
Lubrication 500 hours
1 Machine in service position.
2 Clean the area around each grease cup before greasing.

3 Lubricate the lubricating points of the machine with lubricating

grease, see section F Technical data.
Also do a visual check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Points lubricated by the central lubrication are
indicated by *.
7
6
9
10 10
4 4
5 5
9
2-3 6 2-3
015014
1 1
Overview, lubrication points, 500 hours
Po- Lubrication points Reference

s.
1 Wheel hubs (2 pc) Wheel hub, page C:16
2 Wheel spindles (4 pcs)*
3 Link arms (4 pcs)* Link arms, page C:16
4 Brake pedals (2 pc) Brake pedal, page C:17
5 Hinges doors (x2) and cover lid (x1) Hinge doors and cover lid, page C:17
6 Mast, mast wheels (4 pc)* Mast, page C:18
7 Mast, chain wheels (2 pc)*
8 Mast, chains (2 pc)
9 Mast, slide plates (4 pc)
10 Tilt cylinders (4 pc)* Tilt cylinder, page C:18

Wheel hub
4 Lift the right steering wheel with a jack (40 ton) so that wheel
bearing and wheel spindle are unloaded, do not lift so high that
the wheel hangs freely.
5 Grease the wheel hub until grease comes out at the seal on the
hub's inside.
Lift the seal ring's lip with a small screwdriver to facilitate pressing
out of air. Grease until grease comes out by the seal.
NOTE
Be careful so that the seal is not damaged.
009125
Grease point wheel hub
Wheel spindle
6 Grease the wheel spindle's upper and lower bearings.
1
NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.
NOTE
On machines with central lubrication, check that the lubrication
reaches the actual lubrication points, see section 9 Frame,
2 body, cab and accessories, group 9.14 Central lubrication.
009126
Lubrication points wheel spindle

1. Upper lubrication point
2. Lower lubrication point
Link arms
1 2 7 Lubricate both link arms' outer and inner bearings with grease.
NOTE
On machines with central lubrication, check that the lubrication
reaches the actual lubrication points, see section 9 Frame,
body, cab and accessories, group 9.14 Central lubrication.
8 Lower the wheel.

9 Repeat steps 4 - 8 on the left steering wheel.
009127
Lubrication points link arm

1. Inner bearing
2. Outer bearing

Brake pedal
10 Lubricate the brake pedal's hinge with grease.
11 Wipe off excess grease.
Grease points brake pedal
Hinge doors and cover lid

12 Lift the left-hand door slightly and lubricate the hinges with
lubricating grease.
1 NOTE
Do not lift the door off the hinges.
13 Let the door down and wipe off excess grease.

14 Repeat steps 12-13 on the right-hand door.
15 Lift the battery cover slightly and lubricate the hinges with
lubricating grease.
NOTE
Do not lift the cover lid off the hinges.
014040
16 Let the cover lid down and wipe of excess grease.

2
1. Hinge, door
2. Hinge, cover lid

1 Mast
17 Start the machine and raise the mast to facilitate access to
2 lubrication points.
18 Turn off the engine.
19 Secure the mast in a way that ensures safety.
3
20 Lubricate the chain wheel, mast wheel, slide plates and the slide
plates' contact surfaces with lubricating grease, see section F
Technical data. For lowered lubrication points, lubricate the mast
wheel and the chain wheel down on the mast .
21 Brush or spray the chains with chain oil. Make sure that the chains
are well lubricated.
3
009130
2
Lubrication points for mast
1. Chain wheel
2. Mast wheel
3. Slide plates.
Tilt cylinder
22 Grease the tilt cylinder axles with lubricating grease.
NOTE
Unload the mast when lubricating.
009128
Lubrication points on the tilt cylinder

Lubrication 1000 hours
1 Lower carriage and engage full spreading.
2 Turn off the engine and turn off the main electric power.
3 Clean the area around each grease cup before greasing.
4 Lubricate the machine's grease points with Lubricating grease

as shown on the diagrams below, see section F Technical data.
Also do a visual check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Points lubricated by the central lubrication are
indicated by *.
4-8
1 1
2
015013
Overview, lubrication points, 1000 hours
Po- Lubrication points Reference

s.
1 Universal joints (2 pc) Universal joint, page C:20
2 Trolley, mast (4 pc)* Trolley, page C:20
3 Locking cylinders (2 pc)* Attachment, page C:21
5 Contact pins (2 pc)*
6 Spreading cylinders (4 pc)*
7 Side shift cylinder (x 4)
8 Electric connectors (not shown on diagram) Electric connectors, page C:22

Universal joint
5 Grease universal joints with lubricating grease.
Grease nipple for universal joint, example
Trolley
7 Secure the trolley in a way that ensures safety.
8 Lubricate the mast wheel with lubricating grease, see section F
Technical data.
1
013493
Lubrication points for trolley.

1. Mast wheel

Attachment
9 Lubricate the locking cylinder mounts (position 1) with lubricating
grease.
014714
3
Lubrication points for side lift attachment with twistlock

1. Mounting locking cylinders
2. Contact pins
3. Mounting spreading cylinders
4. Mounting side shift cylinders
10 Lubricate contact pins (position 2) with lubricating grease. Check
that the sensors are undamaged and free from grease.
11 Grease the spreading cylinder mounts (position 3) with lubricating
grease.
12 Grease the side shift cylinder mounts (position 4) with lubricating
grease.

13
On machines with central lubrication, check the grease levels in

the pump units on the frame and attachment.
Top up with lubricating grease if the grease levels in the reservoirs
are below the middle.
Filling takes place through the grease nipples on the pump units.
NOTE
If grease has penetrated out from the safety valve, it means
there is a stop in the system, this means that no points are
greased, see section 9 Frame, body, cab and accessories,
group 9.14 Central lubrication.
Electric connectors
14 Grease electric connectors with electric connector grease. Check
that damp does not enter the connectors.
Pump unit central lubrication, example illustration

1. Filling point
2. Safety valve
Checking for cracks
DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
mast and attachment.
DANGER
Welds in areas of high stress concentration must be
checked in accordance with recommended intervals.
The interval is calculated according to the machine
being used for normal handling and on a level, smooth
ground surface. For other handling or, e. g., rough
surface, the interval should be shortened.
If the welds show signs of cracking, take the machine
out of operation immediately and contact Cargotec
Support.
1 Turn off the engine and turn off the system voltage.
2 Clean every weld carefully before inspection.

3 Check for damage and cracks in the areas with high stress
concentration, see Check points, page C:24. Check the whole
length of every weld.
When uncertain, welds can be tested with magnetic powder and
even penetrating fluid as follows:
a. The magnetic particle method is used to determine if there's a
crack or not, and where it is. See Magnetic particle method,
page C:23.
b. Confirmed cracks are investigated further with penetrating
fluid. See Checking cracks with penetrating fluid, page C:23.
Magnetic particle method

1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic particle and the following equipment:
• Equipment: Yoke Tiede
005375 • Method:
a Alternating current AC
b Contrast colour
Rim
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
005376
any remaining cleaning fluid evaporate.

4 Spray detection fluid part no. 923626.0670 on the area.
Rim
5 Let the sprayed area dry 1-2 hours.
6 Visually inspect the area.

1 2
If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
If the crack check indicates linear or point-shaped cracks, contact
Cargotec Support.
001705
Examples of cracks
1. Linear crack
2. Pointed crack

Check points
1 Check the following welds extra carefully:
7
8
009660
1 9
Check points, overview
Po- Check point Reference

s.
1 Steering axle mounts Steering axle mounts, page C:25
2 Tilt cylinder and tilt cylinder mount. Tilt cylinder and tilt cylinder mount., page C:25
3 Mast Mast, page C:26
4 Mounting of frame beam to back piece Mounting of frame beam to back piece, page C:26
5 Drive axle mount Drive axle mount, page C:26
6 Mast mount Mast mount, page C:27
7 Side lift attachment Side lift attachment, page C:27
8 Twistlocks
8 Trolley Trolley, page C:28
9 Lift cylinder bracket Lift cylinder bracket, page C:28

Steering axle mounts

2 Check the steering axle mounts in the frame and the steering axle
a. Steering axle mounts in the frame.
b. Steering axle mounts in the steering axle cradle.
a Tilt cylinder and tilt cylinder mount.
3 Check the attachment lugs on the tilt cylinder.
009664
4 Check the tilt cylinder's mounting in the mast.
009662
5 Check the tilt cylinder's mounting in the frame.

009663

Mast
6 Check the horizontal support beams in the mast.
009666
7 Check the welds between the horizontal and the vertical mast
beam.
009667
Mounting of frame beam to back piece

8 Check the attachment of the frame beam to the rear section.
009672
Drive axle mount

9 Check the drive axle mount in frame.
015528

Mast mount
10 Check the mast mount in the frame.
015104
11 Check the weld between mast beam and mount tab.
009670
Side lift attachment

12 Check the side lift attachment's welding seams.
014735

Trolley
13 a. Check the trolley's welding seams.
b. Check the wheel pin welds in the trolley.
Check the inner mast wheel pins as well.
b
013622
Trolley
a Examples of welded joints in the trolley
b Wheel pins
Lift cylinder bracket

14 Check the mounting of the lift cylinders' lower support mount
against mast beam.
009661

0:1
0 Complete machine
Contents 0 Complete machine

Complete machine..............................................................................................0:3

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Complete machine, description
Kalmar DCT 80-90 is a forklift truck for empty container handling. The
machine has a lifting capacity of 8-9 tonnes depending on version.
The engine is a straight six-cylinder, four-stroke, turbocharged

low-emission diesel engine with a unit injector, air-to-air intercooler
5 and electronically controlled fuel injection.
The transmission is hydro-mechanical with gears in constant mesh

and it has three gears in each direction. The engine's power is
transmitted using a torque converter.
The power transmission consists of propeller shaft and a rigid drive

axle with differential and hub reduction. The machine has front-wheel
drive.
7 The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the disc
brake type and acts on the drive axle's input shaft.
The machine is steered with the rear wheels using a double-acting

hydraulic cylinder. The steering axle is oscillation-mounted in the
6
frame.
The wheels are mounted on the hubs with studs and nuts. The drive
axle has twin wheels, the steering axle has single wheels.
Load handling consists of components and functions for handling

loads. Loads are lifted with a side lift attachment secured to a trolley
that is fitted on a mast. Load handling is divided into the functions
lifting/lowering, tilt, side shift, spreading and load carrying.
• Lifting/lowering is the function for lifting and lowering the trolley.
014183
1 2 3 4 • Side shift is moving the side lift attachment laterally along the
trolley.
1. Steering axle • Spreading is adjusting the width between Twistlock on the side
2. Engine lift attachment.
3. Frame • Tilt is for angling the load in the longitudinal direction of the truck
using the mast.
4. Drive axle
• Load carrying is the locking of the load to the side lift attachment.
5. Mast
6. Side lift attachment The control system includes functions to warn the operator of
dangerous situations and faults. The control system has diagnostic
7. Cab
options that facilitate troubleshooting.
The frame supports the machine. The engine, transmission, drive

axle, and steering axle are installed in the frame. On the sides of the
frame are tanks for fuel and hydraulic oil. The cab is located on the
rear section of the frame.
The hydraulic system is supplied by two hydraulic oil pumps. The

pumps are mounted on the transmission's power take-off. One fixed
pump supplies load handling and the other fixed pump supplies the
brake system, steering and cooling circuit over a combined priority
valve and accumulator charging valve. The hydraulic oil tank is fitted
on the right-hand side of the machine. The hydraulic oil filters are
return filters that are fitted in the hydraulic oil tank.

0:4 0 Complete machine – Complete machine
The machine's electrical system is built up around control units at

strategic locations on the machine. The control units receive signals
from sensors and contacts and they control components in the vicinity
of each respective control unit. The control units have redundant
voltage feed and communicate via redundant CAN bus. Engine
and transmission have their own control units from their respective
suppliers. These control units communicate via CAN bus with a control
unit in the cab.

1:1
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.2 Fuel system......................................................................................................1:9
1.2.1 Fuel tank ...................................................................................................1:10
1.2.3 Fuel prefilter .............................................................................................. 1:11
1.2.4 Fuel filter ...................................................................................................1:15
1.5 Engine's mechanical parts .............................................................................1:17
1.5.4 Valve mechanism ......................................................................................1:17
1.5.6 Crank mechanism .....................................................................................1:21
1.6 Air intake and exhaust outlet..........................................................................1:22
1.6.1 Air cleaning system ...................................................................................1:22
1.6.2 Turbo .........................................................................................................1:24
1.6.3 Exhaust system .........................................................................................1:25
1.6.4 Intercooler .................................................................................................1:26
1.7 Cooling system ..............................................................................................1:27
1.7.4 Radiator and expansion tank ....................................................................1:27
1.7.5 Cooling fan ................................................................................................1:28
1.7.7 Coolant ......................................................................................................1:34
1.8 Lubrication system .........................................................................................1:39
1.9 Control system engine ...................................................................................1:43
1.10 Ignition/heating...............................................................................................1:44
1.11 Start/stop........................................................................................................1:45

1:2

1 Engine – Engine 1:3
1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.
The engines are low-emission engines and meet governing emission

standards. The following engine alternatives are available:
• Yuchai YC6A240-30
• Cummings QSB6.7
Engine alternative Yuchai YC6A240-30,

function description
The Yuchai YC6A240-30 is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit common rail injection and air-to-air
intercooler.
rpm ˚C
kph
0 . bar
P I
II
III
1
8
3 13
D790-2 D795
D790-1 D797-1
2 12
4
D794 11
5
H2O H2O
SENSORS 7 M 6
015049
10 9
1. Ignition (S150) 8. Accelerator pedal (B690)
2. Control unit cab (D790-1) 9. Make-contact (closing switch), coolant level (B759)
3. Control unit KIT (D790-2) 10. Make-contact (closing switch), water in fuel (B760)
4. Control unit engine (D794) 11. Sensor fuel level (B757)
5. Relay, starter motor (K360) 12. Control unit frame (D797-1)
6. Starter motor (M654) 13. Control unit KID (D795)
7. Electric components engine

1:4 1 Engine – Engine
Engine alternative Yuchai YC6A240-30,

component location
1 2
3
4
14
13
5
12
7
8
9
10
014622
11
Engine alternative Yuchai YC6A240-30, left side (in the machine's travel direction)
1. Make-contact (closing switch), low coolant level 8. Connection radiator inlet
(B759)
9. Oil filter
2. Expansion tank
10. Relay, starter motor (K360)
3. Thermostat housing
11. Starter motor (M654)
4. Connection radiator outlet
12. Connection exhaust system
5. Coolant pump
13. Turbo
6. Connection cab heat
14. Connection air cleaner
7. Draining the radiator

10
014641
8 7 6
Engine alternative Yuchai YC6A240-30, right side (in the machine's travel direction)
1. Filling point engine oil 6. Control unit engine (D794)
2. Connection intercooler 7. Fuel filter
3. Relay preheating (K312) 8. Connection intercooler
4. Preheating coil (E8000) 9. Fuel pump
5. Dipstick engine 10. Alternator

Engine alternative Cummins QSB6.7,

The Cummins QSB6.7 is a straight, 6-cylinder, 4-stroke, turbocharged
low-emission diesel engine with common rail injection, air-to-air
intercooler and electronically controlled fuel injection.
°C
. bar
0 rpm
P I kph
II
III
1
8 <°
D D
D D
3 9 2
D794 D790-1 D790-2
D797-1 D795
12 13
D
D D
D
D H2O
4 SENSORS
10 11
7
6 M 5
015050
1. Ignition (S150) 8. Accelerator pedal (B690)
2. Control unit KIT (D790-2) 9. Control unit cab (D790-1)
3. Control unit engine (D794) 10. Make-contact (closing switch) coolant level (B759)
4. Preheating coil (E800) 11. Sensor fuel level (B757)
5. Starter relay 12. Control unit frame (D797-1)
6. Starter motor (M654) 13. Control unit KID (D795)
7. Engine sensor

Engine alternative Cummins QSB6.7,

component location
2
5
1
10
015097
9
Engine alternative Cummins QSB6.7, left side (in the machine's direction of travel)
1. Dipstick engine 6. Connections cab heat
2. Filling point engine oil 7. Intake coolant
3. Outlet exhaust system 8. Oil filter
4. Outlet coolant to radiator 9. Starter motor
5. Alternator 10. Crankcase ventilation

6
5
4
3
2
1
14
13
12
7
9
11
015096
10
Engine alternative Cummins QSB6.7, right side (in the machine's direction of travel)
1. Alternator 8. Air intake
2. Outlet coolant to radiator 9. Control unit engine (D794)
3. Air intake turbo 10. Draining the engine oil
4. Air outlet turbo 11. Vibration damper (rubber)
5. Dipstick engine 12. Fan drive
6. Filling point engine oil 13. Water pump
7. Fuel filter 14. Drive belt tensioner

1 Engine – Fuel system 1:9
1.2 Fuel system

Fuel system, description
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the
tank is shown on an operating menu on the display in the cab. Fuel
prefilter with water trap and fuel filter are on the engine. The water trap
is equipped with electrical indication, an event menu appears on the
display when the water trap must be emptied of water.
For position of components see:

• Engine alternative Yuchai YC6A240-30, component location,
page 1:4
• Engine alternative Cummins QSB6.7, component location ,

page 1:7
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
Fuel system, bleeding (engine alternative Yuchai

YC6A240-30)
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
The fuel system must be bled, e.g., if the fuel tank has been run dry
or after long periods of operation.
1 Machine in service position, see section B Safety.
2 Place a container under the fuel pre-filter.
3 Open the air bleeder screw on the fuel filter.
4 Pump with the hand pump until the flowing fuel is free from air.
NOTE
If only the fuel filter is changed, no further bleeding is necessary.
5 Close the screw when clean (air-free) fuel flows out.

6 Wipe off the fuel pre-filter and remove the collection container.
1. Hand pump
2. Air bleeder screw

1:10 1 Engine – Fuel tank
Fuel system, bleeding air (engine alternative

Cummins QSB6.7 )
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
NOTE

2 Open the bleed screw.
3 Turn the hand pump anticlockwise to open the pump.
4 Pump until the fuel is completely free of air bubbles.
5 Tighten the bleed screw and close the fuel hand pump.
6 Start the engine and check sealing.
015541
Hand pump
1.2.1 Fuel tank
Fuel tank, cleaning
NOTE

4
2 Empty the fuel tank of fuel. Use a pumping device.
3 Remove the drain plug from the fuel tank.
2
4 Rinse the fuel tank clean through the fuel filler hole.
1 5 Reinstall the drain plug.
3
013534
1. Fuel filler
2. Fuel tank
3. Drain plug, under tank
4. Battery hatch

1 Engine – Fuel prefilter 1:11
1.2.3 Fuel prefilter

Fuel pre-filter, draining condensation water (engine
alternative Yuchai YC6A240-30)
NOTE
NOTE
The fuel pre-filter should be drained of water every 50 operating
hours.

3 Drain the fuel pre-filter of water.
Open the drain valve on the underside, close the valve when
clean fuel flows out.
014134
Drain cock fuel prefilter

1:12 1 Engine – Fuel prefilter
Fuel prefilter, draining the condensation water (engine

alternative Cummins QSB6.7 )
NOTE
NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.

3 Drain the fuel pre-filter of water.
Open the drain valve on the underside, close the valve when
clean fuel flows out.
4
NOTE
Do not over-tighten the drain cock, as the threads may be
damaged.
Close the drain cock by pushing the valve up and tightening it

by hand. Bleed the fuel system, see Fuel system, bleeding air
(engine alternative Cummins QSB6.7 ), page 1:10.
015539

Drain cock fuel prefilter

1 Engine – Fuel prefilter 1:13
Fuel pre-filter, changing (engine alternative Yuchai

YC6A240-30)
NOTE

3 Drain the fuel prefilter of fuel and water.
Open the drain valve on the underside, close the valve when the
filter is empty.
4 Disconnect the wiring from Sensor water in fuel (B760).
5 Remove Sensor water in fuel (B760) from the filter insert.
6 Remove the fuel filter with the filter removal tool.
7 Install Sensor water in fuel (B760) on the new fuel pre-filter.
8 Fill the fuel pre-filter with clean fuel.
015012
CAUTION
Fuel prefilter
The fuel system is sensitive to impurities.

Risk of product damage.
Only use new fuel from a clean container to reduce the
risk of impurities in the fuel system.
9 Lubricate the O-ring on the new fuel filter with engine oil.
10 Install the new fuel pre-filter.
Tighten to contact and then an additional one-half to three-quarter
turn.
11 Connect the line supply to the sensor water in fuel.
13 Turn on the system voltage and start the engine. Check that the
filter seals tight.

1:14 1 Engine – Fuel prefilter
Fuel prefilter, changing (engine alternative Cummins

QSB6.7 )
NOTE

2 Open the drain cock and drain any water.
3 Remove the filter cartridge.
4 Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush a small amount of oil onto the gasket.
5 Screw the filter cartridge onto the filter bracket.
6 Bleed the fuel system. Fuel system, bleeding air (engine
alternative Cummins QSB6.7 ), page 1:10.
015540
Fuel prefilter

1 Engine – Fuel filter 1:15
1.2.4 Fuel filter

Fuel filter, changing (engine alternative Yuchai
YC6A240-30)
NOTE
2 Place a container under the fuel filter.
3 Remove the fuel filter with the filter removal tool.

4 Lubricate the O-ring on the new fuel filter with engine oil.
5 Fill the fuel pre-filter with clean fuel.
CAUTION
The fuel system is sensitive to impurities.
Risk of product damage.
Only use new fuel from a clean container to reduce the
risk of impurities in the fuel system.
6 Install the new fuel filter.

Tighten to contact and then an additional one-half to three-quarter
01501 1
turn.
7 Wipe off the fuel filter and remove the collection container.
Fuel filter
8 Turn on the system voltage and start the engine. Check that the
fuel filter seals tight.

1:16 1 Engine – Fuel filter
Fuel filter, changing (engine alternative Cummins

QSB6.7 )
NOTE
2 Remove the fuel filter.

3 Clean the filter's contact face on the filter bracket.
4 Moisten the O-ring on the new filter with fuel.
5
NOTE
Do not fill the new fuel filter with fuel before installing. There is
a risk that impurities might get into the fuel system and cause
malfunctions or damage.
Install the new filter on the engine.

Screw on the fuel filter until it makes contact with the contact face,
then tighten a further 3/4 turn.
015529
6 When needed, bleed the fuel system, see Fuel system, bleeding
Fuel filter air (engine alternative Cummins QSB6.7 ), page 1:10.

1 Engine – Engine's mechanical parts 1:17
1.5 Engine's mechanical parts

1.5.4 Valve mechanism
Valves, checking/adjusting (engine alternative

Cummins QSB6.7 )
NOTE
Coolant temperature must be below 60 ºC.
Removing
2 Disconnect the system voltage with the battery disconnector.
3 Carefully clean all attachments, mountings and joints with

compressed air to remove all loose particles.
4 Release the injectors' drain hose from the rear section of the
rocker cover.
5 Remove the screws that attach the drain hose to the rocker cover.
008025
6 Remove mounting screws and insulators from the valve cover.
NOTE
It might be necessary to bend the ventilation hose carefully to
pry it from the valve cover.
7 Remove the valve cover
NOTE
Do not remove the rocker cover gasket on engines where the
gasket is fitted in a groove on the rocker cover; these gaskets
008026
can be re-used. If the gasket is removed from the rocker cover,

it must be replaced.
8 Check that the gasket does not show signs of damage against the
sealing surface. Replace the gasket if it is damaged or if it has
been removed from its groove in the rocker cover.
NOTE
Check the valve cover gasket when it is still sitting in the valve
cover. When the gasket has been removed from the valve
cover, it must be replaced.
008027

1:18 1 Engine – Valve mechanism
9 If the valve cover gasket must be replaced, follow these

instructions for installing a new gasket:
1. First press the corners of the gasket down into the groove on
the valve cover.
2. Then push the rest of the gasket down into the valve cover.
008029
10 Check to see if the rubber insulators are cracked. Replace the
008028 insulators if they are cracked or damaged.
Adjusting
11 Use special tool, part number 3824591 to rotate the crankshaft
until cylinder no. 1 is located in the top dead centre (T.D.C.).
The top dead centre (T.D.C.) can be determined by the following
method:
NOTE
The indicator for the top dead centre (T.D.C.) is on the vibration
damper/crankshaft speed indicator.
1. Rotate the vibration damper/crankshaft speed indicator ring

008030
until the indicator for the top dead centre (T.D.C.) is pointing
straight up (12 o'clock).
2. If the valve lifters for cylinder 1 are not loose, rotate the
crankshaft 360 degrees.
3. If the valve lifters for cylinder 1 are loose, continue with the
next step.
NOTE
Cylinder number 1 is the cylinder nearest the cooling fan.
008031

1 Engine – Valve mechanism 1:19
12 With the engine in this position, the valve clearance can be

checked for the following valves:
(E=exhaust valves, I=intake valves)
Cylinders 1I, 1E, 2I, 3E, 4I and 5E.
008032
13 Check that the valve clearance is within the limits.
Valve clearance tolerance

MIN MAX
Intake valves 0,152 mm 0,381 mm
Outlet valves 0,381 mm 0,762 mm
NOTE
Valve clearance checks are usually performed as a part of
008033
troubleshooting, and adjustments are normally not necessary

during inspection as long as the valve clearance lies between
the tolerance figures listed above.
NOTE
The valve clearance is correct when the feeler gauge can be
moved forward and backward between the top side of the push
rod and the seat of the valve lifter with only a slight resistance.
14 Measure the valve clearance by placing a feeler gauge, with a

thickness corresponding to the valve clearance to be adjusted,
between the top side of the push rod and the seat of the valve
lifter. If the valve clearance does not correspond, loosen the lock
nut and adjust the valve clearance to the correct value.
Valve clearance
Intake valves 0.254 mm
Outlet valves 0.508 mm
Tighten the lock nut and check the measurement of the valve
008034
clearance again. Torque tighten to 24 Nm.

1:20 1 Engine – Valve mechanism
15 Use special tool, part number 3824591, and rotate the crankshaft
360 degrees.
Follow the same steps and specifications as above and measure
the clearance for the following valves:
(E=exhaust valves, I=intake valves)
Cylinders 2E, 3I, 4E, 5I, 6I and 6E.
008030
Installing
16 Reinstall the valve cover.
Reinstall the insulators and mounting screws.
Tighten the screws to a tightening torque of 24 Nm.
008026
17 Lubricate the O-ring on drain hose connection with clean engine

oil.
18 Fit the injectors' drain hose on the rocker cover. Tighten the
screws to a tightening torque of 10 Nm.
19 Close the battery disconnector.
008035

1 Engine – Crank mechanism 1:21
1.5.6 Crank mechanism
Vibration damper, rubber, check (engine

alternative Cummins QSB6.7 )
1 Check that the index lines (A) on the vibration damper hub (B) and
the outer section (C) are in line with each other. If the position
between the lines deviates more than 1.59 mm, replace the
vibration damper.
008036
2 Check the rubber part for signs of wear. If any rubber pieces are
missing or if the surface of the rubber is more than 3.18 mm below
the metal surface, replace the vibration damper.
3 Check that the damper ring cannot move longitudinally in
relation to the hub. Replace the vibration damper if it can move
longitudinally.
For position of vibration damper, see Engine alternative Cummins
QSB6.7, component location , page 1:7.
008037

1:22 1 Engine – Air intake and exhaust outlet
1.6 Air intake and exhaust outlet

Air intake and exhaust outlet, description
There is an air cleaner on the machine. The air cleaner is equipped
with an indicator that indicates when the air filter needs replacing. The
air cleaner has two filter inserts, one main insert and a safety insert.
The air cleaner is connected to the engine by the turbocharger.
The exhaust system consists of pipe and silencer. The silencer is

located on the upper rear counterweight, the end-pipe is attached to
the rear of the cab.
As an option the machine can be equipped with a raised air intake.
1.6.1 Air cleaning system

Air filter, changing
2 Clean the outside of the air filter housing.

3 Remove the cap from the air filter housing.
2
3
1
008040
1. Dust reservoir
2. Air cleaner
3. Indicator air filter
4 Remove the filter cartridge.

1 Engine – Air cleaning system 1:23
5 Clean the dust reservoir.
6 Check the safety insert, change as needed. (The safety insert

should be changed every other time the filter insert is changed).
7 Fit a new filter insert.
NOTE
The filter cartridge should be changed, not cleaned.
8 Fit the cover to the air cleaner casing.

9 Check that the hoses from the air filter housing (and other parts)
are intact and sealed.

1:24 1 Engine – Turbo
10 Reset the indicator.
1.6.2 Turbo
Turbo, check (engine alternative Yuchai YC6A240-30)
2 Fold up the hood.
3 Disconnect the inlet pipe from the turbo.
4 Check that the impeller rotates freely and that the axial clearance
is max. 1 mm.
In case of deviations, replace or overhaul the turbocharger.
5 Connect the inlet pipe to the turbo.
6 Close the hood.

1 Engine – Exhaust system 1:25
1.6.3 Exhaust system
Exhaust system, checking
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, silencer or
catalytic converters when the machine is in operation
or has recently been switched off!

2 Check the exhaust system's sealing and other wear.
1
3 Check that the exhaust system suspension is intact.
2
3
014700
1. End-pipe
2. Silencer
3. Exhaust pipe

1:26 1 Engine – Intercooler
1.6.4 Intercooler
Intercooler, checking
2 Fold up the hood.
3 Clean the intercooler with compressed air.
1 NOTE
Do not use high pressure wash.
2
4 Check that the intercooler suspension is intact.
4
5 Check the sealing and check that the intercooler's hoses and
3 clamps are in good condition.
014686 6 Close the hood.
1. Intercooler
2. Transmission oil cooler
3. Radiator
4. Condenser AC
Charge-air pipe, check (engine alternative Cummins

QSB6.7 )
2 Check the charge-air pipes, hose connections, and the condition
of the clamps for visible cracks and external damage. If the pipes
are damaged or if connections leak, the boost pressure will be too
007962
low and engine power is reduced.

3 Check that there is no oil in the charge-air pipes. If the pipes have
Charge air pipe, principle illustration oil on the inside, this indicates leakage by the turbo's turbine shaft
seal. Then replace the whole turbocharger.
NOTE
If there is oil in the intercooler hoses, very carefully clean the
intercooler and all pipes and hoses in the intercooler system on
the inside before the engine is started.

1 Engine – Cooling system 1:27
1.7 Cooling system

Cooling system, description
The engine radiator is located together with the intercooler and the
transmission oil cooler in one unit, a cooling unit.

page 1:4

page 1:7
1.7.4 Radiator and expansion tank
Radiator, external cleaning

2 Clean the radiator with compressed air.
NOTE
1 Do not use high pressure wash.
3 Check that the cooling flanges are whole.

2
4
3
014686
1. Intercooler
2. Transmission oil cooler
3. Radiator
4. Condenser AC

1:28 1 Engine – Cooling fan
1.7.5 Cooling fan

Drive belt, check (engine alternative Yuchai
YC6A240-30)
1 Warm up the machine. Check after operating when the belts are
warm.
3 Fold up the hood.
4 Check the belts' condition and tension. Change when needed.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
Check that the belts do not have any intersecting cracks.

Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
008011
It should be possible to press down the belts 10-15 mm, measured

between the pulleys, at a pressure of 40-50 N.
5 Close the hood.
Drive belt, check (engine alternative Cummins QSB

6.7)
1 Warm up the machine. Check after operating when the belts are
warm.
3 Fold up the hood.
4 Check the belts' condition and tension. Change when needed.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
Check that the belts do not have any intersecting cracks.

Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
008011
It should be possible to press down the belts approx. 3-4 mm

between the belt pulleys.
NOTE
The belt tensioners are automatic.
5 Close the hood.

1 Engine – Cooling fan 1:29
Drive belts, changing (engine alternative Yuchai

YC6A240-30)
2 Fold up the hood.
3 Release the AC belt's tension.

Loosen the AC compressor attaching bolts and release the belt
tension.
4 Remove the AC belt.
5 Release the fan belt's tension.

Loosen the lock nut at the belt pulley and release the tensioning
screw on the belt tensioner.
6 Remove the fan belts.
1. Tensioning screw
2. Lock nut

7 Release the drive belt's tension.

Loosen the alternator's attaching bolts and release the belt tension.
8 Change the drive belt when required. Check that the belt is
aligned correctly in the grooves.
9 Tighten the drive belt and tighten the attaching bolts to a torque
of 20-30 Nm. It should be possible to press down the drive belt
10-15 mm at a pressure of 40-50 N, measured between the water
pump and alternator.
10 Position the fan belts in the grooves for the pulleys, change if
necessary.
11 Tension the fan belts and tighten the belt tensioner's lock nut. It
should be possible to press down the fan belts 10-15 mm at a
pressure of 40-50 N, measured between the drive belts.
1. Tensioning screw
2. Lock nut

12 Position the AC belt in the grooves for the pulleys, change if

necessary.
13 Tension the AC belt and tighten the lock nut. It should be possible
to press down the fan belts 10-15 mm at a pressure of 40-50 N,
measured between the drive belts.
14 Close the hood.
Drive belt, changing (engine alternative Cummins

QSB6.7 )

2 Fold up the hood.
3 Lift up the belt tensioner to remove the drive belt.
NOTE
The belt tensioner is tensioned in the direction that the spring is
bent over the tensioner arm. To reduce the tension in the belt,
rotate the belt tensioner in order to tighten the spring more firmly.
CAUTION
008013
Do not use excessive force in either the winding

direction or in the opposite direction after the tensioner
has been wound to its positive stop. Continued winding
can cause the tensioner arm to break.
4 Lift up the belt tensioner and fit the drive belt. If it is difficult to fit
the drive belt (the belt seems too short), first place the belt in the
grooved belt pulley. Then continue to hold up the belt tensioner
and pry the belt over the coolant pump's belt pulley.
Loosen the belt tensioner and check that the belt is sitting correctly
in the grooves and is correctly tensioned.
5 Close the hood.

Drive belt tensioner, check (engine alternative

Cummins QSB6.7 )
2 Check that neither the lower nor the upper tension lever stop is
touching the cast stop lugs on the belt tensioner's housing. If any
tension lever stop is touching a stop lug then the drive belt must
be replaced. Check to ensure that the correct drive belt is used.
008014
3 Check that there are no cracks on the drive belt tensioner's wheels
or levers.
If there are cracks then the belt tensioner must be replaced. See
engine supplier documentation.
4 Check that deposits of dirt have not built up on the drive belt
tensioner.
If they have, the drive belt tensioner must be removed and steam
cleaned.
008015
5 Remove the drive belt.

6 Check that the lower tension lever stop is in contact with the lower
stop lug for the tension lever on the belt tensioner housing.
If these two are not in contact with each other, the drive belt
tensioner must be replaced.
008016

7 Check the drive belt tensioner for signs of wear and damage
between the tension wheel and the radius of the tension lever.
If there are signs that these two surfaces are rubbing against
each other, then the centre bearing is worn out and the drive belt
tensioner must be replaced.
008017
8 A worn drive belt tensioner that is slack or a drive belt that
“wanders” off the pulleys indicates that the pulleys are not in
alignment.
This can be measured with a straight edge and a clinometer.
NOTE
The pulleys may not be more than 3 degrees out of alignment.
9 Install the drive belt.

008018
Fan hub, check (engine alternative Cummins QSB6.7

)
2 Remove drive belt, see Drive belt, changing (engine alternative
Cummins QSB6.7 ), page 1:31.
Permissible length clearance fan hub: Max. 0.15 mm.
NOTE
The fan hub must rotate without wobbling or excessive length
clearance.
008019

1:34 1 Engine – Coolant
1.7.7 Coolant
Coolant level, check
WARNING
A
The cooling system is pressurised. Steam or hot fluid

may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
B
Coolant should be filled in the system's expansion tank (position A).
The fluid level should be visible in the sight glass (position C) on the
expansion tank.
NOTE
Open very carefully as hot coolant may jet up.
014191
C If the coolant level becomes too low, the warning light for low coolant
level (position 40) lights up on the instrument panel.
A Position for coolant reservoir (expansion tank)
B Filling point NOTE
C Sight glass A low coolant level may cause engine damage or may cause the
engine to stop.
2 Fold up the hood.
3 If needed, top up (position B) with ready-mixed recommended

coolant. For volume and quality, see section F F Technical data.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
4 Close the hood.

1 Engine – Coolant 1:35
Coolant quality, check (engine alternative Cummins

QSB6.7 )
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.

2 Fold up the hood.
A
3 Check the coolant's quality with test equipment for coolant,
"Quick-Check Coolant Quality Test Strips".
IMPORTANT
Only use testing equipment that is appropriate for the
type of coolant used in the machine. Coolant type
differs depending on engine alternative.
B
4 Change the coolant if the test equipment indicates poor coolant
quality, see Coolant, changing (engine alternative Cummins
QSB6.7 ), page 1:37.
5 Close the hood.
014191

B Filling point
C Sight glass, checking level
Coolant, changing (engine alternative Yuchai

YC6A240-30)
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
2 Fold up the hood.
3 Remove the cap on the expansion tank.
4 Place a container under the radiator and engine. (The cooling

system holds approx. 40 l.)

5 Drain the cooling system.

Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.
014698
Drain cock coolant radiator.
6 Connect a hose to the drain cock on the engine and route the
other end into the container.
7 Open the drain valve on the engine.
8 When all the coolant has run out, close the drain taps.
Drain cock coolant engine, the figure shows a closed

cock.
9 Fill with new ready-mixed coolant of correct type in the expansion

tank. For volume and quality, see section F F Technical data.
A
CAUTION
B
10 Turn on the system voltage and start the engine.
11 Set the cab heat to max.
12 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system. Do not operate the machine.
13 Check the level in the expansion tank, fill if necessary.
014191
C 14 Close the hood.

15 Check the coolant level again after 10 operating hours.
B Filling point
C Sight glass, checking level

1 Engine – Coolant 1:37
Coolant, changing (engine alternative Cummins

QSB6.7 )
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
2 Fold up the hood.
3 Remove the cap on the expansion tank.
4 Place a container under the radiator and engine. (The cooling

system holds approx. 40 l.)
5 Drain the cooling system.

Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.
014698
6 Open the drainage on the engine.

7 When all the coolant has run out, close the drain taps.
015538
Drain point coolant.

8 Fill with new ready-mixed coolant of correct type in the expansion

tank. For volume and grade, see section F Technical data.
A
CAUTION
B
9 Turn on the system voltage and start the engine.
10 Set the cab heat to max.
11 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system.
12 Check the level in the expansion tank, fill if necessary.
014191
C 13 Close the hood.

14 Check the coolant level again after 10 operating hours.
1. Position for coolant reservoir (expansion tank)
2. Filling point
3. Sight glass, checking level

1 Engine – Lubrication system 1:39
1.8 Lubrication system

Lubrication system, description
The engine's lubrication system is completely closed and has no
connections to the machine.

page 1:4

page 1:7
Oil and oil filters, changing (engine alternative

Yuchai YC6A240-30)
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1 Run the engine until warm.
3 Fold up the hood.
4 Remove the drain plug from the engine and drain the engine of oil.
5 Remove the oil filters.

6 Install new oil filters.
Lube the O-rings on the filters with engine oil and install according
to instructions on the filter.
7 Fit the drain plug when the oil has drained. Tighten with torque
of 27-34 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
8 Fill engine oil. For volume and quality, see section F F Technical
data.
014696
9 Start the engine, let it idle.

10 Turn off the engine and check the oil level, see Oil level, check
(engine alternative Yuchai YC6A240-30), page 1:41. Top up as
needed.
11 Close the hood.

1:40 1 Engine – Lubrication system
Oil and oil filters, changing (engine alternative

Cummins QSB6.7 )
NOTE
Safety.
1 Run the engine until warm.
3 Fold up the hood.
4 Remove the drain plug from the engine and drain the engine of oil.
5 Remove the oil filter with the filter tool.

6 Brush a little oil on the new filter's rubber gasket.
7 Check that the contact face on the filter bracket is clean and that
no gasket remains from the old filter.
8 Spin on the filter by hand until the rubber gasket just touches the
contact face on the filter bracket.
Then turn another full turn, not more.
9 When the oil has drained install the oil plug with a new gasket.
Torque tighten to max. 80 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
015537
10 Fill engine oil. For volume and quality, see section F F Technical
Oil filter data.
11 Start the engine, let it idle. Check that the oil pressure is normal.
12 Turn off the engine and check the oil level, see Oil level, check
(engine alternative Cummins QSB6.7 ), page 1:42. Top up
as needed.
13 Close the hood.

1 Engine – Lubrication system 1:41
Oil level, check (engine alternative Yuchai

YC6A240-30)
NOTE
Safety.
Engine oil, general

The engine oil filling pipe (position B) and dipstick (position A) are
under the service hatch in front of the cab.
A B
2 Check the oil level when the engine has been warmed up. The
oil dipstick has two markings, MAX and MIN, between which the
oil level should be.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
3 Fill engine oil (position B) if needed (for volume and grade, see
section F Technical data).
4 Fill – wait awhile – check on the oil dipstick.
NOTE
Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
014192
A Dipstick
B Filling point

1:42 1 Engine – Lubrication system
Oil level, check (engine alternative Cummins

QSB6.7 )
NOTE
Safety.
Engine oil, general

The engine oil filling pipe (position B) and dipstick (position A) are
under the service hatch in front of the cab.
A B 2 Check the oil level when the engine has been warmed up. The
oil dipstick has two markings, MAX and MIN, between which the
oil level should be.
NOTE
3 Fill engine oil (position B) if needed (for volume and grade, see
section F Technical data).
4 Fill – wait awhile – check on the oil dipstick.
NOTE
Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
015095
A Dipstick
B Filling point

1 Engine – Control system engine 1:43
1.9 Control system engine

Control system engine, description
The engine is controlled by a control and monitoring system, for which
the central unit is a control unit.
The control unit controls the amount of fuel to the unit injectors by
opening and closing a fuel valve by each injector. The unit injectors are
activated by an extra cam lobe on the camshaft, which compresses the
injector so that fuel is injected into the cylinder.
The fuel quantity is calculated by the control unit based on signals from
the sensors on the engine and a CAN message about the desired
engine speed (from the accelerator pedal via the cab control unit
(D790-1)).
If serious malfunctions are detected by the control and monitoring

system on the engine, then engine power is limited to protect the
engine from further damage.

1:44 1 Engine – Ignition/heating
1.10 Ignition/heating
Ignition/heating, description (engine alternative
Yuchai YC6A240-30)
The engine features preheating of the induction air, for faster start
at low temperatures. Preheating is activated by Control unit engine
(D794) as needed. The indicator light for preheating is on when
preheating is activated.
For position of components see, see Engine alternative Yuchai

YC6A240-30, component location, page 1:4.
Ignition/heating, description (engine alternative

Cummins QSB6.7 )
The engine features preheating of the induction air, for faster start at
low temperatures. Preheating is activated when the ignition key is in
position II or when the engine's control system detects that preheating
is needed. The indicator light for preheating is on when preheating is
activated. The ignition sends signals to Control unit KIT (D790-2) which
sends messages via CAN-bus drivetrain to Control unit engine (D794).
For position of components see, see Engine alternative Cummins

QSB6.7, component location , page 1:7.

1 Engine – Start/stop 1:45
1.11 Start/stop
Start/stop, description
The engine is started and stopped with the ignition. The ignition sends
signals to Control unit KIT (D790-2) and Control unit cab (D790-1)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794). The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, frame (D797-1). Engine shutdown is controlled by the Control
unit, engine (D794) that cuts off the fuel supply to the engine.
Start lock-out is available as an option, where a code has to be

entered via the display before the engine can be started.
Automatic engine shutdown is available as optional equipment.

This means that the engine turns off automatically after 3-30 minutes
(depending on customer setting) if the machine is at a standstill and
idling.
For position of components, see Engine alternative Yuchai

YC6A240-30, component location, page 1:4 or Engine alternative
Cummins QSB6.7, component location , page 1:7.

1:46

2:1
2 Transmission
Contents 2 Transmission
2 Transmission ......................................................................................................2:3
2.2 Torque converter/Clutch system ......................................................................2:6
2.3 Mechanical transmission..................................................................................2:7
2.6 Lubrication system ...........................................................................................2:8
2.7 Cooling system .............................................................................................. 2:11
2.8 Control system transmission..........................................................................2:12

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, function description
The transmission transfers the engine power to the drive wheels (drive
axle) via the propeller shaft and also drive the hydraulic oil pumps for
the hydraulic system and the brake system.
The transmission is fully automatic with torque converter. It has three

forward gears and three reverse gears.
The torque converter and transmission work together via a common

hydraulic system. The torque converter is a hydraulic clutch placed
between the engine's output shaft and the transmission's input shaft.
The hydraulic oil pumps and the oil pump for control and lubrication
of the transmission are connected to the torque converter via power
take-offs on the transmission.
Gear positions are selected by pressurising of clutches by solenoid

valves controlled by Control unit transmission (D793). The control
unit uses sensors for pressure, temperature, and rpm to decide which
gear position should be activated as well as solenoid valves to activate
the gear.

2:4 2 Transmission – Transmission
F
R
1
5 4
3 20
D 7 9 0 -2 D 795
D 7 9 0 -1 D 7 9 7 -1
6 19
7 D 793 D 794 21
18
12 13 14
16 17
11
15 10
9
8
014687
1. Multi-function lever (S162) 12. Sensor oil pressure transmission (B765)
2. Shifting program selector on Control unit KIT (D790-2) 13. Sensor turbine speed (B751)
3. Control unit KIT (D790-2) 14. Sensor oil temperature (B766)
4. Accelerator pedal (B690) 15. Oil pump transmission
5. Declutch pedal (S220-1) 16. Oil filter transmission
6. Control unit cab (D790-1) 17. Transmission oil cooler
7. Control unit, transmission (D793) 18. Make-contact declutch (S220-2)
8. Solenoid valve clutch reverse (Y631) 19. Control unit frame (D797-1)
9. Solenoid valve clutch 1st gear (Y6067-1) 20. Control unit KID (D795)
10. Solenoid valve clutch 2nd gear (Y6069) 21. Control unit engine (D794)
11. Solenoid valve clutch forward (Y630)

2 Transmission – Transmission 2:5
Transmission, component position
1 2 3
15
4
16
14 5
13 6
17
12
7
014685
11 10 9 8
1. Transmission oil cooler 10. Valve block transmission control
2. Oil pump transmission 11. Return from transmission oil cooler
3. Oil filter transmission 12. Breather filter transmission
4. Sensor turbine speed (B751) 13. Outlet to the transmission oil cooler
5. Solenoid valve clutch reverse (Y631) 14. Sensor oil temperature (B766)
6. Solenoid valve clutch 1st gear (Y6067-1) 15. Thermostat
7. Drain plug and strainer transmission oil 16. Sensor oil pressure transmission (B765)
8. Solenoid valve clutch 2nd gear (Y6069) 17. Output shaft
9. Solenoid valve clutch forward (Y630)

2:6 2 Transmission – Torque converter/Clutch system
1 2 3 4 5
11
10
7
9
014694
8
1. Accelerator pedal (B690) 7. Fuse transmission (F51-3)

2. Control unit KIT (D790-2) 8. Control unit, transmission (D793)
3. Control unit KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. Make-contact declutch (S220-2)
5. Control unit cab (D790-1) 11. Control unit frame (D797-1)
6. Diagnostic socket drivetrain
2.2 Torque converter/Clutch system

Torque converter/clutch, description
The torque converter transmits the engine's power to the transmission.
For position of components see Transmission, component position,

page 2:5.
Breather filter, cleaning

2 Disconnect the breather filter from the transmission.
3 Clean the breather filter from dirt.
014692

2 Transmission – Mechanical transmission 2:7
2.3 Mechanical transmission

Mechanical transmission, description
The transmission is built with all gears in constant mesh. It is shifted
by hydraulic pressurising of clutch discs for each of the gears. The
discs connect the input shaft with the main shaft or tubular shaft,
depending on which gear has been selected. Shifting takes place
without disengaging the transmission from the engine.
Clutches for FORWARD and REVERSE are controlled electrically,

shifting between FORWARD and REVERSE, and vice versa, on the
move can take place at a speed lower than the set limit value, see
section 8 Control system, group 8.5.1.5 DRIVETRAIN. When shifting
between FORWARD and REVERSE, two modulating valves in the
transmission enable smooth power transmission between the clutches
without disengaging any clutch.
There are three gears in each direction for the transmission. Declutch
is controlled with a separate declutch pedal that is activated at a certain
brake pressure.
The electric shifting system is automatic.

page 2:5.

2:8 2 Transmission – Lubrication system
2.6 Lubrication system

Lubrication system, description
The transmission has its own lubrication system that is used for
lubrication, control, and cooling of the transmission. The transmission
oil cooler is located in the cooling unit behind the engine, a thermostat
in the cooler enables the oil to reach operating temperature faster.
At high oil temperature (120 ºC) a warning is activated in Control unit

1 KID (D795) and performance is reduced, if the oil temperature goes
above 125 ºC the transmission declutches.
2 For position of components see Transmission, component position,

page 2:5.
4
3
014686
1. Intercooler
2. Cooler transmission oil
3. Radiator engine
4. Condenser (to AC)
Oil and oil filter, change
NOTE
Safety.
NOTE
Do not over-fill the transmission!
1 Operate and warm up the transmission oil.
3 Remove the drain plug (position 2) and allow the oil drain into
1 the receptacle.
4 Remove the suction strainer (position 3) and clean the strainer
cloth.
If the suction strainer's cloth has caught up metal particles then
the cause must be investigated before the transmission is filled
with new oil.
5 Replace the suction strainer's gasket.
6 When the transmission oil has flowed out, refit the suction strainer
2 (position 3) and the drain plug (position 2).
Make sure that the washer for the drain plug is included.
014693
3 7 Remove the filter holder (position 1) and change the oil filter.
1. Oil filter holder Tighten to contact and then another two-thirds turn.
2. Oil plug
3. Suction strainer

2 Transmission – Lubrication system 2:9
A B 8 Fill new transmission oil through the oil filler point (position B) to
the marking for low level on the dipstick (position A).
For volume and quality, see section F F Technical data.
9 Start the engine and let the engine run at idle for at least two
minutes.
10 Check that the drain plug for transmission oil seals tightly.
11 Check the transmission oil level with the engine running at idle and
top up to the marking for low level.
014193
A. Dipstick transmission oil
B. Oil filler point transmission oil
12 Warm up the transmission so that the oil temperature is approx.

85 ºC on the display. Use operating menu oil temperature to check
the transmission oil temperature.
a
13 Check the oil level. Fill to the MAX mark for oil level.
000356
Operating menu oil temperature

a Transmission oil temperature
b Hydraulic oil temperature
Oil level, check
NOTE
Safety.
The transmission's oil filler pipe and oil dipstick are located under the
hood in front of the cab.

2:10 2 Transmission – Lubrication system
A B 1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 85 ºC on the
display). The oil dipstick has two markings, MAX and MIN, the oil
level should be at MAX.
NOTE
2 Fill transmission oil (position B) if needed (for volume and grade,

see section F Technical data).
Fill – wait awhile – check on the oil dipstick.
NOTE
014193 Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means risk
of transmission damage.
A. Dipstick transmission oil
B. Oil filler point transmission oil

2 Transmission – Cooling system 2:11
2.7 Cooling system

Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:8.

page 2:5.

2:12 2 Transmission – Control system transmission
2.8 Control system transmission

Control system transmission, description
Control unit transmission controls shifting based on signals from
pressure, temperature, and speed (rpm) sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure in
the transmission, so that the selected gear gives the right speed.

page 2:5 and section 11 Common electrical , group 11.5.3 Control units.
In case of serious transmission malfunctions the control unit uses

two modes with reduced functionality to protect the transmission,
Limp-home and Shut-down.
Mode Limp-Home
For certain malfunctions, the control unit activates "Limp-Home". In

this mode the transmission is shifted to neutral position. To be able to
continue operation, travel direction must be selected again with the
gear selector.
In this mode the operator can use the transmission's two first gears in
each direction. If the malfunction occurs in a higher gear, the operator
has to downshift manually to first or second gear to continue.
Mode Shut-Down
For serious malfunctions, the control unit activates "Shut-Down". In

this mode the transmission is locked in neutral, no solenoid valves
are activated.
Machine assumes neutral position
The machine features a safety function that results in the transmission

shifting to neutral position if the operator leaves the operator's station.
The system uses the same switch in the operator's seat as the warning
for released parking brake to sense when the operator leaves the
operator's station.
If the buzzer sounds when the operator sits down in the seat and
releases the parking brake, the switch in the seat may not be working.
Then it is not possible to select any travel direction.
In an emergency the machine can be operated by bypassing the safety

system, for more information see section 8 Control and monitoring
system, group 8.2.2 Bypassing.
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
1 Release the load.
2 Activate switch for bypassing.
3 Select travel direction.
4 Drive the machine to service. Speed is limited to 10 km/h.

3:1
3 Driveline/Axle
Contents 3 Driveline/Axle
3 Driveline/Axle......................................................................................................3:3
3.2 Propeller shaft..................................................................................................3:3
3.3 Drive axle .........................................................................................................3:4

3:2

3 Driveline/Axle – Driveline/Axle 3:3
3 Driveline/Axle
Driveline/Axle, description
The machine's power transmission consists of propeller shaft and drive
axle with differential and hub reduction.
3.2 Propeller shaft

Propeller shaft, description
The propeller shaft transmits the engine power from the transmission
to the drive axle.
005193
Propeller shaft, checking

• After 50h:
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission to 98 Nm (oiled bolt).
• After 500h:
Clean.
Check clearance in universal joints.
• After 1000h:
Grease universal joints with universal grease EP2.
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission to 98 Nm (oiled bolt).
Grease nipple for universal joint, example

3:4 3 Driveline/Axle – Drive axle
3.3 Drive axle

Drive axle, description
The drive axle transmits the engine power to the wheels. After the
drive axle's input shaft there is a differential that changes the gear ratio,
distributes the power between the right and left drive wheel, and makes
it possible for the drive wheels to have different speeds when cornering.
The half shaft transmits the power from the differential to the wheel
hubs. At the wheel hubs there are hub reductions that change the gear
ratio between wheels and engine to reduce the stress on the half shaft.
1. Hub reduction
1 2 3 4
2. Wheel brake
5 6 3. Drive shaft (internal)
4 3 2 4. Mounting drive axle
1
5. Drive axle housing
6. Differential (internal)
7. Drain point drive axle oil hub reduction
10 8. Filling point and level check drive axle oil hub reduction
004336
9
8 7 9. Filling point and level check drive axle oil differential
10. Drain point drive axle oil differential
Drive axle, checking
1 Check the drive axle's attachment to the frame so that there is no

corrosion on structural elements (e.g., attaching bolts).
2 Check-tighten the drive axle's attaching bolts to 1530 Nm (oiled

bolt).
3 Check-tighten the wheel nuts to 650 Nm (oiled bolt).
4 Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
5 Check that drive axle seals tight.
6 Check the oil level in drive axle and the hub reductions.
008046
Attaching bolts drive axle

3 Driveline/Axle – Drive axle 3:5
Drive axle oil, changing
NOTE
Safety.
1 Position the machine so that the hub reductions' drain plugs at the
wheels are in the lowest position.
This applies to both drive wheels.
1 2
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (raise the machine under
the mast) and rotate the wheel into the correct position. Lower
the machine.
015100
3 Position a receptacle by each hub. Position a piece of sheet metal
or similar in the wheel rim to lead oil into the receptacle.
Wheel hub, drive axle
4 Remove the drain plugs for the hubs (position 1) on both sides.
1. Drain plug hub Also remove the level and filling plugs for the hubs (position 2) to
2. Level and filling plug hub facilitate draining.
Both sides shall be drained separately.
5 Position a receptacle under the differential and remove the drain

1 2 plug (position 3). Also remove the level and filling plug for the
differential (position 2) to facilitate draining.
6 Clean the drive axle's breather while the oil is draining.
7 Install the drain plugs on the hubs and the differential.
004337
3
NOTE
Differential drive axle Check that the seals are intact, clean and in the correct position.
1. Bleeding the drive axle (inside frame)
2. Level and filling plug differential
3. Drain plug differential
8 Fill oil in the hubs until the oil level is flush with the filling and
level holes (position 2). For volume and quality, see section F
F Technical data.
1 2
NOTE
The oil is very viscous, fill the oil slowly. Check the level in
stages so that the oil has time to settle.
9 Install the hubs' level and filler plugs.

015100
NOTE
Check that the seals are intact, clean and in the correct position.
1. Drain plug hub
2. Level and filling plug hub

3:6 3 Driveline/Axle – Drive axle
10 Fill oil in the differential until the oil level is flush with the filler and
1 2 level hole.
11 Install the level and filler plug on the differential.
NOTE
Check that the seal is intact, clean and in the correct position.
004337
3
12 Remove the receptacle.
Differential drive axle
1. Bleeding the drive axle (inside frame) 13 Turn on the system voltage and test drive the machine.
2. Level and filling plug differential 14 Check the oil level in the drive axle after a short test-drive.
3. Drain plug differential

4:1
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:3
4.1.1 Brake pedal .................................................................................................4:3
4.3 Power-assisted brake system ..........................................................................4:4
4.3.3 Accumulator charging valve ........................................................................4:6
4.3.4 Accumulator ................................................................................................4:7
4.3.9 Wheel brake ................................................................................................4:8
4.5 Parking brake system ......................................................................................4:9
4.5.4 Parking brake unit ..................................................................................... 4:11

4:2

4 Brakes – Brakes 4:3
4 Brakes
Brakes, general
There are brakes to stop the machine. The brakes act on the drive axle
(steering axle does not have brakes).
The brake system is divided into two functions:

• Power-assisted brake system, function description, page 4:4
• Parking brake system, function description, page 4:9
4.1 Controls and instruments

4.1.1 Brake pedal
Brake pedal, checking and adjusting
1 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2 Check that the brake pedal returns all the way and that the
clearance between the brake pedal and brake valve is 1–1.5 mm.
If needed, adjust the brake pedal's stop bolt so that the clearance
becomes correct.
3 Check that the pedal's travel is smooth.
Stop bolt screw for adjusting clearance between brake

pedal and brake valve. (Illustration shows loose brake
pedal.)
4 Grease the pedal hinges with EP2 universal grease.

5 Check that the rubber on the pedal is intact and that the tread
pattern isn't worn out. Change when needed.
Brake pedal grease points. (Figure shows unattached

brake pedal)

4:4 4 Brakes – Power-assisted brake system
4.3 Power-assisted brake system

Power-assisted brake system, function
description
The power assisted brake system consists of a hydraulic oil tank,
hydraulic oil pump, valve block, accumulator, brake valve, pressure
sensors, brake cylinder and wheel brake units.
Hydraulic oil pump, brakes and steering, pumps oil (from the tank).
Valve block, accumulator charging valve and priority valve, controls the
pressure to the steering, the accumulators or cooling circuit for the
brakes and the hydraulic oil. The brake valve directs pressure from the
accumulators to the brake cylinders. The brake cylinders compress the
discs in the brake units that brake the machine. Make-contact (closing
switch) brake pressure emits a signal so that the brake light is switched
on when the brake cylinders are pressurised.
When the accumulators are charged the valve block for the accumulator
charging valve and priority valve controls hydraulic oil through the
hydraulic oil's cooling circuit, see section 10 Common hydraulics, group
10.6 Temperature control, cleaning and hydraulic oil.
12
D790-2 B
P
T
D
D797-1 5 C
10 8
Pa
11
D 4
D 13
C
2
9 Pa LB
C ACK M 7
P P
T T
6
P 3
1
014644
B
1. Hydraulic oil pump brakes and steering 8. Make-contact brake lights (S216)
2. Valve block, accumulator charging valve and priority 9. Break contact (opening switch) (S204)
valve (part of the main valve)
10. Control unit frame (D797-1)
3. Valve block brake system
11. Brake lights (H411L & H411R)
4. Accumulators
12. Control unit KIT (D790-2) warning lamp, brake
5. Brake valve pressure
6. Brake cylinder 13. Distribution block drive axle
7. Wheel brakes

4 Brakes – Power-assisted brake system 4:5
Power-assisted brake system, component

location
2
3
4
5
1 6
7
014647
12 11 10 9 8
1. Control unit KIT (D790-2) warning lamp, brake 7. Make-contact brake lights (S216)
pressure
2. Brake cylinder and wheel brake
9. Accumulators
10. Hydraulic oil pump brakes and steering
4. Valve block, accumulator charging valve and priority
11. Brake valve
12. Brake lights (H411L and H411R)
5. Break contact (opening switch) (S204)
6. Distribution block drive axle

4:6 4 Brakes – Accumulator charging valve
4.3.3 Accumulator charging valve

Accumulator charging, check
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil

reaches operating temperature, 50 ºC.
2 Depressurise the hydraulic system, see section B Safety.
˚C
˚C
000475
Operation menu hydraulic oil temperature
3 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

accumulator charging pressure on the accumulator charging valve.
4 Start the engine and let it idle.
014653
Measuring outlet accumulator charging pressure [ACK

M]
5 Close the accumulator drain valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
014619
Close the accumulator drain valve

4 Brakes – Accumulator 4:7
6 Check that the pressure slowly rises to the specified accumulator

charging pressure on the pressure plate.
7 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve shall switch to cooling at 13±0.5 MPa.
9 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
015021
Pressure plate, accumulator charging pressure
NOTE
014619
Close the accumulator drain valve
4.3.4 Accumulator
Accumulator, checking
1 Start the engine and let it idle for approx. 1 minute (until the
accumulator charging valve switches to cooling).
2 Turn off the engine and turn the start key to position I.
3 Apply and release the brake several times, and count the number
of times that the brake can be applied before the warning lamp for
low brake pressure is activated.
It should be possible to apply the brake at least 8 times before
the warning lamp is activated.
If the warning light for low brake pressure is activated earlier, one
of the brake system's accumulators is probably defective and
these should therefore be checked further.

4:8 4 Brakes – Wheel brake
4.3.9 Wheel brake
Wheel brake, bleeding
NOTE
Safety.
Brake cylinder
2 Place a box wrench on the breather nipple and connect a

transparent hose to the breather nipple.
Direct the other end of the hose down into a collection container.
3 Start the machine and push down the brake pedal, hold the pedal
down.
4 Open the breather nipple and let the oil run out of the nipple until it
is free from air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is long.
For this reason allow at least two litres of oil pass through the
breather nipple during bleeding to ensure that no air pockets
Breather nipple brake cylinder, top side of drive axle at remain in the system.
the wheel hub's inner short side (left side).
5 Close the breather nipple.
6 Move the wrench and the hose and collection container and repeat
steps 2-5 on the other side.

4 Brakes – Parking brake system 4:9
4.5 Parking brake system

Parking brake system, function description
The parking brake system consists of hydraulic oil tank, hydraulic oil
pump brakes and steering, valve block accumulator charging valve and
priority valve, valve block brake system, pressure sensor and parking
brake unit.
Hydraulic oil pump, brakes and steering, pumps oil (from the tank).
Valve block accumulator charging valve and priority valve controls the
pressure to the accumulators that store the pressure. The parking
brake unit is released with pressure from the accumulators by means
of the parking brake valve in the valve block brake system pressurising
the parking brake caliper. Make-contact (closing switch) parking brake
emits a signal so that indicator light for parking brake is switched on
when the parking brake is applied.
D
12
1
2 11
D790-1 D790-2
D797-1
3 D
D 8
4 10
C 7
Pa GHB
C HB
ACK M P
T
P 9
6
5
014645
P
1. Switch parking brake (S107) 7. Break-contact parking brake (S200)
2. Control unit cab (D790-1) 8. Accumulators
3. Control unit frame (D797-1) 9. Valve block brake system
4. Solenoid valve, parking brake (Y642) 10. Parking brake caliper
5. Hydraulic oil pump brakes and steering 11. Control unit KIT (D790-2)
6. Valve block, accumulator charging valve and priority 12. Indicator light parking brake

4:10 4 Brakes – Parking brake system
Parking brake system, component location

1 2 3
014648
12 11 10 9
1. Switch parking brake (S107) 7. Parking brake disc
2. Control unit KIT (D790-2), indicator light parking 8. Parking brake caliper
brake
3. Solenoid valve, parking brake (Y642)
10. Accumulators
5. Valve block, accumulator charging valve and priority
12. Control unit cab (D790-1)
6. Break-contact parking brake (S200)

4 Brakes – Parking brake unit 4:11
4.5.4 Parking brake unit
Parking brake unit, checking and adjusting
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Start the engine and run up hydraulic pressure until the

accumulators are fully charged and the accumulator charging
valve switches to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is clean from oil and dirt.
6 Remove the cover from the brake caliper.

Check that there is no oil inside the cover.
7 Loosen the lock nut.

8 Adjust the adjustment screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc becomes 0.5±0.1 mm.
10 Tighten the lock nut.
NOTE
To avoid turning the adjustment screw as well, it must be held
still when tightening the lock nut.
11 Refit the cover on the caliper.

12 Check the function of the parking brake.

4:12 4 Brakes – Parking brake unit
4.5.4.2 Parking brake pads
Brake pads, changing
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Machine in service position and blocked wheels, see section B

Safety.
2 Remove the cover from the brake caliper.
3 Loosen the lock nut.

4 Loosen the adjusting screw so that the brake pads become loose.
5 Remove the split pin and loosen the nut on the attaching bolt
holding the parking brake caliper.

4 Brakes – Parking brake unit 4:13
6 Pull out the attaching bolt so that the brake pads can be twisted
out and removed.
NOTE
The bolt does not have to be removed.
7 Remove the parking brake pads.

8 Clean the brake disc with methylated spirit.
9 Fit the new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and fit a new split pin.
12 Adjust the parking brake, see section 4 Brakes, group 4.5.4
Parking brake unit.

4:14

5:1
5 Steering
Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.2 Power assisted system ....................................................................................5:3
5.2.6 Link arm ......................................................................................................5:4

5:2

5 Steering – Steering 5:3
5 Steering
Steering, general
The function steering means to steer the machine while operating. The
machine is steered with the rear wheels by a power-assisted steering
system.
5.2 Power assisted system

Power assisted system, function description
The function power assisted system refers to steering the machine.
The machine's steering is power-assisted with pressure from the
hydraulic oil pump for brakes and steering.
The steering consists of steering wheel, steering wheel shaft, steering

valve, hydraulic oil pump brakes and steering, valve block accumulator
charging valve and priority valve, steering cylinder, link arms and wheel
spindles.
The steering wheel (via the steering wheel shaft) acts on the steering
valve which in turn directs oil pressure from the hydraulic oil pump
brakes and steering to the steering cylinder. Between the hydraulic oil
pump for brakes and steering and the steering valve is the valve block
for accumulator charging valve and priority valve that gives priority to oil
supply to the steering valve ahead of accumulator charging and cooling
of the brakes. The steering cylinder acts on the wheel spindles. The
link arms are located between the steering cylinder and wheel spindles.
2 C P
3
LS
C T L R
O
P
LSO
2
4
1
014654
1. Hydraulic oil pump 3. Steering valve

2. Valve block, accumulator charging valve and priority 4. Steering cylinder

5:4 5 Steering – Link arm
Power assisted system, component position
2 3
1
014655
1. Steering axle with steering cylinder 4. Valve block, accumulator charging valve and priority
2. Steering valve
5.2.6 Link arm
Link arm, checking

Check the link arms' guide bearings, axles and the bolts that lock
the link arms' axles.
007918

6:1
6 Suspension
Contents 6 Suspension
6 Suspension .........................................................................................................6:3
6.2 Suspension ......................................................................................................6:3
6.2.1 Steering axle cradle ....................................................................................6:3
6.2.2 Wheel spindle..............................................................................................6:4
6.2.3 Wheel hub ...................................................................................................6:5
6.3 Tyres and rims .................................................................................................6:6
6.3.1 Tyres .........................................................................................................6:13
6.3.2 Rim ............................................................................................................6:14

6:2

6 Suspension – Suspension 6:3
6 Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the driveline/axle, see section 3 Driveline/Axle, group3.3 Drive axle.
6.2 Suspension
Suspension, description
The steering axle cradle is mounted to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journalled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journalled wheel hubs where
the wheels are mounted.
Suspension, component location

Suspension refers to:
1 2 3 4 5 6
• Steering axle cradle
• Steering spindle
• Wheel hub
008047
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. Spindle bolt / bearing
6.2.1 Steering axle cradle
Steering axle cradle, checking
1 Machine in service position, see section B Safety, with transverse

wheels.

6:4 6 Suspension – Wheel spindle
2 Check that the bushings in the suspension are intact.
008078
3 Measure the distance between the frame and the steering axle
cradle. Note the measurement.
4 Lift the machine under the rear counterweight.
NOTE
Do not lift under the steering axle.
5 Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
6 Calculate the difference between the two measurements. The
difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.
007842
The figure shows front mounting
6.2.2 Wheel spindle

Wheel spindle bearing, checking
1 Machine in service position, see section B Safety, with transverse
wheels.
2 Measure dimension A with a feeler gauge. Note the measurement.

3 Lift the machine under the rear counterweight.
4 Re-measure measurement A.
5 Calculate the difference between the two measurements. The
difference must be max. 0.25 mm.
If the difference is greater, shimming must be repeated, see
Workshop manual.
A
008079

6 Suspension – Wheel hub 6:5
6.2.3 Wheel hub
Wheel hub, checking
1 Clean the hub covers on the control wheels.

2 Remove the hub cover.
3 Wipe off grease from hub cap and hub nut. Handle it as
environmentally hazardous waste.
008080
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
5 Torque the bearing nut as follows.

A. Lube the thread on the spindle and the side of the nut that
faces the bearing with oil SAE 80W/140 or equivalent.
B. Tighten the nut to 250 Nm.
C. Rotate the hub at least 2 revolutions and then tighten the nut
45 degrees.
D. Rotate the hub again at least 2 revolutions and then tighten
the nut another 45 degrees.
6 Fit the lock washer and outer lock nut.
7 Tighten to at least 250 Nm or as tight as required to fold the
locking washer into the closest groove.
8 Fill the bearing cap with grease and fit it.
9 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate pressing
out of air. Grease until grease comes out by the seal.
NOTE
Be careful so that the seal is not damaged.

6:6 6 Suspension – Tyres and rims
6.3 Tyres and rims

Tyres and rims, safety
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.

6 Suspension – Tyres and rims 6:7
CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
When removing drive wheels, make sure that the
wheels are secured when removing the spacer rings.
If the wheels move they may move the spacer rings,
which may result in crushing injuries.
When installing drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,
pieces of wood, metal filings, etc.
Check if tyre wear is abnormal, this could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.
Tyre and rim system, description

The tires are the points of contact between the machine and the
ground, and the tires absorb unevennesses and provide suspension.
The drive axle is exposed to high forces during operation, if the drive
wheels' rolling circumference is different the stresses increase on
the drive axle. It is important that the tyres on the drive axle are the
same model, type and make, and have equal wear and proper inflation
pressure.
Tyres and rims, check

Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:6.

DANGER
inflating! Lock ring and lock lugs may release and
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Do not exceed prescribed air pressure! When changing
tyre or rim version, another air pressure may apply,
contact Cargotec.
1 2 3 4 1 Check the rims.

• Check that the lock ring and lugs are installed correctly.
• Check that there are no cracks in the rims' parts.
In case of damage, the tyre and rim must be removed and
checked.
015101
1. Lock ring
2. Side ring
3. Rim bead seat taper
4. Rim
2 Check the air pressure in the tyres, see section Tyres, inflating,
page 6:13.
The pressure must be 1.0 MPa, inflate if necessary.
3 Check the tyres.
• Check for uneven and fast wear, this is caused by mechanical
defects such as, e.g., uneven brake action. Make sure that
such defects are repaired immediately.
• Remove penetrating objects such as crushed glass, pieces of
wood, metal filings, etc.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change, page 6:14.
4 If the tyres and rims have no defects, check-tighten the wheel nuts.
Tighten crosswise to a torque of:
• 650 Nm oiled screw.
008153
Examples: The figure shows inflation of drive wheel.

Tyre and rim system, removing and fitting (drive

axle)
Removing
2 Lift the machine under the drive axle by the relevant wheel.
Support under the drive axle in a secure way.
DANGER
With double wheel fitting both tyres must be deflated
otherwise the inner may explode when the outer is
removed.
Risk of tyre explosion! Fatal danger!
Empty both tyres of air.
3 Release the air from the tyres by:

a) Unscrewing the valve and releasing the air.
014571
b) If this does not work, undo the valve in the rim and release the air.
NOTE
Only applies to tubeless tyres.
014573

c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove all wheel nuts.
6 Lift the wheel away and position it safely so that it does not fall or
move.
7 Secure the inner drive wheel with lifting equipment.
8 Remove the spacer ring.
NOTE
The spacer ring is heavy.
9 Remove the inner drive wheel and position it safely so that it does
not fall or move.
005124
Installing
10 Fit the inner drive wheel. Take care that the screw threads are
not damaged.
11 Fit the spacer ring.
12 Install the outer drive wheel. Take care that the screw threads
are not damaged.
13 Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
14 Inflate the tyres, see Tyres, inflating, page 6:13.
15 Lower the machine and remove the jack.
16 Test-drive the machine and check that the wheels are secure.
17 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.

Tyre and rim system, removing and fitting

(steering axle)
Removing
2 Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.
3 Release the air from the tyres by:

a) Unscrewing the valve and releasing the air.
014571
b) If this does not work, undo the valve in the rim and release the air.
NOTE
Only applies to tubeless tyres.
014573

c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove the wheel nuts.
6 Remove the wheel and position it safely so that it does not fall or
move.
Installing
7 Fit the wheel.
8 Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
9 Inflate the tyre, see Tyres, inflating, page 6:13.
10 Lower the machine and remove the jack.
11 Test-drive the machine and check that the wheels are secure.
12 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.
005124

6 Suspension – Tyres 6:13
6.3.1 Tyres
Tyres, inflating
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must
be dismantled and the rim checked for damage.
Never install rim components by striking with a
hammer while inflating. Never strike fully or partly
inflated tyres or rim sets.
Never inflate tyres before all parts are in place.
008153
Wheels shall be inflated on the machine or in a

protective device, designed and dimensioned so that
it can handle or dissipate a shock wave from a tyre
Examples: The figure shows inflation of drive wheel.
explosion as well as catch the ejected parts.
Do not exceed the prescribed tyre pressures which
must be checked at ambient temperature. When
changing tyre or rim version, another air pressure
may apply, contact Cargotec. Plate for air pressure
in tyres must be replaced with a plate that shows
applicable pressure.
inflating. Lock ring and lock lugs may release and
Check that all parts are in place when the tyre
pressure is 30 kPa.
NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1 Make sure that the lock ring and lock lugs are in the correct
position before inflating.
2 Connect the compressor with a locking air-chuck to the nipple

on the tyre.
3 Stand at an angle behind the tyre and remain there until inflating
has been completed in order to prevent being hit by rim parts in
the event of an explosion.
4 Inflate the tyre to prescribed pressure, see specifications.

When changing tyre or rim version, another air pressure may
apply, contact Cargotec.

6:14 6 Suspension – Rim
Tyre, change
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre company.
Check the rim in connection with tyre change, see Rim, check, page
6:14.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimise risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and size.
Over-dimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
1 Dismantle the rim, see Tyre, change, page 6:14.
2 Carefully clean the outside of the rim edge with a steel brush.
005375
3 Measure wear after the lock ring.

The lock ring's wear on the tyre bead often gives a mark, A in the
figure. The mark occurs between the lock ring's ends.
Measure wear depth at point A using a steel ruler and sliding
gauge. If wear exceeds 0.5 mm then the wheel rim, lock ring and
the tapered rim must be discarded and replaced with new parts.
A
Max 0,5 mm
005377

6 Suspension – Rim 6:15
4 Check the rim's diameter.

Measure the rim edge's circumference (O) with a measuring tape
and calculate the diameter (D). [D = Circumference (O) / 3.14]
Compare the value of the diameter with specified min.
measurement. If diameter is smaller, then the wheel rim, lock
ring, and the tapered rim must be discarded and replaced with
new parts.
D Information about min. diameter can be obtained from Cargotec.
O
005374
O. Circumference
D. Diameter
5 Check for damage in the areas with high stress concentration.

Checking is done in two steps:
1. The magnetic particle method is used to determine if there's a
crack or not, and where it is.
2. Confirmed cracks are investigated further with penetrating
fluid.
Typical rim damages are circumference cracks, corrosive damage,
rust, warping and wear.
001702
Magnetic particle method

1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic particle and the following equipment:
• Equipment: Yoke Tiede
• Method:
005375
a Alternating current AC
b Contrast colour
Rim
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
005376
any remaining cleaning fluid evaporate.

4 Spray detection fluid part no. 923626.0670 on the area.
Rim
5 Let the sprayed area dry 1-2 hours.

6:16 6 Suspension – Rim
6 Visually inspect the area.

1 2
If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
If the crack check indicates linear or point-shaped cracks, contact
Cargotec Support.
001705
Examples of cracks
1. Linear crack
2. Pointed crack

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .....................................................................................................7:3
7.2 Lifting/lowering .................................................................................................7:4
7.2.9 Mast ............................................................................................................7:6
7.2.10 Position sensor mast ...................................................................................7:9
7.2.11 Trolley........................................................................................................7:10
7.4 Side shift ........................................................................................................ 7:11
7.5 Spreading.......................................................................................................7:13
7.5.4 Spreader beam .........................................................................................7:18
7.7 Tilt ..................................................................................................................7:20
7.7.7 Tilt cylinder ................................................................................................7:21
7.7.8 Mast ..........................................................................................................7:21
7.8 Levelling.........................................................................................................7:22
7.9 Load carrier....................................................................................................7:23
7.9.1 Twistlocks ..................................................................................................7:23
7.10 Other functions...............................................................................................7:31
7.10.1 Container counter......................................................................................7:31
7.10.2 Speed reduction ........................................................................................7:31

7:2

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The function load handling refers to, e.g. lifting/lowering, side shift, tilt
and securing a load. Load handling also includes help functions to
handle loads, e.g. container counter.
Load handling is divided into different sub-functions.

• Lifting/lowering
• Side shift
• Spreading
• Tilt
• Load carrier (side lift attachment with twistlock locking)
• Other
009149
- Container counter
Lifting/lowering Load handling is primarily controlled with the control levers while
certain functions have separate switches.
Certain sub-functions (e.g. Load carrier) can in turn be divided into

different technical solutions. In these cases, the sub-function is
broken down into further sub-functions.
Many functions change depending on the options with which the

machine is equipped. In these cases the basic function is described
first, then there is a description of how the different options affect
the basic function.
014022
Side shift
009150
Tilt
014023
Spreading

7:4 7 Load handling – Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, function description
Damping
Lifting/lowering means that the mast's components are raised and
lowered so that the attachment is raised and lowered. The machine is
equipped with a duplex lift mast. During lifting, the inner mast is raised
with the lift cylinders. The chain, which is secured in the carriage and
in the outer mast, runs over the chain wheel at the top of the inner
mast and lifts the carriage at the same time as the inner mast is lifted.
The lifting/lowering function is controlled by control lever or linear

control levers . The control lever sends a voltage signal
proportional to lever deflection to the control system in order to control
the lifting/lowering function. Hydraulic oil pump load handling pumps
hydraulic oil to control valve lift, tilt and attachment which pressurises
009149 the lift cylinders. Load control valves on the lift cylinders prevent
uncontrolled lowering.
Engine speed is increased automatically if the machine is

disconnected when lift is activated in order to increase the lifting
speed.
Damping
Damping means that the speed of functions is reduced automatically
close to the upper end position. This entails that mechanical parts are
exposed to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When

damping is activated, the relevant control unit reduces the control
current to the solenoid valve for the relevant function.

7 Load handling – Lifting/lowering 7:5
Condition Reference value

Control switch Not activated
Twistlocks Locked or unlocked, not intermediate position
Contact Mast down: no contact
1b 1a D
D
2 11
D790-1 D794
D797-1
3
4
D
D 10
5
C
P2 9
9
6 A
7
12
014656
8
1. a. Control lever lifting/lowering (R8071) 7. Control valve lift, tilt and attachment (part of the main
b. Control lever (S815-P1) valve)
2. Control unit cab (D790-1) 8. Accumulator lift

3. Control unit frame (D797-1) 9. Lift cylinder
4. Relay control switch lifting/lowering (K3007) 10. Position sensor mast (B7211-2)
5. Solenoid valve lifting (Y6005) and lowering (Y6004) 11. Control unit engine (D794)
6. Hydraulic oil pump load handling 12. Hydraulic oil filter

7:6 7 Load handling – Mast
Lifting/lowering, component location
1 3 4 5
2
6
7 8
10
12
015005
11
1. Solenoid valve lifting (Y6005) and lowering (Y6004) 7. Control lever (S815-P1)
2. Control valve lift, tilt and attachment (part of the main 8. Control lever lifting/lowering (R8071)
valve)
3. Lift cylinder
10. Relay control switch lifting/lowering (K3007)
4. Position sensor mast (B7211-2)
11. Accumulator lift
5. Mast
6. Hydraulic oil pump load handling
7.2.9 Mast
Mast suspension, checking

2 Visually check that the frame's mounting points and welding
seams are intact.
3 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
015104

7 Load handling – Mast 7:7
Mast suspension, checking bearings
1 Raise and secure the trolley
WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.
3 Visually check that the frame's mounting points and welding

seams are intact.
4 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
5 Make a marking on the mast.

6 Remove the load from the mast mountings in an appropriate
manner.
7 Make a new marking on the mast. Measure the distance between
the markings. The measurement should be max. 1 mm.
8 If the difference is greater, the bearings in the mast mountings
must be replaced, see Workshop manual.
009673
Slide plates, checking
2 Check that the slide surfaces in the mast and trolley have a normal
appearance and do not show signs of damage or unevenness.
3 Check the clearance in the mast and between the trolley and mast.
4 When a noticeable clearance arises, which corresponds to a

minimum clearance of 2 mm, the clearance must be reduced by
using adjustment shims, see Workshop manual. If less than 5 mm
wear limit remains on the slide plates they must be replaced.
NOTE
Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
Lifting chains, checking and adjusting

With the aim of increasing safety, the lifting chains should be checked
regularly according to the following:
The chains must be thoroughly cleaned over their entire length. The
check is performed without a load on the side lift attachment.

7:8 7 Load handling – Mast
Wear checking
1 The chain must not have extended more than 3%. Measure the
length of the 25 links that first (and most often) travel over the
chain wheel during lifting. This is where the extension is greatest.
Compare with the value in the table. If the 3% limit is exceeded,
the chains must be replaced.
2 P-measurement = the distance between 2 pins
Measurement over 25 links

P-mea- P-mea- [mm]
005670
surement surement
[in] [mm] Max.
New chain
measurement
3/4 19.05 476.25 490
1 25.4 635 654
1.1/4 31.75 793.75 817
1.1/2 38.1 952.5 981
2 50.8 1270 1308
On chains with up to 1 inch pitch, it is possible to use a special

measuring tape intended to measure the wear.
The measuring tape is marked with:
• Zulässige Verlängerung = permitted lengthening.
• Kette austauschen = chain must be replaced.
The measuring tape can be ordered from Cargotec.
Adjusting
3 Check that the pins for the outer washers are securely fastened.
4 Check that the washers are free of visible cracks.
5 Check that the chain is free from mechanical damage.
6 Check that the chain is free of rust.
7 Check that the chain bends easily over the pulley (does not jam
when bending).
8 Place the machine on level surface with the mast vertical (0° tilt).
9 Lower the carriage to the bottom position.
10 Check that there is 10-20 mm of space between carriage and the

mast. Adjust the position by tensioning or loosening the chains
equally on the adjustment nut in the carriage.
NOTE
If the chain is slack when the carriage is in its lowest position,
the chain must be tightened.
009153
Inspection hole, distance between carriage and mast.

7 Load handling – Position sensor mast 7:9
11 Adjust the chains so that the carriage is lifted evenly in the mast.
3 • Loosen the locking washers (position 1) and remove the lower

nut (position 2).
1 • Lift the chain tightener (position 4) out of the carriage and
remove the old locking washer.
• Reinstall with new locking washer, chain tightener, locking
1 washer and lower nut. Repeat on the other side.
2
009152
4 NOTE
1. Locking washer Reinstall only new locking washers.
2. Lower nut
3. Upper nut • Adjust the nuts on each side to balance the carriage so that
the distance between carriage and mast is 10-20 mm.
4. Chain tightener
• Tighten the nuts.
• Test lift and check that the lifting chain stretches equally on
each side so that the carriage is balanced.
Repeat adjustments as needed.
• When the chains are aligned, lock the nuts with locking
washers.
12 Lubricate the chains after completed inspection.
7.2.10 Position sensor mast
Position sensor, checking
2 Wipe the sensors clean with a rag or similar item.

3 Check that they are secured properly.
4 Check that the distance between sensor and inner mast (when it
is directly opposite the sensor) is 10±1 mm
014740

7:10 7 Load handling – Trolley
7.2.11 Trolley
Slide plates trolley, checking
1 Park the machine with attachment lowered as far down as possible

and spreaders in their narrowest position.
3 Clean the lower slide plates (position 2) and measure the

thickness.
1
NOTE
The thickness of the slide plate should be at least 10 mm.
4 Clean the upper slide plates (position 1) and measure the

thickness.
NOTE
The thickness of the slide plate should be at least 10 mm.
5 Check the clearance between the side lift attachment and the
trolley.
NOTE
If the measured clearance between the trolley's slide plates
and the attachment's main beam is greater than 5 mm, the
clearance must be adjusted using adjustment shims.
3
6 Check that the slide surface is clean and lubricate the slide surface
2 of the side lift attachment.
013681
7 Start the machine and side shift the attachment to both of its
3 end positions. Check that the clearance between trolley and
The illustration shows slide plates between trolley and attachment is sufficient along the whole of the attachment and
attachment. that there is no metallic contact.
8 For adjustment and replacement, see Workshop manual.
1. Upper slide plates
2. Lower slide plates
3. Attachment's mounting

7 Load handling – Side shift 7:11
7.4 Side shift

Side shift, function description
Side shift means to move the attachment sideways. The attachment
can be side-shifted ±600 mm in relation to the trolley.
The side shift function is controlled with control lever or linear control
levers . The control lever sends a voltage signal proportional
to deflection to the control system in order to control the side shift
function. Hydraulic oil pump load handling pumps hydraulic oil to
control valve lift, tilt and attachment which pressurises control valve
attachment when the function is used. Control valve attachment
pressurises the side shift cylinder that moves the attachment's main
beam in relation to the trolley.
014022

1b 1a
D
2
D790-1
D797-1 D791-1
3 7
D
D
C 4 8
P2
P1
5 11 A 9
6 T1 A B
10
014658
1. a. Control lever side shift (R8072) 7. Control unit attachment (D791-1)

b. Control lever (S815-P3) 8. Solenoid valve, side shift left (Y6020) and right
(Y6021)
9. Control valve attachment
10. Side shift cylinder
4. Solenoid valve hydraulic attachment (Y6062-2)
11. Hydraulic oil filter
6. The control valve lift, tilt and attachment

7:12 7 Load handling – Side shift
Side shift, component location
2
4
1 3
10
11 5
6
015007
9 8 7
1. Side shift cylinder 7. Control unit cab (D790-1)

2. Hydraulic oil pump load handling 8. Control unit frame (D797-1)
3. Control valve lift, tilt and attachment (part of the main 9. Control unit attachment (D791-1)
valve)
10. Solenoid valve side shift right (Y6021) and left
4. Solenoid valve hydraulic attachment (Y6062-2) (Y6020)
5. Control lever (S815-P3) 11. Control valve attachment
6. Control lever side shift (R8072)

7 Load handling – Spreading 7:13
7.5 Spreading
Spreading, function description
Damping
Spreading means changing the width between the twistlocks. The
spreading distance is between 20 feet (side lift attachment retracted)
and 40 feet (side lift attachment maximum extension).
The spreading function is controlled by control lever or switch .

The control lever or switch sends a voltage signal to the control
system to control the spreading function. Hydraulic oil pump load
handling pumps hydraulic oil to control valve lift, tilt and attachment
which pressurises control valve attachment when the function is used.
The control valve attachment pressurises the spreading cylinders,
which actuate the spreading booms in and out. Inductive position
sensors indicate the position of the spreader booms.
Damping
014023
Damping means that the speed of functions is reduced automatically
close to end-positions. Four seconds after damping has been
activated the function is cancelled. This entails that mechanical parts
are exposed to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When

damping is activated the control unit reduces the control current to
the solenoid valves.

7:14 7 Load handling – Spreading

Twistlocks Unlocked or bypass activated
1b 1a
D
2
D790-1
D797-1 D791-1
3 7
D
4 D D D
C 8 9
C D
P2
P1
5 15 A
6 10
T1 B A A B
13 11 12 14
014659
1. a. Switch spreading 20'-40' (S1012) 9. Solenoid valve, spreading out left (Y6018L) and
spreading in left (Y6019L)
b. Control lever (S815-T1.1 and S815-T1.2)
11. Spreading cylinder, right
12. Spreading cylinder, left
13. Sensor, end-position 20'-40' right (B769R)
14. Sensor, end-position 20'-40' left (B769L)
6. Control valve lift, tilt and attachment (part of the main
valve) 15. Hydraulic oil filter
7. Control unit attachment (D791-1)
8. Solenoid valve, spreading out right (Y6018R) and
spreading in right (Y6019R)

30-foot stop, function description

30-foot stop is an additional function for spreading and is activated with
Switch stop at 30'. When 30-foot stop is activated spreading stops at
30 feet, to spread further the spreading must be activated once again.
Two inductive position sensors indicate the position of the spreading
beams and activate damping. At 30 foot stop, two sensors are used
to control the stop.

D 1
D
2b 2a 30-
35
3
D790-1
D797-1 D791-1
4 6
D D D D
D D D
30' 30'
014660
5 8 9 7 7 8 9
1. Switch stop at 30' (S1004) 7. Solenoid valve spreading out left (Y6018L) and
Solenoid valve spreading out right (Y6018R) or
2. a. Switch spreading 20'-40' (S1012) Solenoid valve spreading in left (Y6019L) and
b. Control lever (S815-T1.1 and S815-T1.2) Solenoid valve spreading in right (Y6019R)
3. Control unit cab (D790-1) 8. Sensor end-position 30' left (B777L) and Sensor
end-position 30' right (B777R)
9. Sensor end-position 20'-40' left (B769L) and Sensor
5. Solenoid valve hydraulic attachment (Y6062-2) end-position 20'-40' right (B769R)

7:16 7 Load handling – Spreading
Automatic spreading 20-40 foot, function

description
Automatic spreading 20'-40' is an option for spreading that is activated

with Switch automatic spread 20'-40'. When the switch is activated,
spreading automatically switches to the next end position when
spreading is activated using the control lever. The buzzer on the trolley
sounds during automatic spreading. Automatic spreading works for
both spreading in and spreading out.
If the machine is equipped with 30-foot stop and it is activated,

then spreading stops at 30'. Activate spreading again to go to the next
position.

Doors Closed
Parking brake Released
D
1
D
2b 2a
3 11
D790-1 D795
D797-1 6 D791-1
4 D D D
D D D D
D
014661
5 8 9 7 10 7 8 9
1. Switch automatic spreading 20'-40' (S1012-2) 7. Solenoid valve spreading out (Y6018L & Y6018R)
2. a. Switch spreading 20'-40' (S1012) Solenoid valve spreading in (Y6019L & Y6019R)
b. Control lever (S815-T1.1 and S815-T1.2) 8. Sensor end-position 20'-40' (B769L & B769R)
3. Control unit cab (D790-1) 9. Sensor end-position 30' (B777L & B777R)
4. Control unit frame (D797-1) 10. Buzzer automatic spreading (H9003)
5. Solenoid valve hydraulic attachment (Y6062-2) 11. Control unit KID (D795)

Spreading, component location
1 2 1
8 9
7
3
4
5
6
5
4
3
3 4-6 10
11
16
12
17
015008
15 14 13
1. Spreader beam 9. Hydraulic oil pump load handling

2. Spreading cylinders 10. Control lever (S815-T1.2 and S815-T1.2)
3. Indicator plate 20' 11. Switch spreading 20'-40' (S1012)
4. Indicator plate 30' 12. Control unit cab (D790-1)
5. Indicator plate 40' 13. Control unit frame (D797-1)
6. Sensor end-position 20'-40' (B769L & B769R) 14. Control unit attachment (D791-1)
Sensor end-position 30' (B777L & B777R) 15. Control valve attachment
7. Control valve lift, tilt and attachment (part of the main 16. Solenoid valve spreading in (Y6019R & Y6018R)
valve)
17. Solenoid valve spreading out (Y6019L & Y6018L)

7:18 7 Load handling – Spreader beam
7.5.4 Spreader beam

Spreader beam, description
The spreader beams are the part of the attachment that grips the
container. Two spreader beams run inside the main beam. The
spreader beams are slid in and out with hydraulic cylinders.
Twistlocks are fitted in the spreader beam, see 7.9.1 Twistlocks,

page 7:23.
014737
Spreader beams
Slide plates spreading beam, checking

1 Park the machine with attachment lowered as far down as possible
and spreading extended approx. 1000 mm.
1000 mm
013683

7 Load handling – Spreader beam 7:19
3 Check that the clearance between slide plates and main beam is
maxmax 5 mm both laterally and vertically. This is equivalent to
the dimensions X1–X2 = max 5 mm and Y1–Y2 = max 5 mm.
NOTE
If the measured clearance between slide plates and beams
is greater than 5 mm, the clearance must be adjusted using
Y2
Y1
adjustment shims.
X2
Y2
Y1
013690
X1
Left side
X2
013689
X1
Right side
4 For adjustment and replacement, see Workshop manual.

7:20 7 Load handling – Tilt
7.7 Tilt
Tilt, function description
Tilt means the angling of the mast in relation to the machine.
The tilt function is controlled with control lever or linear control levers
. The control lever sends a voltage signal proportional to deflection
to the control system in order to control the tilt function. Hydraulic oil
pump load handling pumps hydraulic oil to control valve lift, tilt and
attachment which pressurises the tilt cylinders. The tilt cylinders angle
the mast in relation to the machine. The load holding valves on the tilt
cylinders rod side prevent the mast being tilted due to the load.
009150

1b 1a D
D
2
D790-1
D797-1
4 3
D
5 8
C
P2
9
6 10 A B 7 8 014657
9
1. a. Control lever tilt (R8072) 6. Hydraulic oil pump load handling
b. Control lever (S815-P2) 7. Control valve lift, tilt and attachment (part of the main
valve)
8. Load holding valve
9. Tilt cylinder
4. Relay control switch tilt (K3002)
5. Solenoid valve tilt in (Y6011) and Solenoid valve tilt
out (Y6010)

7 Load handling – Tilt cylinder 7:21
Tilt, component location
1 2 3 4 5 6
7 8
11
10
015006
1. Solenoid valve tilt in (Y6011) and Solenoid valve tilt 6. Hydraulic oil pump load handling
out (Y6010)
7. Control lever (S815-P2)
valve) 8. Control lever tilt (R8072)
3. Mast 9. Control unit cab (D790-1)
4. Tilt cylinder 10. Relay control switch tilt (K3002)
5. Load holding valve 11. Control unit frame (D797-1)
7.7.7 Tilt cylinder
Tilt cylinder, checking

Check:
• visually that the frame's mounting points and welding seams are
intact.
• that the tilt fork is securely fastened to the tilt cylinder (136 Nm
tightening torque).
• that the tilt cylinders are correctly adjusted.
that the tilt cylinders are properly aligned, so that both cylinders
reach their end positions simultaneously.
7.7.8 Mast
Mast suspension, checking

See Mast suspension, checking, page 7:6.

7:22 7 Load handling – Levelling
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the twistlock mountings can spring
outwards and adjust the height of the twistlocks to the inclination of
the container being lifted. This means that the machine can handle
loads on uneven ground, up to ±3° levelling.
014021

7 Load handling – Load carrier 7:23
7.9 Load carrier

Load carrier, description
Load carrier means holding any loads. The load is held by the
twistlocks that secure the load with rotatable lift pins.
7.9.1 Twistlocks
Twistlocks, function description
The container is secured in place on the side lift attachment with two
twistlocks.
Twistlocks are controlled by Switch twistlocks. Hydraulic oil pump load

handling pumps hydraulic oil to control valve lift, tilt and attachment
which pressurises control valve attachment when the function is used.
A section in Solenoid valve attachment pressurises two hydraulic
cylinders, connected in parallel, one on each side of the side lift
attachment. Each hydraulic cylinder acts on a linkage that turns a
twistlock. Four position sensors, two on each side of the side lift
attachment, detect the position of the linkage and indicate whether
twistlocks are open or locked. Control lights on the side lift attachment
and in the cab show status for twistlocks.
A contact pin and a sensor at each twistlock indicate when the

attachment is in contact with the container. This is used to control when
twistlocks can be activated. Indicator lights on the side lift attachment
and in the cab show when the side lift attachment has full contact and
whether the twistlocks are open or locked. An event menu shows
which twistlocks have contact (1–2). To activate twistlocks, contact is
required at both twistlocks.

7:24 7 Load handling – Twistlocks

Contact Full contact or bypass activated
17
2b 1
D
2a
3 16
D 15
D790-1 D790-2 D795
D797-1 D791-1
D 4 8
D
5 D
C D 13 14
9
C 12
P2
P1 A
7 18 A
6 T1 B
10 11 12
D
014662
13 D 14
1. Switch lock twistlocks (S1003) 10. Control valve attachment

2. a. Switch open twistlocks (S1002) 11. Over centre valve
b. Control lever (S815-T2) 12. Lock cylinder
3. Control unit cab (D790-1) 13. Sensor contact left and right (B7203L and B7203R)
4. Control unit frame (D797-1) 14. Sensor unlocked twistlocks (B7204L and B7204R),
Sensor locked twistlocks (B7205LL and B7205RL)
15. Control unit KID (D795)
valve) 16. Control unit KIT (D790-2)
7. Hydraulic oil pump load handling 17. Indicator lights attachment
8. Control unit attachment (D791-1) 18. Hydraulic oil filter
9. Solenoid valve open twistlocks (Y6039) and lock
twistlocks (Y6040)

7 Load handling – Twistlocks 7:25
Twistlocks, component location
1
7 9
2 10
8
11
6 5 4 3
19
12
13
18
015009
17 16 15 14
1. Sensor locked twistlock (B7205LL/RL) 11. Switch lock twistlocks (S1003)

2. Lock cylinder twistlocks 12. Control lever (S815-T2)
3. Sensor contact (B7203L/R) 13. Switch open twistlocks (S1002)
4. Sensor unlocked twistlock (B7204L/R) 14. Control unit cab (D790-1)
5. Contact pin
6. Twistlocks
7. Indicator lights attachment
8. Over centre valve
valve) 19. Solenoid valve lock twistlocks (Y6039)
10. Solenoid valve hydraulic attachment (Y6062-2) Solenoid valve open twistlocks (Y6040)

Twistlocks, checking
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
1 1 Check that the twistlocks function correctly.

2 3 Lock and open the twistlocks, check that the indicator lights work,
both in cab and on attachment.
2 Clean the twistlocks from any dirt.
3 Under the rubber cover for twistlocks: check pin, link arm and
lock nut.
4 Clean the area around sensor contact.
5 Press in the alignment pin so that the head is flush with the
spreader beam's underside. Check the distance to sensor contact,
the distance should be 5±1 mm. Adjust when needed.
014716
5 4
NOTE
1. Sensor contact The contact pin should move easily and spring back completely.
2. Sensor unlocked twistlock
3. Sensor locked twistlock
4. Lift pin
5. Contact pin
6 Put a crowbar between the lift pin (position 5) and the lift pin's
guide, check the clearance max. clearance: 1–1.5 mm. If
necessary, replace the wear washer (position 1) between
twistlocks and holder.
1
015527
1. Wear washer

7 Turn twistlocks to locked position and check wear of the lift pin.
Change the lift pin as needed.
8 Repeat steps 1-8 on both twistlocks.
m Max. 4 mm
m
0
.7
in
M
009776
Wear limits lift pin.

Twistlock, checking for cracks
DANGER
Twistlocks should be checked in accordance with
recommended intervals. The interval is calculated
according to the machine being used for normal
handling and on a level, smooth ground surface. For
other handling or, e.g., rough surface, the interval
should be shortened.
If there are signs of cracking, the machine must be
immediately taken out of operation and Cargotec
Service contacted.
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.
NOTE
Check for cracks shall take place every other year or every 4000
operating hours.
1 Remove the lift pins from the attachment.
NOTE
Twistlocks are heavy, be careful when removing.
2 Check for cracks within the marked area on the lift pins without
causing damage.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
009777
4 Install approved twistlocks.

Area for checking for cracks on lift pins
NOTE
Use new bearing cap, new bolts and new lock nuts.

Sensor contact, checking and adjusting

1 Check that the alignment pins in the corner boxes can move freely
up and down. The contact pins shall spring down when not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the light indicators
on the sensor are turned off.
4 Lower the attachment onto a container and check that Indicator
light contact is lit.
5 Lift the container a little bit so that the Indicator light contact is
switched off.
6 With the container raised, check how much movement on the
014717
contact pins is needed to detect contact (light indicator on the
1 2 sensor is lit). The movement should be 3–4 mm.
Right side
1. Sensor contact
2. Contact pin
7 If necessary, loosen the lock nut and screw the sensor in/out until
the distance between the sensor and the contact pin is 5±1 mm.
014718
2 1
Left side
1. Sensor contact
2. Contact pin

Sensor twistlocks, checking and adjusting

1 Check that the sensors are free of damage and dirt.
2 Turn the start key to position I and check that the light indicator
on the sensor for unlocked twistlock is lit.
If necessary, loosen the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 5±1 mm.
3 Check that indicator light twistlocks open is lit.
4 Lower the attachment over a container and lock twistlocks.
5 Check that the light indicator on the sensor for locked twistlock
is lit.
If necessary, loosen the lock nut and screw the sensor in/out until
014719
1 2 the distance between the sensor and the indicator plate is 5±1 mm.
Right side
6 Check that indicator light twistlocks locked is lit.

014720
2 1
Left side

7 Load handling – Other functions 7:31
7.10 Other functions

7.10.1 Container counter
Container counter, function description
Container counters count the number of containers lifted. The counter

has two counter units that can be reset separately.
The container counter uses Sensor alignment and Sensor twistlocks to

decide when a container is lifted. The container counter counts a lift
when contact disappears with locked twistlocks and twistlocks do not
open again within eight seconds.

4
D795
D791-1
3 D
D
1 2
004297
1. Sensor contact left and right (B7203L and B7203R) 3. Control unit attachment (D791-1)
2. Sensor locked twistlock left and right (B7205LL and 4. Control unit KID (D795)
B7205RL)
7.10.2 Speed reduction

Speed reduction with load
When operating with a load the machine's speed is limited to 15 km/h.

7:32

8:1
8 Control system
Contents 8 Control system

8 Control system ...................................................................................................8:3
8.2 Monitoring ........................................................................................................8:6
8.2.2 Bypass ........................................................................................................8:6
8.2.3 Speed limitation...........................................................................................8:6
8.2.4 Service indicator..........................................................................................8:7
8.3 Error codes ......................................................................................................8:8
8.4 Diagnostics ....................................................................................................8:10
8.4.1 CAN/POWER ............................................................................................8:13
8.4.2 LIGHTS .....................................................................................................8:14
8.4.3 CAB ...........................................................................................................8:15
8.4.4 CLIMATE ...................................................................................................8:15
8.4.5 HYD...........................................................................................................8:16
8.4.6 ENGINE ....................................................................................................8:17
8.4.7 TRANSM ...................................................................................................8:19
8.4.8 ELECTRIC SERVO ...................................................................................8:20
8.4.9 ATTACH ....................................................................................................8:21
8.4.10 OLS ...........................................................................................................8:21
8.4.11 EXTRA ......................................................................................................8:22
8.5 Settings ..........................................................................................................8:24

8:2

8 Control system – Control system 8:3
8 Control system
Control system, general
In many cases the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator or
limit the machine's functions in case of certain dangerous situations or
if there are malfunctions in the machine.
The function control system is divided into the following functions:

• Monitoring functions
• Error codes
• Diagnostics
• Settings
• Software
Monitoring functions describe the machine's monitoring functions that

warn the operator or limit the machine's functions in the event of a
dangerous situation.
Error codes notify operators and mechanics when malfunctions have

been detected.
Diagnostic test is tool for performing service and troubleshooting with

menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

8:4 8 Control system – Control system
Control system, description

The machine is equipped with an electronic system used for
B C D
controlling and monitoring the machine’s different functions.
The system provides information to the operator in the form of alarm

information, operating information, and event-controlled information.
The information is shown on the steering wheel panel's display (C)
and on a panel for warning and indicator lights (B).
The function keys are used to navigate in the display menus for
service and troubleshooting, for example.
000053
A
A Function keys (KIT)
B Warning and indicator lights
C Display (KID)
D Alarm indicator
Function keys
Function keys
The function keys (A) are used to navigate in the menu system. They
are also used to enter values in the system, change light contrast in
the keys/indicator panel, and to acknowledge a warning.
000055
• Function key 1: Scroll anticlockwise in menu system as well as

enter value 1.
• Function key 2: Scroll clockwise in menu system as well as enter
value 2.
• Function key 3 (Reset): Abort selection of menu/session in
progress as well as enter value 3. Confirm alarm.
• Function key 4: Enter value 4, gradually adjust settings (for
example, contrast in guide lights for function keys) and gradually
change values in operating menus.
• Function key 5: Enter value 5, gradually adjust settings (for
example, contrast in guide lights for function keys) and gradually
change values in operating menus.
• Function key 6 (Return): Confirm selection of menu and
sub-menu, as well as confirm entered value.

8 Control system – Control system 8:5
Operating menus
Operating menus
Operating menu Engine and transmission are shown in the display

1 2 when the machine is started. This menu is shown until another
menu is selected or an event-controlled menu is shown (e.g., in case
of error code of the type "WARNING" and "STOP"). Other menus
(see list below) are scrolled with the function keys 1 (arrow left) and
2 (arrow right).
For overview of operating menus see, section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments.
The following operating menus are available to aid the operator:

• Operating menu engine and transmission
• Operating menu engine
• Operating menu transmission and hydraulics
014182
• Operating menu electrical system
Examples of available operating menus • Service menu

• Operating menu heating and air conditioning
• Operating menu service interval
• Operating menu statistics
Event-controlled information
Under certain conditions, the control system calls the operator's

attention to important information with figures on the display. Examples
of warnings are warning for overloading when the overload system
is activated.
For overview of the event menus see, section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments.
Warnings are described in connection with each function. The following

event menus are available:
• Contact side lift attachment, twistlock
• Locked/unlocked twistlock
• Open door
• Automatic spreading
Service menu
Service menu
The service menu is the gateway to the machine's diagnostic system.

Different parts of the Service menus are made available by pressing
"Enter" and entering different codes. The different service menus are:
000056
• Error codes, description, page 8:8

• Diagnostics, general, page 8:10
• Setup, general, page 8:24

8:6 8 Control system – Monitoring
8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
• Bypass
• Speed limitation
• Service indicator
8.2.2 Bypass
Bypass, description
Bypass is activated with the bypass switch.
Bypassing the safety system makes it possible to:

• lock and open twistlocks without full contact
• Spread 20'-40' with locked twistlocks
• lower load with contact on side lift attachment
• manual steering of recirculation damper by ECC or EHC
• release of parking brake in case of malfunction of switch parking
brake
• output signal to solenoid valves with active error codes
• machine engages neutral when no one is sitting in the driver's seat
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
8.2.3 Speed limitation

Speed limitation, description
Speed limitation prevents the machine's speed from exceeding pre-set

value by limiting gear position and engine rpm.

8 Control system – Service indicator 8:7
8.2.4 Service indicator

Service indicator, resetting
2 Navigate first to the service menu and press Enter.
000056
3 Enter code for resetting service indicator.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Service, Diagnostics, Initiation or Calibration).
4 Reset the service indication by pressing Enter. NEXT SERVICE is

SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh To change duration of the service interval, set the desired interval
SERVICE INTERVALL with the plus and minus key.
STORED XXXXh
004908
PRESENT XXXXh

8:8 8 Control system – Error codes
8.3 Error codes

Error codes, description
When a malfunction occurs in the machine error messages (error
codes) are generated by the control unit in question that is sending the
error code via the CAN-bus to control unit KID (D795) that shows the
error codes on the display and stores the error codes.
Explanation of error codes is found in Operator's manual and Workshop

manual.
Error code indication
53 54 Error code indication
Error code is indicated with activate Indicator for active error codes
(position 36). Error codes are divided into three error code levels,
depending on how serious they are.
Error code levels are indicated as follows:

B • STOP is indicated with a STOP-sign on the display together
with a flashing red light from indicator for control and monitoring
system (position 54) and activated Indicator for active error codes
(position 36).
Error code with level STOP shown automatically on display.
36 • WARNING is indicated on the display, together with a flashing red
light for control and monitoring system (position 54) and activated
Indicator for active error codes (position 36).
Error code with level WARNING shown automatically on display.
• INFORMATION is indicated with activate Indicator for active error
codes (position 36).
Error code with level INFORMATION shown in error code list
under operating menu for service.
000348
B. Symbol error code level

36. Indicator active error codes
53. Display control system
54. Indicator for the control system
Error code display
Error code display
Error code information is shown with display figures in two ways:

• Automatically on display.
The error code is acknowledged with function key Reset (R).
003817
When the error code has been acknowledged the display returns
to previously selected menu. If the error code is active, it is stored
in the error code list under operating menu for service.
Example of automatic display figure
If the error code is active it is repeated to remind the operator
of the error status, stop every 3rd minute, warnings every 5th
minute.

8 Control system – Error codes 8:9
• In the error code list under operating menu for service.

Active error codes are stored in the error code list. Navigate
to the operating menu for service. Show the error code list by
pressing in function key Enter for two seconds. Navigate in the
error code list with function key arrow right and arrow left. Exit
the error code list by pressing function key Reset (R).
001998
Example of display in error code list
NOTE
If error code isn’t included in the error code list, it may be due
to the following:
– condition for error detection no longer exists, e.g.,
control lever is released or engine is off.
– loose connection/poor contact.

8:10 8 Control system – Diagnostics
8.4 Diagnostics
Diagnostics, general
The machine has built-in functions for troubleshooting called diagnostic
test. The diagnostic test consists of several menus that are shown in
the display. The menus are grouped for faster access.
The following pages show compilations of the diagnostic menus. The

workshop manual has a more detailed description of each diagnostic
menu.
The diagnostic test is divided into the following groups:

• CAN/POWER, menu overview, page 8:13
• LIGHTS, menu overview, page 8:14
• CAB, menu overview, page 8:15
• CLIMATE, menu overview, page 8:15
• HYD, menu overview, page 8:16
• ENGINE, menu overview (engine alternative Yuchai YC6A240-30),
page 8:17
ENGINE, menu overview (engine alternative Cummins QSB6.7
), page 8:18
• TRANSM, menu overview, page 8:19
• ELECTRIC SERVO, menu overview, page 8:20
• ATTACH, menu overview, page 8:21
• OLS, menu overview, page 8:21
• EXTRA
– OPT, menu overview, page 8:22

8 Control system – Diagnostics 8:11
Diagnostic menu, description

1 The diagnostic tests are built up of menus. The menus are grouped
2 3 4 according to logical areas. With the diagnostic menus it is possible to
read off how the control unit interprets input signals as well as what
7 DIAG CAB 2(X) output signals are sent by the control unit.
FRONT WIPER
SWITCH (1-3) 2 Signal values (position 6) in the menu indicate measured values by
5 the relevant control unit. The control units have internal voltmeters
OUTPUT 11 6
005592
FEEDBACK 0 and ammeters that measure the signal on the connectors out to
components or in from components.
1. DIAG = Diagnostic menus Output signals are control of solenoid valves, lights, relays, etc.
2. Menu group (CAB = cab functions)
Input signals are sensor signals, signals from controls and switches,
3. Menu number feedback control signals, etc.
4. Total number of menus in the loop. The number
of menus depends on how the machine is The figure shows an example of a menu, here for diagnostics of
equipped, which is why the number of menus is windshield wiper. The table below indicates what you can read out
indicated by (X) in this manual. from the menu figure.
5. Variable
6. Signal value
7. Menu heading
Pos. Designation Description

1 DIAG Indicates that diagnosis has been selected. There is also initiation (INIT) and calibration (CALIB).
2 CAB Indicates which menu group is selected. These groups are available:
CAN/POWER - for diagnosis of CAN-bus and electric power supply.
LIGHTS - for diagnosis of lighting and lights.
CAB - for diagnosis of components in cab.
CLIMATE - for diagnosis heat and ventilation system.
HYD - for diagnosis of common hydraulics and brakes.
ENGINE - for diagnosis of engine.
ELECTRIC SERVO - for diagnosis of lifting/lowering and tilt.
ATTACH - for diagnosis of attachment.
OLS - for diagnosis of overload system.
EXTRA - for diagnosis of optional functions.
3 2 Number of current menu (menu group CAB contains several menus in a loop).
4 (X) Total number of menus in group CAB. The number of menus depends on how the machine is
equipped, which is why the number of menus is indicated in this manual by (X).
5 Variable Which signal is being measured. Here are a few examples.
SWITCH refers to switch windshield wipers.
OUTPUT refers to status of a feed, in this case feed to the wiper motor.
FEEDBACK refers to feedback signal, in this case signal from the wiper motor when it operates.
6 Signal value Measuring value or status for the signal for the variable on the same line.
7 FRONT WIPER Name of the function that can be controlled. FRONT WIPER means front windshield wiper.

8:12 8 Control system – Diagnostics
Diagnostics, operating instructions

To choose diagnostics, do the following:
1 Navigate to the service menu.
2 Push Enter.
000056
3 Enter the code for diagnostics.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Service, Diagnostics, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
DIAGNOSIS with Enter.
CAN/POWER LIGHTS CAB
Each group consists of a sequence of numbered menus. The first
CLIMATE HYD ENGINE menu for selected diagnostic menu is shown in the display, use
TRANSM ELSERV ATTACH arrow keys (1 and 2) to change menu.
005263
OLS EXTRA

8 Control system – CAN/POWER 8:13
8.4.1 CAN/POWER
CAN/POWER, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG CAN/POWER 1(X) DIAG CAN/POWER 2(X) DIAG CAN/POWER 3(X)

PRESENT REDCAN STATUS PRESENT REDCAN STATUS PRESENT OPTION KDU
COMMUNICATION MODE X CONNECTED CITIES
NUMBERS OF UNITS X D797-1 D797-2 XX KDU D797-2 XY
SEGMENT ERROR X D795 D791-1 XX KDU D791-1 XY

PRESENT DRIVE-TRAIN IGNITION EMERGENCY STOP, SW X
CAN BUS STATUS KEY IN X RELAY K3009-1 XY
ENGINE X RELAY K315-1 XY FEEDBACK X
TRANSMISSION X RELAY K315-2 XY RELAY K3009-2 XY

790-1 CAB 790-1 CAB 795 DISPLAY
POWER XX.XXV 24V SENSOR SUPPLY XY
5V REF X.XXV 24V SUPPLY,RPM>500 XY RED.POWER LE X RI X

797-1 FRAME 797-1 FRAME 793 TRANSMISSION
POWER XX.XXV POWER XX.XXV
RED.POWER LE X RI X 5V REF X.XXV IGNITION POWER XX.XXV
POWER 2 X SENSOR SUPPLY XX.XXV

NOT USED NOT USED 791-1 ATTACHMENT(OPT)
EME POWER XX.XXV
RED.POWER LE X RI X
EME POWER 2 X
DIAG CAN/POWER 16(X) DIAG CAN/POWER 17(X)

791-1 ATTACHMENT (OPT) REDCAN STATUS CHECK
24V SENSOR SUPPLY XY PRESS ENTER
5V REF X.XXV
015038
SEGMENT ERROR X

8:14 8 Control system – LIGHTS
8.4.2 LIGHTS
LIGHTS, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG LIGHTS 1(X) DIAG LIGHTS 2(X) DIAG LIGHTS 3(X)

MAIN LIGHT PRESENT OUTPUT SIGNAL HEAD LIGHTS
SWITCH X SWITCH X
SIDE LIGHTS XY HEAD LE/RI XY
REAR LIGHTS XY DIMMED LE/RI XY

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL ROTATION BEACON
HAZARD SWITCH X HAZARD/FLASHER SWITCH X
FLASH.SW. LE X RI X LEFT F/R XY OUTPUT XY
RIGHT F/R XY

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL CAB LIGHT
BRAKE LGT SWITCH X BRAKE LGT LE XY RI XY MANUAL SWITCH X
REVERSE LGT SIGNAL X REV. LGT LE XY RI XY DOOR SWITCH X
REVERSE ALARM XY OUTPUT XXX

WORKING LIGHT MAST WORKING LIGHT EXTRA WORKING LIGHT CAB
SWITCH X OUTPUT SWITCH X
OUTPUT LE/RI XY D797-1 C1 P42 XY
D797-2 C1 P42 XY OUTPUT 20' XY 40' XY

WORKING LIGHT ATTACH SWITCH LIGHTS STEP LIGHT
SWITCH X SWITCH X
OUTPUT LE XY RI XY OUTPUT XXX OUTPUT XXX
009154

8 Control system – CAB 8:15
8.4.3 CAB
CAB, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG CAB 1(X) DIAG CAB 2(X) DIAG CAB 3(X)

WASHER FRONT WIPER REAR WIPER
SWITCH X SWITCH (1-3) X SWITCH X
OUTPUT FRONT XY OUTPUT XY OUTPUT XY
OUTPUT REAR ROOF XY FEEDBACK X FEEDBACK X
DIAG CAB 4(X) DIAG CAB 5(X) DIAG CAB 6(X)

ROOF WIPER HORN BUZZER X
SWITCH X SWITCH X SWITCH SEAT X
OUTPUT XY SWITCH 2 X ALARM X
FEEDBACK X OUTPUT XY OP X
DIAG CAB 7(X) DIAG CAB 8(X)

FUEL SEAT HEATER
SENSOR VALUE XXXohm SWITCH X
PROC XXX OUTPUT XY
009155
8.4.4 CLIMATE
CLIMATE, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG CLIMATE 1(X) DIAG CLIMATE 2(X) DIAG CLIMATE 3(X)

PRESENT INPUT SIGNAL TEMP COIL XXX PRESENT INPUT SIGNAL
REQUIRED TEMP XXX TEMP COOLANT XXX PRESSURE SWITCH X
PRESENT TEMP XXX TEMP AMBIENT XXX
WATER VALVE FEEDB. XXX TEMP DE-ICE XXX
DIAG CLIMATE 4(X) DIAG CLIMATE 5(X) DIAG CLIMATE 6(X)

PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL
WATER VALVE XX.XXV REQUIRED TEMP XX.XXV FAN SPEED XXX
DRAUGHT VALVE XX.XXV REQ. DRAUGHT XX.XXV RECIRKULATION XY
REQ. FAN SPEED XX.XXV COMPRESSOR XY
DIAG CLIMATE 7(X) DIAG CLIMATE 8(X)

OUTPUT WATER VALVE OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
005596

8:16 8 Control system – HYD
8.4.5 HYD
HYD, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG HYDRAULIC 1(X) DIAG HYDRAULIC 2(X) DIAG HYDRAULIC 3(X)

HYDRAULIC OIL NOT USED HYDRAULIC PRESSURE
TEMP XXX
FAN XY LIFT CYLINDER XXX
SET OUTPUT +/- X TILT CYLINDER XXX
DIAG HYDRAULIC 4(X) DIAG HYDRAULIC 5(X) DIAG HYDRAULIC 6(X)

PRESSURE SWITCHES P-BRAKE NOT USED
BRAKE PRESSURE X SWITCH X/Y
BRAKE LIGHT PRESS. X FEEDBACK SWITCH X
DECLUTCH PRESSURE X VALVE XY
DIAG HYDRAULIC 7(X) DIAG HYDRAULIC 8(X)

NOT USED PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM.
VALVE XY
015039
SET OUTPUT +/- X

8 Control system – ENGINE 8:17
8.4.6 ENGINE
ENGINE, menu overview (engine alternative Yuchai
YC6A240-30)
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG ENGINE 1(10) DIAG ENGINE 2(10) DIAG ENGINE 3(10)

PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
ACCELERATOR X.XXV ENGINE SPEED EDC XXXX PRESENT TORQUE XXX
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT INPUT SIGNAL
PREHEAT SWITCH X PREHEAT X OIL PRESSURE XX.X
CRANK ENGINE SWITCH X CRANK ENGINE X BOOST PRESSURE XX.X
D+ X CRANK ENGINE WIRE XY

PRESENT INPUT SIGNAL PRESENT EDC ERROR FUEL CONSUMPTION
OIL TEMP XXX NR OF ACT ERROE XX MOMENTARY l/h XXX
COOLANT TEMP XXX SPN XXXX
INTAKE MAIN.TEMP XXX FMI XX
DIAG ENGINE 10(10)

PRESENT INPUT SIGNAL
PRE-HEAT FEEDBACK X
WATER IN FUEL SW. X
015040
COOLANT LEVEL SW. X

8:18 8 Control system – ENGINE
ENGINE, menu overview (engine alternative Cummins

QSB6.7 )
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG ENGINE 1(X) DIAG ENGINE 2(X) DIAG ENGINE 3(X)

PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
ACCELERATOR X.XXV ENGINE SPEED EDC XXXX PRESENT TORQUE XXX
REQUIRED SPD PROC XXX ENGINE SPEED TCU XXXX REQUIRED TORQUE XXX
REQUIRED SPD RPM XXXX PRES TORQUE @ PRM XXX

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT INPUT SIGNAL
PREHEAT SWITCH X PREHEAT X OIL PRESSURE XX.X
CRANK ENGINE SWITCH X CRANK ENGINE CAN X BOOST PRESSURE XX.X
D+ X CRANK ENGINE WIRE XY OIL LEVEL XXX

PRESENT INPUT SIGNAL PRESENT EDC ERROR FUEL CONSUMPTION
OIL TEMP XXX NR OF ACT ERROR XX MOMENTARY l/h XXX
COOLANT TEMP XXX SPN XXXX
INTAKE MAIN.TEMP XXX FMI XX
DIAG ENGINE 10(X)

NOT USED
015041

8 Control system – TRANSM 8:19
8.4.7 TRANSM
TRANSM, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG TRANSM. 1(14) DIAG TRANSM. 2(14) DIAG TRANSM. 3(14)

PRESENT INPUT SIGNAL SWITCHES PRESENT VALUE
BRAKE PEDAL X.XXV FORWARD X FORWARD X
DECLUTCH SWITCH X REVERSE X REVERSE X
DECLUTCH PRESS SW. X SHIFT MODE X GEAR X

OPERATING STATE OPERATING STATE NOT USED
AUT/MAN MODE X SHIFT IN PROGRESS X
WARNING X FAULT X
OPERATING MODE X OLD FAULT X

NOT USED NOT USED NOT USED

DIAG TRANSM. 13(14) DIAG TRANSM. 14(14)

ACT ERROR AREA XXX MANUAL GEAR SHIFT
TYPE XXX
NUMBER OF OCCU. XXXXX GEAR X 015042
TIME AGO XXXXX (+/-)

8:20 8 Control system – ELECTRIC SERVO
8.4.8 ELECTRIC SERVO

ELECTRIC SERVO, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG ELSERVO 1(X) DIAG ELSERVO 2(X) DIAG ELSERVO 3(X)

PRESENT INPUT SIGNALS NOT USED OUTPUT LIFT
P1 XX.XXV REFERENCE XY
P2 XX.XXV REQUIRED VALUE XXXmA
P3 XX.XXV FEEDBACK XXXmA

OUTPUT LOWER OUTPUT TILT IN OUTPUT TILT OUT
REFERENCE XY REFERENCE XY REFERENCE XY
REQUIRED VALUE XXXmA REQUIRED VALUE XXXmA REQUIRED VALUE XXXmA
FEEDBACK XXXmA FEEDBACK XXXmA FEEDBACK XXXmA



PRESENT INPUT SIGNALS NOT USED NOT USED
SPREADER IN X OUT X
PISTOL X
015044
UNLOCK TW X

8 Control system – ATTACH 8:21
8.4.9 ATTACH
ATTACH, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG ATTACHMENT 1(X) DIAG ATTACHMENT 2(X) DIAG ATTACHMENT 3(X)

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
P3 XX.XXV P5 XX.XXV SPREADER IN X OUT X
P4 XX.XXV AUTO 20/40 X
P7 XX.XXV 30/35 STOP X

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
LOCK CONT X LE RI
PISTOL X UNLOCK CONT X LOW SPEED 20/40 X X
30/35 STOP X X

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT OUTPUT SIGNAL
ALIGNMENT LE RI LE RI LOCK CONT XY
X X LOCKED CONT X X UNLOCK CONT XY
UNLOCKED CONT X X

PRESENT OUTPUT SIGNAL OUTPUT SIDESHIFT LE OUTPUT SIDESHIFT RI
IND. LOCKED CONT XY REFERENCE XY REFERENCE XY
IND. UNLOCKED CONT XY REQUIRED VALUE XXX REQUIRED VALUE XXX
IND. ALIGNMENT XY FEEDBACK XXX FEEDBACK XXX


NOT USED OUTPUT SPREAD LE OUT OUTPUT SPREADER LE IN
REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX

OUTPUT SPREAD RI OUT OUTPUT SPREADER RI IN PRESENT OUTPUT SIGNAL
REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX BUZZER AUTO 20-40 XY
015043
FEEDBACK XXX FEEDBACK XXX
8.4.10 OLS
OLS, menu overview
Not used.

8:22 8 Control system – EXTRA
8.4.11 EXTRA
8.4.11.1 VBFS
VBFS, menu overview

Not used.
8.4.11.2 EL-STEERING
EL-STEERING, menu overview

Not used.
8.4.11.3 EXT-ATTACH
EXT-ATTACH, menu overview

Not used.
8.4.11.4 FREELIFT
FREELIFT, menu overview

Not used.
8.4.11.5 MOVE-CAB
MOVE-CAB, menu overview

Not used.
8.4.11.6 OPT
OPT, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
DIAG OPTION 1(X) DIAG OPTION 2(X) DIAG OPTION 3(X)

OPTION SWITCH PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
S199-1 X S199-4 X CENTRAL LUBRICATION D797-1 C1 P42 XY
S199-2 X FRAME XY
S199-3 X ATTACHMENT XY
DIAG OPTION 4(X) DIAG OPTION 5(X)

NOT USED PRESENT OUTPUT SIGNAL
D791-1 C1 P14 XY
D791-1 C1 P28 XY
015045

8 Control system – EXTRA 8:23
8.4.11.7 I/O
I/O, menu overview

Not used.
8.4.11.8 RMI
RMI, menu overview

Not used.

8:24 8 Control system – Settings
8.5 Settings
Setup, general
Settings offer the option of adapting the properties of the functions
for each unique machine. Settings are entered via the menus in the
display. Settings options are divided into sections such as Initiations
and Calibrations
Initiation is performed before the machine is put into operation. This

is done to compensate for mechanical and electrical tolerance values
(variations between different machines).
Calibration should be performed to optimise the use of important

functions. Certain functions require calibration in order to operate.

9:1
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ...................................................................9:3
9.1 Controls and instruments .................................................................................9:4
9.2 Safety and emergency equipment ...................................................................9:9
9.3 Seats..............................................................................................................9:10
9.4 Heating, ventilation and air conditioning ........................................................9:13
9.4.1 Fresh air filter ............................................................................................9:25
9.4.8 Condenser.................................................................................................9:25
9.4.9 Moisture filter.............................................................................................9:26
9.5 Wiper/washer system.....................................................................................9:27
9.6 Lighting system ..............................................................................................9:28
9.7 Signalling system ...........................................................................................9:30
9.8 Entertainment and communication ................................................................9:32
9.9 Glass/windows/mirrors...................................................................................9:33
9.9.3 Roof window..............................................................................................9:33
9.9.5 Rearview mirror .........................................................................................9:33
9.10 Cab structure and suspension .......................................................................9:34
9.10.2 Doors.........................................................................................................9:34
9.10.3 Cab undercarriage ....................................................................................9:35
9.11 Cab interior ....................................................................................................9:36
9.12 Frame.............................................................................................................9:37
9.13 Body structure................................................................................................9:38
9.14 Central lubrication ..........................................................................................9:39
9.15 Paint/coatings ................................................................................................9:41

9:2

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:3
9 Frame, body, cab and

accessories
Frame, body, cab and accessories,
description
The machine consists of frame, body and cab.
The frame (chassis) is the machine's structural part and is made of

high-strength steel.
The body consists of fenders, engine hood, tanks and other parts
mounted on the frame.
The cab is built separately and isolated from the frame using
heavy-duty rubber dampers. Driver's seat, steering wheel, and control
lever for hydraulics can be adjusted for optimal individual operating
position. Effective insulation gives a minimum of vibrations and a low
sound level. The machine is equipped with heating and ventilation, air
condition is available as an option.

9:4 9 Frame, body, cab and accessories – Controls and instruments
9.1 Controls and instruments

Controls and instruments, overview
Overview
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
14
015102
1. Left instrument panel
2. Gear and multi-function lever (S162)
3. Steering wheel panel
4. Steering wheel
5. Switch direction indicators (S161)
6. Panel for hydraulic functions
7. Control breaker for hydraulics (S250)
8. Switch for parking brake (S107)
9. Control lever (S815)
10. Driver's seat
11. Accelerator pedal (B690)
12. Brake pedals
13. Declutch pedal (S220-1)
14. Electronic box with fuses and relays
15. Hour meter (P708)

9 Frame, body, cab and accessories – Controls and instruments 9:5
Left-hand dashboard panel

Left-hand dashboard panel
16. Switch for fan (S118)
17. Switch for heat (S117)
29 30 31 18. Switch for air distribution (S139)
24..28
19. Switch for work lights cab roof (S105-1)
19..23 20. Switch working lights carriage and attachment (S105-2)
18 Extra working lights attachment and carriage
17
010907
21. Switch for work lights mast (S105-3)
16
Extra working lights mast
Left instrument panel
22. Switch for rotating beacon (S110)
23. Switch for hazard lights (S109)
24. Switch for headlights (S100)
25. Spare
26. Spare
27. Spare
28. Spare
29. Spare
30. Spare
31. Socket 12 VDC

Steering wheel panel

Steering wheel panel
36
35
34 32. Warning lamp for low battery charge
33
32 33. Warning lamp for low brake pressure
34. Indicator for active error codes
35. Warning lamp for bypass of hydraulic functions
36. Not used
37..41 37. Warning lamp for high coolant temperature
49
38. Warning lamp for low oil pressure engine
42..46 39. Indicator light for preheating
47 48 40. Warning lamp for low coolant level engine
41. Warning lamp for high oil temperature transmission
42. Warning lamp for low fuel level
43. Warning lamp for high temperature hydraulic oil
50 51 52 53 44. Indicator light for high beam
45. Indicator light for travel direction
46. Indicator light for parking brake
47. Indicator light for locked twistlock (secured load)
48. Indicator light for contact (attachment / load)
49. Indicator light for unlocked twistlock (load released)
50. Panel for warning and indicator lights
51. Display for control and monitoring system
64
54 52. Indicator for control and monitoring system
63 53. Ignition key lock
55
62 54. Switch for defroster
56
55. Switch for windshield wiper roof, interval
008132
61 60 59 58 57
56. Switch for windshield wiper roof, continuous
Steering wheel panel 57. Switch for interior lighting
58. Switch for windshield wiper rear, interval
59. Switch for windshield wiper rear, continuous
60. Function keys for control and monitoring system
61. Driving direction indicator, Forward Neutral Reverse
62. Shifting program A, automatic shifting
63. Shifting program 1, locked to gear position one
64. Shifting program 2, locked to gear position two

9 Frame, body, cab and accessories – Controls and instruments 9:7
Panel for hydraulic functions

Panel for hydraulic functions
68 65. Lift/lower (R8071)
66. Tilt (R8072)
70
67. Side shift (R8073)
72
68. Opening the twistlock (S1002)
69. Switch for horn (S149)
74
70. Switch for twistlock, automatic/manual locking (S1003)
71. Switch for spreading 20'-40' (attachment) (S1012)
74
72. Switch for stopping spreading at 30' (attachment) (S1004)
73
73. Switch for automatic spreading 20'-40' (S1012-2)
74. Switch for by-pass of hydraulic functions (S1005)
Key for bypass of hydraulic functions
014179
8 7 69
Panel for hydraulic functions and control lever
65
66
68 67
7
69
70
71
72
73
014178
8 74 74
Panel for hydraulic functions and linear control levers

Operating menus, overview
1 2 3 4
9 8 7 6
10
014668
11 12 13 14
1. Operating menu engine and transmission 8. Operating menu service
2. Operating menu engine 9. Operating menu heating and air conditioning
3. Operating menu for oil temperature 10. Operating menu code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
7. Operating menu statistics 14. Operating menu statistics, lift statistics
Event menus overview
Event menus overview
Side lift attachment with twistlock locking
1 2 3 4
014669
1. Event menu contact twistlock

2. Event menu twistlocks
3. Event menu open door
4. Event menu automatic spreading

9 Frame, body, cab and accessories – Safety and emergency equipment 9:9
9.2 Safety and emergency equipment

Safety and emergency equipment, description
A good working environment has safety and emergency equipment to
make the operator's work safe. The machine may be equipped with
the following equipment.
6,7,10
2
3
1
11 9
014175
5 8
1. Back-up alarm . 7. Buzzer in cab to indicate alarm or forgotten action,
e.g., if the operator leaves the cab without first
2. Revolving beacon.
applying the parking brake.
3. Horn.
8. External rear view mirrors.
4. Electrically powered loud horn .
Used to provide increased visibility for operating.
5. Fire extinguisher . 9. Blinking brake lights when reversing.
If the machine is supplied with a fire extinguisher, it 10. Control breaker for hydraulics (servo circuits).
should be of the type ABE in accordance with EN 3
part 1, 2, 4 and 5. With such a fire extinguisher, it Breaks all transmission of power and control signals
is possible to extinguish fires in both solid organic to the hydraulics.
materials and fluids. Adapted fire extinguishing
11. Buzzer automatic spreading (H9003) .
equipment can be ordered from Cargotec.
6. Seat belt.

9:10 9 Frame, body, cab and accessories – Seats
9.3 Seats
Seat, description (product alternative Hao Bang)
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
1 several adjustment features and meets high comfort requirements.
The seat has the following equipment:

• mechanical height adjustment
• angle of seat
• armrest right
• two-point seat belt
• head restraint
2 3
The seat features a sensor that senses if the seat cushion is pressed
down. It is used to activate buzzer if the operator leaves the seat
without applying the parking brake and shifts the transmission to
neutral if the operator leaves the seat.
7
5
014151
4
1. Head restraint
2. Adjustable arm rest, right
3. Adjustable tilt, backrest
4. Display of weight adjustment
5. Adjustable seat height
6. Adjustable seat angle
7. Longitudinal adjustment

9 Frame, body, cab and accessories – Seats 9:11
Seat, description (product alternative BE-GE

9200)
1 2 and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
3 The seat has the following equipment:

• mechanical height adjustment
• armrest right
4 • two-point seat belt
• seat heating
• head restraint
• armrest left
5 The seat features a sensor that senses compression of the seat. It
is used to activate buzzer if the operator leaves the seat without
applying the parking brake and shifts the transmission to neutral if the
8 6
006825
operator leaves the seat.

7
Controls
1. Adjustable lower back (lumbar) support
3. Adjustable arm rest, left
5. Adjustable suspension position

9:12 9 Frame, body, cab and accessories – Seats
Seat, description (product alternative BE-GE 9200

air suspension)
1 2 and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
The air suspension automatically adapts the seat height and
3 suspension to the operator's weight. The air suspension is supplied
by a special compressor installed on the underside of the cab.
The seat has the following equipment:

4 • air suspension (with external compressor)
• armrest right
• three-point seat belt
• seat heating
5 • armrest left
• head restraint
8 6
006826
The seat features a sensor that senses compression of the seat. It

7 is used to activate buzzer if the operator leaves the seat without
Controls BE-GE 9200 applying the parking brake and shifts the transmission to neutral if the
operator leaves the seat.
1. Adjustable lower back (lumbar) support
3. Adjustable arm rest, left
5. Adjustable suspension position

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:13
9.4 Heating, ventilation and air

conditioning
Heating and ventilation unit, function description
(product alternative EHC)
The heating and ventilation unit (EHC) handles heating and
ventilation. (The heating and ventilation unit cannot add cooling.)
The temperature in the cab is thermostat-controlled by Control unit

cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 ºC. The
system is operated with controls on the instrument panel.
The heating and ventilation system used heat from the engine's
cooling system via a heater to warm the outdoor air. Outdoor air is
forced by the fan through the heater and on through channels in the
cab's interior, and is then directed at, e.g., the windshield (defroster)
or the feet.
At the air inlet before the cab fan there is a filter that cleans the air
before it is forced into the machine.
001839
The heating and ventilation unit can:

• add fresh air to the cab
Defroster nozzles • clean the air from impurities
• warm the air when it is cold
• defrost the windows (defroster function)

9:14 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
1 2 3 17
D D 16
D
4 ˚C D
D
˚C
D 6
7 D
D790-1 D790-2 D795
15 D
11
M D794
M
14 D 10
˚C
5 M ˚C 9
D D 8 12
13
M
009891
1. Switch fan (S118) 10. Control unit engine (D794)
2. Switch temperature (S117) 11. Water valve (Y673)
3. Switch air distribution (S139) 12. Heat exchanger
4. Sensor cab temperature (B775-1) 13. Actuator recirculation (M612)
5. Sensor temperature outlet fan (B775-2) 14. Fan motor heat (M657)
6. Sensor outdoor temperature (B774) 15. Damper motor (Y672)
7. Control unit cab (D790-1) 16. Switch defroster on Control unit KIT (D790-2)
8. Engine 17. Operating menu on Control unit KID (D795)
9. Sensor engine temperature

Air conditioning, function description (product

alternative ECC)
Air conditioning is available as an option to the heating unit, this

combination is called (ECC) and handles heating, ventilation, cooling,
and dehumidification.
The temperature in the cab is thermostat-controlled by Control unit

cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 ºC. The
system is operated with controls on the instrument panel.
For cooling, the compressor that compresses the refrigerant is

activated. Refrigerant is evaporated in the evaporator in the cab.
When the refrigerant is evaporated, cold is then generated in the
evaporator. The outdoor air is cooled when it is forced through the
evaporator by the cab fan. Then the air can be directed in the same
way as for the heating system.
001839
The air conditioning adds the following functions to the heating and
Defroster nozzles ventilation unit:
• dehumidification of the air when it is humid
• cooling of the air when it is warm
As an option for the air conditioning there is automatic shut-off

of cooling when the door is open. This means that cooling is turned
off when a door is open. Cooling is activated again when the door
is closed. The air conditioning has a delay of 45 seconds between
cut-off and cut-in.

2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690
1. Switch temperature (S117) 15. Damper motor (Y672)
2. Switch fan (S118) 16. Control unit frame (D797-1)
3. Switch air distribution (S139) 17. Magnetic clutch (M645)
4. Sensor cab temperature (B775-1) 18. Compressor
5. Sensor temperature outlet fan (B775-2) 19. Condenser
6. Sensor outdoor temperature (B774) 20. Moisture filter
7. Control unit cab (D790-1) 21. Pressure switch (S246)
8. Engine 22. Expansion valve
9. Water valve (Y673) 23. Sensor temperature in refrigerant circuit (B775-3)
10. Sensor engine temperature 24. Heat exchanger for cooling
11. Heat exchanger 25. Switch defroster on Control unit KIT (D790-2)
12. Control unit engine (D794) 26. Operating menu on Control unit KID (D795)
13. Actuator recirculation (M612)
14. Fan motor heat (M657)

Heating, ventilation and air conditioning,

component location
1 2 3
16
15
13
6
7
12
8
11
005221
10 9, 14
1. Operating menu on Control unit KID (D795) 10. Cab fan (M657)
2. Switch defroster on Control unit KIT (D790-2) 11. Fresh air and recirculation damper (M612)
3. Sensor outdoor temperature (B774) 12. Fresh air filter
4. Control unit cab (D790-1) 13. Heat exchanger (cold and heat)
5. Sensor cab temperature (B775-1) (inside of the left 14. Sensor temperature refrigerant (B775-3)
control panel, behind a grating)
(located the copper pipe inside the expansion valve)
6. Switch air distribution (S139)
15. Air distributor (Y672)
7. Switch temperature (S117)
16. Sensor temperature outlet fan (B775-2) (in air
8. Switch fan (S118) distributor)
9. Expansion valve

3
1b 1a
5
7
4
014695
1. Compressor 4. Condenser
a Compressor Yuchai YC6A240-30 5. Pressure switch (S246)
b Compressor Cummins QSB6.7 6. Moisture filter
2. Magnetic clutch compressor (M645) 7. Sight glass
3. Water valve (Y673)

General recommendations for work on the air

conditioning unit
CAUTION
Authorisation is required to perform repairs on the
climate control unit.
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
WARNING
Electric fans can injure hands.
Avoid placing hands near the cooling fans when the
engine is running.
Air conditioning, checking/performance test
NOTE
The air conditioning does not work at temperatures below approx.
0 ºC since the pressure in the refrigerant circuit is too low. If the
pressure in the refrigerant circuit becomes too low the low pressure
switch cuts off power supply to the compressor's magnet clutch,
which means that the air conditioning stops working.
Should be performed during continuous operation every week from

early spring to late autumn as well as in winter during long periods
of high humidity.
In winter, during cold and dry periods of low operation, the compressor
should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are lubricated.
1 Check that the condenser is not clogged – clean condenser fins
with compressed air as needed.
2 Check that the compressor turns on and off without error.
3 Check that the drain for the cooling element's condensation water
is not clogged.

4 Check that there is no refrigerant leakage. In case of leakage, oil

and gas often form a dusty, dirty spot.
5 Start the engine and engage the cooling function with setting on
maximum cooling.
Let the engine run at min. 1,500 rpm. (At temperatures below
approx. 0 ºC, the cooling function will not start due to low pressure
in the system.)
6 Set the fan to intermediate speed.
7 After running for 10 minutes, check that there are no bubbles

visible in the receiver dryer's sight glass. (Bubbles should occur
only when the compressor starts and stops).
8 Place a thermometer by the air vent closest to the evaporator. After
5-10 minutes, the temperature should be under 10 ºC. (Deviations
in the measurement result can occur if the performance test is
conducted when the ambient temperature is below approx. 18 ºC).
If bubbles occur, subsequent filling should be done by an expert.
013669
Check the temperatures on the hoses and similar items

as follows:
1 Check that the hoses and components on the pressure side have
roughly the same temperature by feeling them with your hand.
NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) can be very hot. Risk of burn injuries.
2 All hoses and components on the pressure side (from the

compressor to the expansion valve) should be warm.
3 All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
4 Check the expansion valve. Frost or cold temperatures on

the intake side indicate that it is defective or clogged and that
circulation is limited or stopped on the pressure side.
5 Check that the compressor cuts in and out normally. Run the
cab fan at low speed and let the compressor work at high rpm.
When the temperature in the air vents nozzles is close to 0 ºC,
the compressor cuts out via the thermostat or ECC and cuts in
again when the temperature has increased approx. 3-7 ºC. (If the
compressor does not cut out, there is a risk of the evaporator icing
up and cooling performance decreasing.)

WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
Refrigerant amount, checking

Using the sight glass an estimation of the correct amount of refrigerant
can be checked. Normally it should not be possible to see bubbles
when the air conditioning system is operating. Bubbles may appear if
the plant contains the wrong amount of refrigerant, in connection with
the compressor stopping and starting, and if the condenser is defective
or at very high ambient temperature.
It is easiest to confirm bubbles if you observe the sight glass at the

same time as the compressor starts. Then bubbles are usually seen
from a few seconds after the compressor has started, until the system
starts to work normally.
NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 ºC.
Sight glass inspection

3 Switch on the air conditioning with max. cooling and fan.

4 Check that no bubbles are visible in the sight glass on the particle
and moisture filter.
Bubbles in the glass means that the quantity of refrigerant is
incorrect or that the condenser is defective, clogged by, e.g., dust,
or that the ambient temperature is very high.
013669
Action in the event of leakage in the system

1 Turn off the air conditioning.
2 Check the cooling plant and pinpoint leaks. For this purpose, use
special leak detection equipment. If there still is refrigerant left,
the remaining refrigerant amount shall be evacuated and then
measured.
3 Rectify faults, seal leaks by replacing gaskets, hoses, etc.
4 Fill with the correct quantity of R134a refrigerant according to the

following points when all defects have been repaired.
5 The following work requires special filling equipment.
6 Connect the suction pressure gauge's blue hose to the service

valve on the compressor's suction side marked with S, SUC or
SUCTION.
7 Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.
8 Connect the hoses to the fluid reservoir.
9 Connect the yellow filler and vacuum hose to the nitrogen tube.
Open the cock on the tube and then the cock on the pressure
side. Open the valve on the cylinder and then the valve on the
pressure side. Now the gas flows through the system and back
to the suction side of the compressor, which can be seen on the
blue pressure gauge which slowly indicates a pressure equivalent
to the pressure in the cylinder (see red pressure gauge). (If the
blue pressure gauge does not move then there is a stop in the
system.) Turn off the valve on the pressure side and then the
cock on the tube.
10 Now the system contains a mix of nitrogen gas and air. This gas
amount is enough to indicate a leak.
11 Conduct leakage detection of all hose nipples and other

connections by applying leakage indicator around all sealing
surfaces and check whether gas bubbles arise.
12 Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.

13 Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then, open the cock on the pressure side, use vacuum suction
for at least 30 minutes. Preferably longer.
14 First close both valves on the pressure gauge set. Then turn off
the vacuum pump. Work in this order, otherwise the air will rush
back. Wait approx. 15 min and check on the pressure gauges that
the vacuum does not change.
15 Move the yellow hose to the refrigerant cylinder and open the
valve on the cylinder.
16 Bleed the yellow hose by unloading the service connection at the

manometer set until pure gas flows out.
17 Open the cock on the suction side and allow the gas to flow
around until the pressure gauges indicate the same pressure as
in the tube.
18 Start the compressor and set the cooling thermostat and fan to
max.
19 Open the valve on the pressure side and let the compressor suck
from the cylinder. Observe the sight glass. At the beginning the
fluid is mixed with a lot of bubbles. The longer the compressor
sucks, there will be less bubbles and the fluid will be clearer.
If the bubbles suddenly disappear the cooling thermostat has
probably cut out. Bypass the thermostat using a cable directly
from the connection 24 V or wait until the thermostat cuts in again.
Continue until the correct refrigerant amount has been reached.
NOTE
Directly bypassing the compressor's coupling magnet can lead
to compressor damage caused by incorrect refrigerant quantity.
Close the valve on the suction side and then the valve on the
cylinder. Disconnect the service hoses from the compressor and
install the protective caps. Check for leaks according to step 11
or with a special leak detector.
20 In case of overfilling, the pressure and temperature increase
slowly until the high-pressure monitor cuts off the current to the
013669
compressor's electromagnet. This is due to the refrigerant rushing

around in the system without being evaporated or condensed in
the condenser. The result is that the cold in the cooling coil is
lost and high heat is generated in the condenser. Also, a steady
stream of bubbles can be seen in the sight glass. Return to step 2.
21 In case of underfilling or a lack of refrigerant, bubbles appear in
the sight glass - return to step 2.
Compressor cooling oil

22 At delivery, the compressor is filled with cooling oil. Under normal
conditions the oil should not be changed or refilled. In the event
of suspected incorrect oil quantity, see the instruction: "When
replacing the compressor."
In case of refrigerant loss there may also be oil loss, since
approx. 25% of the oil volume is absorbed by the refrigerant.
Recommended oil types that may be used are shown in the
section F Technical data.

When replacing the compressor

23 The compressor is filled with cooling oil when delivered. When
changing cooling compressor, change the oil as follows:
• Drain the defective compressor of oil and measure the
quantity.
• Then drain the new compressor of oil and refill with the same
amount that was drained from the defective compressor. For
oil volume in the system, see section F Technical data.

9 Frame, body, cab and accessories – Fresh air filter 9:25
9.4.1 Fresh air filter
Fresh air filter, changing

The fresh air filter is located at the front of the cab.
2 Remove the cover and change the fresh air filter.
9.4.8 Condenser
Condenser, cleaning
2 Blow clean the condenser's cooler with compressed air.

014732
1. Condenser

9:26 9 Frame, body, cab and accessories – Moisture filter
9.4.9 Moisture filter
Moisture filter, checking

3 Check the colour of the indicator on the moisture filter.
Blue indication = moisture filter ok.
Grey or pink indication = change moisture filter (see Moisture filter,
changing, page 9:26).
Indicator moisture filter
Moisture filter, changing
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
2 Drain the air conditioning of refrigerant R134a, with the intended

draining equipment.
IMPORTANT
Working on the air conditioning requires special
authorisation.
3 Disconnect hoses and cabling from the moisture filter.

4 Disconnect the moisture filter pressure switch from the moisture
filter.
5 Change the moisture filter.
6 Fit the pressure switch and connect the hoses to the moisture filter.
7 Leak test and refill the machine with refrigerant R134a, using the
intended equipment.
For volume, see section F Technical data.

9 Frame, body, cab and accessories – Wiper/washer system 9:27
9.5 Wiper/washer system

Wiper/washer system, description
On the cab there are wipers for the front windshield, rear window,
and roof window. The function is to clean the windows and maintain
B good visibility from the cab.
The wiper arm is attached to the wiper motor's shaft over a splined
taper. The shaft is made of hardened steel and the wiper arm's
E C bracket is made of a mild die cast material.
When installing it is important to make sure that the splines are free
D from metal burrs or similar. Also, the nuts shall be tightened so tight
that the splines are pressed into the bracket and work like drive
flanges. Counterhold the wiper arm when installing so that the torque
is not transmitted to the motor as it may be damaged (16–20 Nm
002214
A tightening torque).
A Wiper motor front The wipers turn off automatically 2 minutes after the operator has left
the cab. The wipers are activated automatically when the operator sits
B Wiper motor roof in the set, selects a gear, or if the accelerator pedal is pressed down.
C Wiper motor rear
D Washer motor and reservoir
E Wiper, front

9:28 9 Frame, body, cab and accessories – Lighting system
9.6 Lighting system

Lighting system, function description
The function of the lighting is to increase safety during operation and
load handling.
The lights are turned off automatically after 5 minutes of idling so that
the lights do not drain the batteries. Extra work lights are turned off after
2 minutes. The lighting is activated automatically when the operator
sits in the set, selects a gear, or if the accelerator pedal is depressed.
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 2 3 5 4
8
9
12 10
6
13 13
16
14
15 M
7 11
D790-1 D790-2
D797-1 D791
18 17 27
Pa
014663
19 20 21 22 23 24 25 26 28 29
1. Switch work lights cab roof (S105-1) 17. Make-contact brake lights (S216)
2. Switch work lighting attachment (S105-2) 18. Control unit frame (D797-1)
3. Switch working lights mast (S105-3) 19. Direction indicator (H422, H423, H426 & H427)
4. Switch headlights (S100) 20. Running lights (H416-1, H416-2, H417-1 & H417-2)
5. Switch revolving beacon (S110) 21. Driving lights low beams (E400L & E400R)
6. Break-contact door (S266-LE & S266-RI) 22. Driving lights high beams (E402L-1 & E402R-1)
7. Control unit cab (D790-1) 23. Tail lights (H412L & H412R)
8. Multi-function lever (S162) 24. Brake lights (H411L & H411R)
9. Lever direction indicator (S161) 25. Working lights mast (E404L-1 & E404R-1)
10. Switch interior lighting on Control unit KIT (D790-2) 26. Extra work lights mast (E404L-4 & E404R-4)
11. Control unit KIT (D790-2) 27. Control unit attachment (D791)
12. Relay work lights cab roof (K3017-1 and K3017-2) 28. Work lights Twistlock attachment (E404L-3 &
E404R-3)
13. Work lights cab roof (E406L-1 E406R-1, E406L-2
and E406R-2) 29. Extra work lights Twistlock attachment (E404L-5
14. Back-up lights (E405L & E405R) & E404R-5)
15. Revolving beacon (H428)

16. Interior lights (E434-1)

9 Frame, body, cab and accessories – Lighting system 9:29
Lighting system, component location

The function of the lighting is to increase safety during operation and
load handling.
NOTE
F Technical data.
The following lighting is available:
1 4 5 6 6 7 9
3,8,10
12
24
23
22
014664
19, 20, 21 18 17 16 15 11, 13, 14
1. Working lights mast (E404L-1 & E404R-1) Brake lights (H411L & H411R)
2. Extra work lights mast (E404L-4 & E404R-4) 14. Direction indicators rear (H426 & H427)
3. Relay working lights cab roof (K3017-1 & K3017-2) 15. Break-contact door (S266-LE & S266-RI)
16. Switches, see Controls and instruments, overview,
4. Multi-function lever (S162) page 9:4
5. Control unit KIT (D790-2) 17. Control unit frame (D797-1)
6. Interior lights (E434-1) 18. Make-contact brake lights (S216)
7. Work lights cab roof (E406L-1 & E406R-1) 19. Direction indicators front (H422 & H423)
8. Extra work lights cab roof (E406L-2 & E406R-2) 20. Running lights front (H416-1 & H417-1)
9. Revolving beacon (H428) 21. Driving lights low beams (E400L & E400R)
10. Control unit cab (D790-1) Driving lights high beams (E402L-1 & E402R-1)
11. Running lights rear (H416-2 & H417-2) 22. Control unit attachment (D791-1)
12. Back-up lights (E405L & E405R), white 23. Work lights twistlock attachment (E404L & E404R)
13. Tail lights (H412L & H412R) red 24. Extra work lights carriage (E404L-5 & E404R-5)

9:30 9 Frame, body, cab and accessories – Signalling system
9.7 Signalling system

Signal system, function description
The function of the signals is to increase safety during operation and
load handling. This can take place with light and sound. The machine
has the following signal systems:
NOTE
F Technical data.
1 2 3 4
17 6
7
15
16
D6
13 18
14 M
8 19
D790-1 5 D790-2 D795
9
D797-1 D791-1
20
10 11 21
009767
12
1. Switch revolving beacon (S110) 15. Relay loud horn (K3016)

2. Switch hazard lights (Hazard) (S109) 16. Loud horn (H850-1)
3. Switch parking brake (S107) 17. Make-contact operator in seat (S230)
4. Switch horn (S149-3) 18. Buzzer cab (H853)
5. Control unit cab (D790-1) 19. Control unit KID (D795)
6. Multi-function lever (S162) 20. Control unit attachment (D791-1)
7. Lever direction indicator (S161) 21. Buzzer automatic spreading (H9003)
8. Control unit KIT (D790-2)
9. Control unit frame (D797-1) NOTE
10. Direction indicator (H422, H423, H426 & H427) On machines with side lift attachment, the sound
signal can also be activated with button open
11. Back-up lights (E405L & E405R) twistlock (S1002) on the hydraulic functions panel
12. Back-up alarm (H965) or open twistlock on the joystick, providing that the
function for open twistlocks at contact is not active.
13. Horn (H850)
14. Revolving beacon (H428)

9 Frame, body, cab and accessories – Signalling system 9:31
Signalling system, component location

The following communication systems are available.
1 2 3 4 5 6
014665
19 18 17 16 15 14 13 12 10,1 1 9 8 7
1. Control unit KID (D795) 11. Control unit cab (D790-1)
2. Buzzer cab (H853) 12. Make-contact operator in seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switches, see Controls and instruments, overview,
5. Lever direction indicator (S161) page 9:4
6. Revolving beacon (H428) 15. Loud horn (H850-1)
7. Back-up alarm (H965) 16. Control unit frame (D797-1)
8. Back-up lights (E405L & E405R) 17. Direction indicators front (H422 & H423)
9. Direction indicators rear (H426 & H427) 18. Control unit attachment (D791-1)
10. Relay loud horn (K3016) 19. Buzzer automatic spreading (H9003)

9:32 9 Frame, body, cab and accessories – Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, general
For information and description of equipment, see supplier's

documentation for each product.

9 Frame, body, cab and accessories – Glass/windows/mirrors 9:33
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component location
The function of the window panes is to enclose the cab and to give
C the operator good visibility. Tempered glass windows are standard on
all trucks. Roof windows are a safety feature and are therefore always
D made of polycarbonate plastic.
The rear-view mirrors are of the type convex mirror. There is an

interior rear view mirror on all machines.
The machine has tinted windows in tempered glass.
The following panes may be of laminated glass:

• Side windows front, position E
001512
A E B • Windshield (front window), position B
A Side windows
B Windscreen (front window)
C Roof window
D Rear window
E Side windows, front
9.9.3 Roof window

Roof window, description
Roof windows are a safety feature and are therefore always made
of polycarbonate plastic.
Roof window, checking

Check that the roof window is not damaged or cracked. If the roof
window is defective, change it immediately.
WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!
9.9.5 Rearview mirror

Rearview mirror, description
The rear-view mirrors are of the type convex mirror. There is an interior
rear view mirror on all machines.

9:34 9 Frame, body, cab and accessories – Cab structure and suspension
9.10 Cab structure and suspension

Design and suspension, description
The cab has a flat floor with a bracket for the operator's seat. It is
suspended in the cab substructure via heavy-duty rubber insulators
located on the cab's underside. This is to minimise vibrations from
1 the frame to the cab. There is an insulator at four points, one in each
corner. Each insulator bracket has a rubber bushing and a bolt.
003206
4
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.2 Doors
Doors, description
The cab has two doors, the left is the driver's door and the right is the
emergency exit. The doors have:
• hand rail
• handle
• keylock
• opening window (emergency exit door )
There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be controlled with the diagnostics menu, see section
8 Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5
MOVE-CAB, menu 1.
Doors, checking
2 Visually inspect the door's mounting points.

Lubricate the hinges of the doors if necessary.
3 Check the door's locking mechanism with regard to function and
wear.
006914

9 Frame, body, cab and accessories – Cab undercarriage 9:35
9.10.3 Cab undercarriage
Cab undercarriage, checking

2 Check that the welding seams at the cab's mounting points are
intact and free of visible cracks.
3 Check that the isolators are intact. Replace any damaged isolator.
4 Check that bolted joints are tightened and that the brackets are
undamaged. Attend to as needed.
008393
The cab's mounting points with dampers.

9:36 9 Frame, body, cab and accessories – Cab interior
9.11 Cab interior

Cab interior, description
The cab is designed for best operator comfort. On the dashboard
panels there are grouped switches, controls, warning and indicator
lights to give the operator a good working environment.
Recycled material is used for all parts.

• Instrument panels
• Interior plastic parts
• Interior textile/fabric parts
• Insulation

9 Frame, body, cab and accessories – Frame 9:37
9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:
2 1
014666
3 4 5 6
1. The rear section of the frame with counterweights 4. Bracket front fenders
2. Engine compartment with engine and transmission 5. Cab mounts (4 points)
mounts
6. Steering axle mounts
3. The rear section of the frame with drive axle mounts

9:38 9 Frame, body, cab and accessories – Body structure
9.13 Body structure

Body, description
The body's function is a part of the frame. There are fenders to deflect
dirt, footsteps and handrail to facilitate access on the frame, engine
hood to deflect dirt and objects from the engine compartment and a
counterweight to balance the machine's lifting capacity.
2 1
014667
3
1. Counterweight
2. Hood engine compartment
3. Fenders

9 Frame, body, cab and accessories – Central lubrication 9:39
9.14 Central lubrication

Central lubrication, description
Central lubrication lubricates the machine's lubrication points

automatically during operation according to preset intervals and
replaces the lubrication in preventive maintenance. The machine
has two separate central lubrication systems, one for the machine
and one for the attachment.
The central lubrication is built up of the following components:

• Pump unit, with lubricant reservoir.
• Distribution block, that distributes and portions the grease
between the different grease points.
The distribution block lubricates one point at a time. If a point
cannot be lubricated properly, e.g. in the event of a line blockage,
the following points will not be lubricated. The grease is forced
out through the safety valve on the pump unit.
• Lines, between main unit and distribution block as well as
distribution block and grease nipples.
• Grease nipples, at grease points.
On the pump unit it is possible to adjust the lubrication interval's

frequency and duration.
Example illustration, components, central lubrication
The central lubrication is supplied with voltage when the parking
1. Pump unit
brake is released.
2. Safety valve
3. Distribution block NOTE
The central lubrication does not grease the propeller shaft's
universal joint or the brake pedal, these must still be greased
during preventive maintenance.

9:40 9 Frame, body, cab and accessories – Central lubrication
Central lubrication, checking
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling the
connections at the distribution block. A blocked hose remains
pressurised and the connection becomes firm.
NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2 Turn the start key to position I.

3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in switch manual
operation (position 5).
If the indicator pins do not move even when the pump is running,
troubleshoot the pump unit.
NOTE
The system can be lubricated manually through the grease
nipple on the distribution block.
Overview of central lubrication. Example figure.
1. Lubricant nipple, filling point, lubricating grease 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
2. Safety valve
3. Lubricant nipple, manual lubrication of the
system
4. Indicator pin
5. Switch, manual operation

9 Frame, body, cab and accessories – Paint/coatings 9:41
9.15 Paint/coatings
Paint and surface finish, description
The machine is finished with an alkyd based single component paint
that is applied by brush or sprayed. For colour code (RAL), see
machine card.
Check the machine often for stone chips, impact damage, and
scratches to the paintwork, repair these immediately to avoid corrosion
on the underlying metal. Only use touch-up paint for minor stone chip
damage and scratches, major damage to paintwork should be repaired
by a paint shop.
NOTE
Before performing touch-ups, the surface area must be carefully
cleaned.
For information on other surface and material colours, contact

Cargotec.

9:42

10:1
Contents 10 Common hydraulics

10 Common hydraulics .........................................................................................10:3
10.2 Safety valves..................................................................................................10:4
10.3 Tanks and accumulators ................................................................................10:5
10.4 Pumps............................................................................................................10:6
10.6 Temperature control, cleaning and hydraulic oil...........................................10:10
10.6.6 Breather filter hydraulic oil tank ...............................................................10:12
10.6.7 Hydraulic oil filter .....................................................................................10:12
10.6.8 Hydraulic oil.............................................................................................10:13
10.6.9 Fine filter hydraulic oil..............................................................................10:15

10:2

10 Common hydraulics – Common hydraulics 10:3
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps the supply load handling, brakes and
steering with hydraulic pressure.
Pressure plate
On the machine there is a pressure plate with the most important

pressure information (stamped in). The pressure plate is located on
the left side of the frame in front of the cab steps.
Pressure levels vary with the equipment and therefore they are unique
to each machine. When checking pressure the pressures must
correspond with the pressure plate.
8
4
7
5
6
014670
1. Feed pressure control valve attachment 5. Servo pressure

2. Brake pressure 6. Accumulator charging pressure
3. Precharging accumulators 7. Pump pressure brakes and steering
4. Steering pressure 8. Pump pressure load handling

10:4 10 Common hydraulics – Safety valves
10.2 Safety valves

Safety valves, component location
NOTE
1
The valves shall be closed during operation and are opened to
depressurise the machine.
2
014683
1. Accumulator drain valve with opening knob and

lock ring.
2. Relief valve attachment (figure shows open
valve).

10 Common hydraulics – Tanks and accumulators 10:5
10.3 Tanks and accumulators

Tanks and accumulators, component location
Tank
1 2 1 3 2 4 5 Tank
1. Cap for hydraulic oil filter
2. Filler plug hydraulic oil
3. Sight glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs hydraulic oil
008086
Accumulator
Accumulator
1 2
1. Brake system accumulators
2. Accumulator lift
014672

10:6 10 Common hydraulics – Pumps
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from two hydraulic oil pumps
1 2
with fixed displacement. One pump supplies brakes and steering
and the other supplies load landing. The pumps are mounted on
the transmission's power take-off.
Hydraulic oil pump for load handling (position 1) supplies Control

valve lift, lower, tilt and attachment.
The hydraulic oil pump for brake pressure and steering (position 2)
supplies brakes, steering and the hydraulic system's cooling circuit
via Valve block accumulator charging valve and priority valve, see
section 4 Brakes.
014671
1. Hydraulic oil pump for load handling

2. Hydraulic oil pump for brake pressure, steering
Hydraulic oil pump brakes and steering, check
NOTE
Safety.
1 Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 ºC.
˚C 3 Depressurise the hydraulic system, see section B Safety.
˚C
000475

pump pressure brakes and steering on the main valve.
014649
Measuring outlet, pump pressure brakes and steering

[PM]

10 Common hydraulics – Pumps 10:7
6 Close the accumulator drain valve and check the pump pressure
during charging.
NOTE
Check that the pressure rises to the specified feed pressure on

the pressure plate.
014619
Close the accumulator drain valve.
015023
Pressure plate, pump pressure brakes and steering
NOTE
014619

10:8 10 Common hydraulics – Pumps
Hydraulic oil pump load handling, check

1 Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 ºC.
˚C 3 Depressurise the hydraulic system, see section B Safety.
˚C
000475

pump pressure load handling on the main valve.
014650
Measuring outlet, pump pressure load handling [P2]
5 Close the accumulator drain valve and relief valve attachment.

014619

10 Common hydraulics – Pumps 10:9
7 Check that the feed pressure corresponds with the pressure plate.
015024
Pressure plate, feed pressure load handling
NOTE
014619

10:10 10 Common hydraulics – Temperature control, cleaning and hydraulic oil
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
The hydraulic system's oil is cooled and cleaned by means of it
circulating through coolers and filters for the wheel brakes. The cooler
has a temperature-controlled electric fan that counteracts overheating.
Temperature control consists of hydraulic oil tank, hydraulic oil pump,

valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine
filter, hydraulic oil temperature sensor and bypass valve.
Hydraulic oil pump brakes and steering pumps oil (from the tank)
through the brake system's cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases the air flow through the cooler when the temperature
needs to be reduced. When the oil is cold, a bypass valve opens
and leads the oil directly to the tank so that resistance through the
cooler and filter does not become too great. The bypass valve closes
when the oil gets hot and then instead leads the oil through the cooler
and filter. The temperature sensor controls activation of the fan and
temperature display in the display.
Return oil from brakes, steering and load handling is filtered through
the hydraulic oil filter in the hydraulic oil tank.
10 8
D795 D790-2
D797-1
9
D 2 4
15 C
SPOL
P2
D P
11 M
7 5
C 16 3 C
6
12
14 1
014646
8 °C 13
1. Hydraulic oil pump brakes and steering 9. Control unit frame (D797-1)
2. Valve block, accumulator charging valve and priority 10. Control unit KID (D795)
11. Cooling fan
3. Hydraulic oil filter brakes and steering
12. Thermal bypass valve
13. Hydraulic oil tank
5. Wheel brake
7. Hydraulic oil cooler valve)
8. Sensor hydraulic oil temperature (B776) 16. Hydraulic oil filter load handling

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:11
Temperature control, cleaning and hydraulic oil,

component location
1
2
10
014673
8 7 6
1. Breather filter hydraulic oil tank 6. Thermal bypass valve

2. Hydraulic oil filter 7. Sensor hydraulic oil temperature (B776)
3. Fine filter, hydraulic oil 8. Main valve
4. Cooling fan 9. Hydraulic oil pump brakes and steering
5. Cooler hydraulic oil 10. Hydraulic oil tank

10:12 10 Common hydraulics – Breather filter hydraulic oil tank
10.6.6 Breather filter hydraulic oil tank
Breather filter hydraulic oil tank, changing
2 Clean the area around the filter housing.

1 2 1 3 2 4
3 Remove the filter housing.
Press down and turn approx. 1/8 turn clockwise.
4 Replace the filter insert.
Handle the filter cartridge as environmentally hazardous waste.
5 Fit the filter housing.
Press down and turn approx. 1/8 turn anticlockwise.
008084
6 Reset the filter indicator by pressing down the button in the middle
on the glass centred on the filter cartridge.
1. Cover plate for hydraulic oil filter
2. Filling point hydraulic oil
10.6.7 Hydraulic oil filter
Hydraulic oil filter, changing
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
On machines with raised cab: Remove the footstep over the

covers and clean the covers and the area around them.

10 Common hydraulics – Hydraulic oil 10:13
3 Remove the cover plates (position 1) over the hydraulic oil filters.
1 2 1 3 2 4
4 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
5 Part the filter unit and remove the filter insert. Handle the filter
cartridge as environmentally hazardous waste. Note position of
the parts.
008084
1. Cover plate for hydraulic oil filter
2. Filling point hydraulic oil
6 Clean the filter holder's parts. Be especially thorough with the

magnetic rod.
7 Fit the new filters and assemble the filter units.
8 Install the filter units and cover plates. Tighten the bolts crosswise.
9
On machines with raised cab: Fit the footstep over the covers.
10 Check the oil level, see Hydraulic oil, level check, page 10:13.
Magnetic rod
10.6.8 Hydraulic oil

Hydraulic oil, level check
NOTE
The oil level is checked with the mast lowered and the attachment in
the 20-foot position.
1 Machine in service position, section B Safety.
2 Check the oil level in the hydraulic oil tank. The oil level should be
in the centre of the sight glass. Fill oil as required. For oil grade,
see section F Technical data.

10:14 10 Common hydraulics – Hydraulic oil
Hydraulic oil, changing
NOTE
Safety.
IMPORTANT
2 Remove the filler cap and pump out the hydraulic oil in a collection
1 2 1 3 2 4 container.
3 When most possible oil has been pumped out. Place a container
under the hydraulic oil tank's drain plug and drain the last hydraulic
oil.
4 Fit the drain plug when the oil has drained.
NOTE
008084
Make sure that the drain plug's washer seal is also removed.
1. Cover plate for hydraulic oil filter 5 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, changing, page
2. Filling point hydraulic oil 10:12.
6 Fill new hydraulic oil in the filler holes on the filter's cover
plates. This filters the oil and protects the hydraulic system from
contamination.
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked when all hydraulic
cylinders are in the retracted position.

10 Common hydraulics – Fine filter hydraulic oil 10:15
10.6.9 Fine filter hydraulic oil
Fine filter hydraulic oil, changing
NOTE
Safety.
IMPORTANT
2 Remove the cover.

3 Take out a drainage receptacle.
4 Lift up the filter cartridge and place it in the receptacle. Let the
hydraulic oil drain.
5 Install the new filter cartridge and put the cover on the fine filter.

10:16

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electrical protection........................................................................................ 11:3
11.2.2 Fuses ........................................................................................................ 11:4
11.3 Batteries......................................................................................................... 11:7
11.3.1 Start battery............................................................................................... 11:7
11.4 Alternator ....................................................................................................... 11:9
11.5 Distribution of electricity ............................................................................... 11:10
11.5.1 Voltage feed ............................................................................................ 11:10
11.5.2 Electrical distribution box......................................................................... 11:15
11.5.3 Control units ............................................................................................ 11:16
11.6 Communication ............................................................................................ 11:18
11.6.1 CAN bus .................................................................................................. 11:18
11.6.2 Redundant CAN-bus ............................................................................... 11:18
11.6.3 CAN-bus drivetrain .................................................................................. 11:18

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN-bus.
11.2 Electrical protection

Electrical protection, component location
1. Control switch
1 2 2. Circuit fuses, electrical distribution box cab
3. Main fuses, electrical distribution box frame
4. Circuit fuses, electrical distribution box frame
5. Battery disconnector
5
014691

11:4 11 Common electrics – Fuses
11.2.2 Fuses
Fuses, description
Main fuses
1 Main fuses
2
3 IMPORTANT
4
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
The electrical system has three main circuits (30-, 15-, and
15E-voltage), see Distribution of electricity, description, page 11:10.
The main circuits are fused several times with main fuses and circuit
fuses.
The main fuses divide the machine's voltage feed into smaller parts
014690
to maintain as many functions as possible in case of damage to

cables harnesses.
Main fuses
1. Electric power feed relay K315-1, electric power By the cab's and frame's electrical distribution boxes there are fuse
to ignition voltage (15), (50 A) plates that describe the different fuses.
2. Battery voltage (30) to cab, engine, and
transmission, (50 A)
3. Electric power feed relay K3009-1, power to
emergency stop switch voltage (15E), (50 A)
4. Ignition voltage (15) to control units on frame,
engine, cab and transmission, (50 A)
Terminal blocks on frame and carriage
The terminal blocks for the electrical system are located in the front
of the frame and the rear of the carriage. They are used when
removing/fitting the mast and carriage.
014197

11 Common electrics – Fuses 11:5
Circuit fuses
Circuit fuses
Circuit fuses are grouped in fuse holders that are located in the
electrical distribution box on the frame and the electrical distribution
box in the cab.
By the fuse holders there are fuse plates with information about fused
function and fuse rating.
E
SUPPLY POWER
A1 10A KCU (KALMAR CAB UNIT)
F B2 5A KCU,START UP (KALMAR CAB UNIT)
X2044980 1
F58-4 15
C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
E5 10A OPT RADIO
MAIN POWER
F6 25A OPT SEAT HEATER, TURNABLE SEAT
F58-4 30
G7 15A OPT WORK LIGHT
CAB
H8 15A OPT AIRCUSHIONED SEAT
A1 25A KCU (KALMAR CAB UNIT)
F58-5 15 SUPPLY POWER CAB

B2 10A KIT (KALMAR INFORMATION TERMINAL)
C3 15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)
D4 5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)
E5 10A SERVICE
F6 5A OPT MAP READING LIGHT
G7 10A OPT CONVERTER 12V
014689
H8 10A OPT COMPRESSOR HORN
Circuit fuses electrical distribution box cab
A
B
C
014198
Fuses on frame
A 30-fuse (battery voltage), 51-3
B 30-fuses (battery voltage), 58-1
C 15-fuses (ignition voltage), 58-2
D 15E-fuses (control breaker voltage), 58-3
Fuses in cab
A 15-fuses (ignition voltage) and 30-fuses (battery
voltage), 58-4
B 15-fuses (ignition voltage), 58-5
014688
Circuit fuses electrical distribution box frame

11:6 11 Common electrics – Fuses
Fuses, changing
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
1 Turn off the system voltage (battery disconnector).
2 Remove the cover from the fuse holder.
3 Check that the fuses are intact. Change when needed.

11 Common electrics – Batteries 11:7
11.3 Batteries
11.3.1 Start battery
Start battery, checking
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed in
the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
1 Check the battery voltage from the operating menu for electrical
system.
With the engine off, the battery voltage should be 23–25 V.
With engine at max. engine speed (2,000 rpm), the battery voltage
should be 27–29 V.
000354
Operating menu for electrical system 3 Check that the batteries are clean on the top to prevent leakage
currents between cells, which can cause reduced battery capacity.
Wipe clean with a cloth and clean warm water without detergent.
4 Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
5 Check the fluid level in the battery cells. Top up with battery water
if needed.
The electrolyte level should be 10 mm above the cells.
NOTE
Use only distilled water if topping up is necessary.

11:8 11 Common electrics – Start battery
Battery cables, checking
DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no
machine parts wear or chafe against the battery cables.
Change damaged battery cables.
The following battery cables should be checked for clamping, risk of

rubbing and damage to the battery cables. Rectify incorrect clamping
and risks of rubbing. Change battery cables that show signs of damage.
Diesel-powered machines
• Plus-cable between battery and battery disconnector.
• Plus-cable between battery disconnector and starter motor.
• Plus-cable between starter motor and alternator.
• Plus-cable between battery disconnector and main fuses.
• Plus-cable between starter motor and preheating relay.
• Plus-cable between preheating relay and preheating coil.
• Ground cable between battery and frame.
• Ground cable between engine and frame.

11 Common electrics – Alternator 11:9
11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. See section 1 Engine.

11:10 11 Common electrics – Distribution of electricity
11.5 Distribution of electricity

Distribution of electricity, description
This section describes distribution of electric power and communication
between control units. Electric power distribution describes the
foundation of the electrical system and the network of control units.
11.5.1 Voltage feed

Start-up of electrical system, description
When the machine is not used, the machine's electrical system is in
a powerless mode, that is, neither power electronics nor control units
are supplied with voltage. At machine start, voltage feed is activated
and the redundant CAN-bus is initiated. Start is handled by control
unit cab (D790-1).
The first pre-requisite for the machine to be able to perform any action
is to first establish the redundant voltage feed for control units and
then establish CAN-bus communication to administer control signals
for functions.
Control units establish communication when:

• Operator’s door is opened
• Interior lighting is lit
• Flashing hazard lights are activated
• Start key in position I
Start-up
Start-up
D791
The following takes place at start-up:
Startup signal
1. Start-up signal to Control unit cab (D790-1).
D790-1 D790-2 D795

014674
D797-1
Start-up signal is sent
2. Control unit cab (D790-1) initiates connection of redundant
D791 voltage feed. See Redundant voltage feed of control units,
description, page 11:12.
3. Control unit cab (D790-1) activates ignition voltage (15).
See Ignition voltage (15), description, page 11:12.
D790-1 D790-2 D795 4. Control unit cab (D790-1) establishes redundant CAN-bus.
See Redundant CAN-bus, description, page 11:18.
5. Control unit cab (D790-1) activates CAN-bus drivetrain. See
CAN-bus drivetrain, description, page 11:18.
014675
D797-1 6. Control unit cab (D790-1) activates control breaker voltage (15E).
Redundant CAN-bus communication See Emergency stop switch voltage (15E), description, page
11:13.

11 Common electrics – Voltage feed 11:11
System down in powerless mode

The system goes down in powerless mode when:
• Start key in position 0 and no activity signal has been sent.
• Start key in position 1 and automatic engine shut-down has been
activated.
The following takes place when the system goes down in powerless
mode.
1. Cab control unit (D790-1) cuts off emergency stop switch voltage
(15E).
See Emergency stop switch voltage (15E), description, page 11:13.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:12.
3. Redundant voltage feed to control units is cut off.
4. Cab control unit (D790-1) disconnects the redundant CAN bus.
See Redundant CAN-bus, description, page 11:18.
5. Cab control unit (D790-1) disconnects the redundant voltage feed.
See Redundant voltage feed of control units, description, page
11:12.
6. Control unit cab (D790-1) awaits start-up signal. Other electronics
are powerless.
11.5.1.1 Battery voltage (30)
Battery voltage (30), description

The battery voltage feeds voltage:
• Control system at start. See Start-up of electrical system,
description, page 11:10.
• Starter motor
• Main relays (15-voltage)
• Control switch relays (15E-voltage)
• Engine
• Transmission

11:12 11 Common electrics – Voltage feed
11.5.1.2 Redundant voltage feed of control units

Redundant voltage feed of control units, description
The redundant voltage feed only feeds the control units' control logic
A
D791 and buses, and is controlled completely by Control unit cab (D790-1).
The control units' outputs remain without power and are supplied with
Startup signal voltage first when ignition voltage is activated.
The redundant voltage feed for each control unit is independent of

D790-1 D790-2 D795 other control units. If a control unit is not working the voltage feed to
other control units is not affected.
When all control units have redundant voltage feed and bus
communication, the system is ready to receive, process signals.
D797-1
When redundant voltage feed is activated the following takes place.
B 1. Start-up signal is sent to Control unit cab (D790-1), see A in

illustration.
D791
2. A hold circuit is activated in Control unit cab (D790-1) which
activates the control unit's control logic.
3. Control unit cab (D790-1) activates redundant voltage feed to the
other control units, see B in illustration.
D790-1 D790-2 D795
Control unit cab (D790-1) has four outputs for voltage feed, other
control units have two inputs for redundant voltage feed. In case
of failure of one feed, the control unit is supplied from the other
feed.
014676
D797-1
A Start-up signal is sent

B All control units are supplied with voltage
11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description
The ignition voltage feeds the power electronics.
The ignition voltage is activated by:

Startup
2 • Start key in position I
• Flashing hazard lights (Hazard) activated
D790-1
When ignition voltage is activated the following takes place.
1
D1 D2
1. Battery disconnector in position 1. Voltage feed to Control unit
D795 cab (D790-1), ignition, switch flashing hazard lights, door switch
3 and interior lighting.
K1 2. Switch for start-up signal gives pulse to Control unit cab (D790-1).
D790-2 CAN bus communication is established (not drive-train).
- + 4 3. Start key in position I or flashing hazard lights activated.
D797-1 4. Control unit cab (D790-1) feeds voltage to power relay ignition
D3 (K315-1) and relay ignition key lock (K315-2) in electronic box
frame.
D4
D793 5. Ignition voltage supplies control units, relays, solenoid valves and
K4 other electronics.
Drivetrain’s CAN bus establishes communication.
014677
D794
Power feed ignition circuit

D1. Diagnostic menu CAN/POWER 5

11 Common electrics – Voltage feed 11:13
11.5.1.4 Emergency stop switch voltage (15E)
Emergency stop switch voltage (15E), description

The emergency stop switch voltage supplies functions which require
S250
a control switch, e.g. working hydraulics.
D1
1 The control switch is activated with Switch control switch.
D790-1
Condition for activating emergency stop switch voltage is that Switch,
2 D5 4 control switch, is not pressed in.
D4 D2 • Start key in position I
• Ignition voltage (15)
K3009-1 K3009-2 D3
• Switch, control switch not activated.
- + 5 D791 When emergency stop switch voltage is activated the following takes
place.
3 1. Ignition voltage is connected to Control unit cab (D790-1).
D4 2. Control unit cab (D790-1) activates Power relay K3009-1 in
Y6010 electrical distribution box frame and emergency stop switch
K3002 voltage (15E) feeds the circuit until relay K3009-2 in electrical
distribution box frame.
5 3. 15E-feed sends a voltage signal to Control unit cab (D790-1) and
D797-1 Y6011 verifies that Power relay control breaker (K3009-1) is active but
that Power relay control breaker (K3009-2) is inactive.
This verifies that the control breaker is working.
D4 4. Control unit cab (D790-1) activates power relay control breaker
Y6004 (K3009-2) in the electrical distribution box and the emergency
K3007 stop switch voltage supplies voltage to the control units (not
drivetrain).
5 5. When Switch control switch (S250) is pushed down, the
Y6005 emergency stop switch voltage (15E) is cut off to Control unit
cab (D790-1) and power is guided to relay K3002 and K3007, as
014678
well as Power relay control switch K3009-1 and K3009-2. Power

supply to the control units is cut off and the functions cease.
Power feed, control breaker circuit As extra safety the cab control unit (D790-1) also sends status
for Switch, control breaker (S250) on the CAN bus. In this way
D1. Diagnostic menu CAN/POWER 7 functions are also cut off at signal level.

11:14 11 Common electrics – Voltage feed
11.5.1.5 Voltage converter
Voltage converter, description
The voltage converter is located under a protective casing to the left

behind the driver's seat.
The voltage converter converts 24 Volt to 12 Volt. 12 V voltage

is available for accessories through connector X067 in the cab's
electrical distribution box. (15 and 30 voltage, ground and 12V.)
12 V voltage is also available in sockets on the instrument panel,

see section 9 Frame, body, cab and accessories group 9.1 Controls
and instruments.

11 Common electrics – Electrical distribution box 11:15
11.5.2 Electrical distribution box

Electrical distribution box, component location
5
4
3
2 14
1 6
15
7
16
8 17
9
10
11
12
13
18
014679
1. Circuit fuses battery voltage (30) F58-3 10. Relay ignition K315-2
2. Circuit fuses ignition voltage (15) F58-2 11. Power relay ignition K315-1
3. Circuit fuses emergency stop switch voltage (15E) 12. Power relay control switch K3009-1
F58-3
13. Power relay control switch K3009-2
4. Diagnostic socket engine, (Engine alternative Yuchai
14. Diagnostic socket machine
YC6A240-30)
15. Circuit fuses cab battery voltage (30) and ignition
5. Diagnostic socket transmission
voltage (15) F58-4
6. Main fuses
16. Diagnostic socket drivetrain
7. Circuit fuse control unit transmission (0.5 A) (F51-3)
17. Circuit fuses cab ignition voltage (15) F58-5
8. Relay tilt in/out K3002
18. Voltage converter
9. Relay lift/lower K3007

11:16 11 Common electrics – Control units
11.5.3 Control units

Control units, general
Control units are appointed responsibility for parts of functions.
Therefore a certain function cannot be associated to a special control
unit, instead the function occurs in cooperation between control units,
sensors, valves, etc.
Control unit cab and control units on the frame and attachment have
indicator lamps that can be used to check basic information on the
status of other control units.
Indicator lamps have the following significations:

Indicator lamps control unit cab
Table Indicator lamps control unit cab
Light 1 Green light when there is battery voltage to unit. The

light is physically controlled by voltage feed to the
4 control unit.
Light 2 Flashes green when redundant voltage feed control
3 unit and redundant CAN-bus communication is active.
2 No power in system.
006767
1 Green light when power electronics and 15-voltage

are supplied with voltage.
Indicator lamps control unit cab
Light 3 Long yellow single flashing light at communication with
Control unit KID (D795), which is a prerequisite for
trouble-shooting.
Short yellow single flashing light at communication
with Control unit engine (D794) and Control unit
transmission (D793).
Double flashing yellow light (short and long flashes)
at communication with display and engine or
transmission.
Light 4 Red light at active error.
Indicator lamps control units on frame and attachment
Table Indicator lamps control units on frame and attachment
1
2 Light 1 Green light when there is battery voltage to unit. The
light is physically controlled by voltage feed to the
3 control unit.
4 Light 2 Flashes green when any redundant voltage feed left,

redundant voltage feed right or 15-voltage is not found.
006766
Green light when redundant voltage feed, left,

redundant voltage feed, right and 15-voltage are
Indicator lamps control units on frame and attachment. supplied with voltage.
Light 3 Yellow single flashing light at communication with
Control unit KID (D795) or Control unit cab (D790-1).
Yellow double flashing light during communication with
Control unit KID (D795) and Control unit KIT (D790-2).
Light 4 Red light at active error.

11 Common electrics – Control units 11:17
Control units, position
1 2 3
014680
7 6 5
1. Control unit, frame (D797-1) 5. Control unit, transmission (D793)
2. Control unit KID (D795) 6. Control unit engine Yuchai (D794)
3. Control unit KIT (D790-2) 7. Control unit engine Cummins (D794)
4. Control unit cab (D790-1) 8. Control unit attachment (D791-1)

11:18 11 Common electrics – Communication
11.6 Communication
Communication, general
1 The machine's communication is handled by a so-called CAN bus
system. The CAN bus system consists of control units connected
together to form a network.
D791
The idea with the network is to share information. Signal values are
sent out by the control unit that, e.g., is connected to a sensor, other
control units can use the signal for their functions.
D790-1 D790-2 D795 The network consists of control units and segments. Segment is the
CAN-bus between control units.
1 D797-1
2
014681
D794 D793
1. Segment
2. CAN-bus drivetrain
11.6.1 CAN bus

CAN-bus, description
The CAN-bus consists of two twisted cables (twisted pair).
11.6.2 Redundant CAN-bus

Redundant CAN-bus, description
Redundant CAN-bus means that each control unit has two
D791 D790-1 D790-2 D795 connections for communication. The CAN-bus is connected in series
CAN R CAN L CAN R CAN L CAN R CAN L
between the control units. This means that the CAN-bus can handle
loss of a segment. If several segments fail, then one or some control
units lose contact with the network and work independently, often with
CAN L CAN R
limited capacity to perform their task.
014682
D797-1
Signals can be checked with diagnostic menu.
Principle illustration redundant CAN-bus
11.6.3 CAN-bus drivetrain

CAN-bus drivetrain, description
Communication with Control unit engine (D794) and Control unit
D790-1 transmission (D793) are separate from the redundant CAN-bus.
Signals can be checked with diagnostic menu.

003171
D794 D793
Principle illustration CAN-bus drivetrain

D:1
D Error codes
D Error codes
Information is found in the Workshop
manual
See Workshop manual DCT 80–90, section D Error codes.
For information how to order Workshop manual, see section A

Foreword.

D:2

E:1
E Diagrams
E Diagrams
Information is found in the Workshop
manual
See Workshop manual DCT 80–90, section E Diagrams.
For information how to order Workshop manual, see section A

Foreword.

E:2

F:1
F Technical data
Contents F Technical data

Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Specifications for lifting capacity and dimensions............................................F:6
Oils and lubricants, recommendation...............................................................F:8
Tightening torques, recommendations...........................................................F:10
Tightening torque, connections for air conditioning unit.................................F:11
Tightening torque, ORFS connections ...........................................................F:12
Unit explanations ...........................................................................................F:13
Conversion SI-units........................................................................................F:14
Conversion table, length ................................................................................F:15
Conversion table, area...................................................................................F:15
Conversion table, volume ..............................................................................F:15
Conversion table, weight................................................................................F:15
Conversion table, pressure ............................................................................F:16

F:2

F Technical data – Technical data F:3
F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.
1. Motor Yuchai YC6A240-30

Cummings QSB6.7
Power acc. to ISO 3046 (net power) 164 kW at 2200 rpm 164 kW at 2200 rpm
Torque ISO 3046 800 Nm at 1500 rpm 949 Nm at 1500 rpm
Max. rpm 2200 rpm 2200 rpm
Number of cylinders 6 cylinders 6 cylinders
Alternator, power 2640 W 2240 W
System voltage, voltage capacity 24 V (2x12 V / 135 Ah)
2. Transmission Dana HR32000

No. of gears, forward - reverse 3 – 3
3. Driveline/Axle
Drive axle, type Kessler D81
Kessler D91
4. Brakes
Footbrake system - wheels affected Wet Disc Brake – drive wheel
Parking brake system - wheels affected Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels
Dimension, front and rear 12.00x24
14.00x24
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air filled. Spare and replacement tyres must be of a brand approved by Cargotec.
9. Cab Spirit Delta
Equivalent sound pressure level Yuchai YC6A240-30

in cab according to EN12053 with Cummings QSB6.7
LpAZ 67 dB(A)
measurement uncertainty σR = 2.5 dB. LpAZ 65 dB(A)
Measuring value with standard engine.
Whole-body vibration in accordance 0.4 - 0.7 m/s2
with EN13059 with measurement
uncertainty k = 0.3 x measured value.

F:4 F Technical data – Technical data
9.6 Frame, body, cab and accessories, lighting system

Light Rating (W) Socket
Control lights 1.2 W2x4.6d
Interior lighting 10 S8.5
Rear lights 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Running lights 5 W2.1x9.5d
Headlights (high and low beams) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work light 70 PK22s (H3)
35 D1S Xenon tubes. Insert and
Work light, Xenon ballast replaced complete.
Revolving beacon 70 PK22s (H3)
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
1.2 Engine, fuel system Yuchai YC6A240-30

Cummings QSB6.7
Fuel tank, volume 380 L
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1–D,
ASTM D 975 No 2–D.
1.7 Engine, cooling system
Coolant volume 32 L 29 L
Coolant filling Volvo Penta Coolant VCS, ES Compleat, Premix
ready-mixed.
See Oils and lubricants, recommendation, page F:8.
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, only use coolant of
the same type that was used before.
1.8 Engine, lubrication system

Oil type, quality See Oils and lubricants, recommendation, page F:8.
Oil volume incl. filter 24 L 20 L

2.6 Transmission, lubrication HR32000

system
Oil type See Oils and lubricants, recommendation, page F:8.
Oil volume 32 L
3.3 Driveline/Axle, drive axle Kessler D81 Kessler D91

Oil grade See Oils and lubricants, recommendation, page F:8.
Oil volume, differential 42 L 54 L
Oil volume, hub reduction 2x4 l 2x4 l
7 Load handling

Refrigerant air conditioning R134a
Volume refrigerant Se sign for air conditioning
Lubricant air conditioning ZEXEL PAG-oil ZXL100
Windshield wiper fluid, volume 5 L
Hydraulic oil tank, volume 320 L
Hydraulic oil system, volume 450 L

Specifications for lifting capacity and

dimensions
β α
A2
100 100
H4
H5
B S
H3
R1
R2
H6
H8
H10
100
014020
100
L3 L2 A1
L
DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Lifting capacity
Classification [kg x 103] 8 9
Centre of gravity distance (L4 [mm]) 1220 1220
Number of containers, 8'6" container 5 6 7 8 5 6 7 8
Number of containers, 9'6" container 5 5 6 7 5 5 6 7
Dimensions
Truck length (L [mm]) 6900 6900
Truck width (W [mm]) 4050 4100
Height, base machine, Spirit Delta (H6 [mm]) 3940 4000
Seat height (H8 [mm]) 2800 2860
Distance drive axle - the attachment's front 1185 1185
section (L2 [mm])
Axle distance (L3 [mm]) 4550 4550
Track (front - rear) (T [mm]) 3270 – 2250 3270 – 2200
Turning radius, outer (R1 [mm]) 6750 7000
Slewing radius, inner (R2 [mm]) 1150 1500

DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Ground clearance, min [mm] 250 300
Minimum track width for 90° stacking, 20' 10600 10850
container (A1 [mm])
Minimum track width for 90° stacking, 40' 14200 14350
container (A2 [mm])
Standard Duplex mast
Lift height (H4 [mm]) 15220 16220 18720 21220 15280 16280 18780 21280
Mast height, min. (H3 [mm]) 8540 9040 10290 11540 8600 9100 10350 11600
Mast height, max (H5 [mm]) 15040 16040 18540 21040 15100 16100 18600 21100
Mast tilting, forward – back (α – ß [mm]) 3 – 3 3 – 3
Attachment
Height under twistlock (H10 [mm]) 2220 2280
Height under lifting hooks (H10 [mm]) - -
Side shift ± (V1 [mm]) 600 600
Weight
Kerb weight [kg x 10 3] 35,5 36,1 37,6 39,1 36,4 37,0 38,5 40,0
Axle load pressure front, (without load) [kg x 22,7 23,3 24,8 26,3 22.9 23,5 25,0 26,5
103]
Axle load pressure front, (with classed load) 34,9 35,5 37,0 38,5 36,7 37,3 38,8 40,3
[kg x 103]
Axle load pressure rear, (without load) [kg] 12800 13500
Axle load pressure rear, (with classified load) 8600 8700
[kg]

Oils and lubricants, recommendation

Cargotec's stated service intervals in the maintenance manual are
conditional on oil selection according to the following table. The
table states recommended viscosity for different oil types and grades
depending on outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.
Oil type, quality °C -20 -10 0 +10 +20 +30 +40

°F -4 +14 +32 +50 +68 +86 +104
1.8 Engine, lubrication system
Yuchai YC6A240-30 SAE 15W-40 (engine oil)
API CH-4 or ACEA E5 SAE 15W-30 (engine oil)
SAE 10W-30 (engine oil)

Cummings QSB6.7
API CH-4 or ACEA E5 SAE 5W-30 (engine oil)
2.6 Transmission, lubrication system

GM Allison C-4 SAE 50
John Deere J20 C, D SAE 40
Caterpillar TO-4 SAE 30
MIL-PRF-2104G
SAE 20
NOTE SAE 10W
Engine oil or GL-5 oil may not be used. SAE 0W-20
3.3 Driveline/Axle, drive axle

API GL-5 SAE 80W-140
SAE 75W-90
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
*) The oil in the brake system must meet one of the quality standards
as well as be a UTTO-oil (Universal Tractor Transmission Oil).
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute

Grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for

all grease points except for lifting equipment and slide plates.
For lifting equipment, use a universal grease type EP according to

NLGI Grade 2 (EP2) with 3-5% Molybdenum disulfide intermix.
For slide plates, use lubricants approved by Cargotec. Order from

Cargotec Parts department. 0.65 kg cartridge for grease gun, part no.
923110.0360, and 5 kg can, part no. 923595.0003.
NOTE
Select grease grade according to relevant climate.
Electrical connector grease
Electrical connector grease 923836.0552.
Sealant silicone
Sealant silicone 923107.0308.
Silicone adhesive
Silicone adhesive 923854.0100.
Coolant
Only use ready-mixed recommended coolant. Select mixture of the

coolant that is adapted for correct temperature.
NOTE
It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protecting properties
decline with time, therefore the coolant must be changed according
to stated intervals.
CAUTION

Tightening torques, recommendations

The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tightening
torque should be reduced by approx. 5%.
For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque varies depending on surface

treatment. Certain combinations of bolts and nuts require lubrication
according to the following table.
State Screw Nut Lubrication

1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9

State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm

Quality 8.8 10.9 12.9

7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, connections for air

conditioning unit
O-ring coupling cooling coils
Hose diameter Thread Tightening torque

mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"
The above values should be considered guidelines and may vary

depending on installation.

Tightening torque, ORFS connections

Pipe and hose coupling
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170

Goods coupling
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400
Unit explanations
Unit Abbreviation
Newton metre Nm
Kilopond metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Meter m
Kilometre km

Conversion SI-units
SI-unit Conversion factor Non-SI Conversion factor SI
Torque
Nm x 10.2 = kg cm x 0.8664 = lb in
Nm x 0.74 = lbf ft x 1.36 = Nm
Nm x 0.102 = kg m x 7.22 = lb ft
Pressure (Pa = N/ m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table, length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1 mm = 0.001 m
Conversion table, area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume

Unit cm3 = cc m3 L in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table, weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table, pressure

Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735,56 Dry (mmHg) = 0.96784 atm

G:1
Contents G Terminology and index

Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:5

G:2

G Terminology and index – Terminology and index G:3

Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Attachment Part of the machine that grabs the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreader and levelling.
Axle distance Distance between drive axle and steering axle.
Bar Unit for measuring pressure.
Battery disconnector Cuts off current from battery.
Daily inspection The actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of the machine’s lift capacity.
Display "Window" showing digital information on steering wheel panel in cab.
Operating hours Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
ECC Electric Climate Control. Climate control unit with thermostat-controlled cooling,
dehumidification, and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) of a pump.
Hanging load Lifted load.
FMI Fault Message Identifier.
Main fuse Located by battery. Cuts the power to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transmit power to different functions.
Indicator Manual "sensor", e.g., shows that a filter is clogged and needs to be replaced.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorised trained person.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to
regulations.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Trolley Lifts the load, located on the mast.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, e.g., release pressure and thus lower
a boom or a fork.
Machine model Machine type. Indicated, for example: DCT 80–90. See also type designation.

G:4 G Terminology and index – Terminology
Term Description
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant mesh.
Product alternatives One of several alternatives is selected for a machine, e.g., engine alternative.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current's amplitude. In everyday language, a stepless valve, as
opposed to an Off/On valve. On, e.g., the transmission's valve housing.
Frame beam Supporting beams in the frame.
Recirculation Circulates again and again.
Serial number Unique machine designation. Available on machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small user movement results in a big machine movement, e.g. power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Levelling Attachment is tilted, for example, if load stands on uneven ground.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Widening of attachment.
Mast Carrier of trolley, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
Steering axle Wheel axle with steering.
Buzzer Audible alarm to catch the operator’s attention.
Option Optional equipment for machine.
Tilting Load is tilted forward or backward.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container for lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
Wet brakes Brake discs in oil-bath.

Valve slide Moving part in the valve. Decides the oil's path.

G Terminology and index – Index G:5
Index ENGINE . . . . . . . . . . . .
Engine's mechanical parts . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 8:17
. . 1:17
Entertainment and communication . . . . . . . . . . 9:32
Environment . . . . . . . . . . . . . . . . . . . B:21
A Error codes . . . . . . . . . .
Exhaust system . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
8:8, D:1
. . 1:25
About the documentation . . . . . . . . . . . . . A:10 EXT-ATTACH . . . . . . . . . . . . . . . . . . . 8:22
About the maintenance manual . . . . . . . . . . . . A:3 EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:22
Accumulator . . . . . . . . . . . . . . . . . . . . 4:7
Accumulator charging valve . . . . . . . . . . . . . 4:6
Air cleaning system . . . . . . . . . . . . . . . . . 1:22
Air intake and exhaust outlet . . . . . . . . . . . . . 1:22
F
Alternator . . . . . . . . . . . . . . . . . . . . . 11:9 Feedback . . . . . . . . . . . . . . . . . . . . . A:11
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:21 Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:15
Foreword . . . . . . . . . . . . . . . . . . . . . A:3
Frame . . . . . . . . . . . . . . . . . . . . . . . 9:37
B Frame, body, cab and accessories . . . . . . . . . . 9:3
FREELIFT . . . . . . . . . . . . . . . . . . . . . 8:22
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:7 Fresh air filter . . . . . . . . . . . . . . . . . . . 9:25
Battery voltage (30) . . . . . . . . . . . . . . . . 11:11 Fuel filter . . . . . . . . . . . . . . . . . . . . . 1:15
Body structure . . . . . . . . . . . . . . . . . . . 9:38 Fuel prefilter . . . . . . . . . . . . . . . . . . . . 1:11
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:3 Fuel system . . . . . . . . . . . . . . . . . . . . 1:9
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3 Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:10
Breather filter hydraulic oil tank . . . . . . . . . . . 10:12 Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:4
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:6
G
C
General safety information . . . . . . . . . . . . . . B:3
CAB . . . . . . . . . . . . . . . . . . . . . . .
8:15 Glass/windows/mirrors . . . . . . . . . . . . . . . 9:33
Cab interior . . . . . . . . . . . . . . . . . . . .
9:36
Cab structure and suspension . . . . . . . . . . . .
9:34
Cab undercarriage . . . . . . . . . . . . . . . . .
9:35
CAN bus . . . . . . . . . . . . . . . . . . . . 11:18
H
CAN-bus drivetrain . . . . . . . . . . . . . . . . 11:18 Heating, ventilation and air conditioning . . . . . . . . 9:13
CAN/POWER . . . . . . . . . . . . . . . . . .. 8:13 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:16
Central lubrication . . . . . . . . . . . . . . . .. 9:39 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:13
CLIMATE . . . . . . . . . . . . . . . . . . . .. 8:15 Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:12
Common electrics . . . . . . . . . . . . . . . .. 11:3
Common hydraulics . . . . . . . . . . . . . . . .. 10:3
Communication. . . . . . . . . . . . . . . . . . 11:18 I
Complete machine . . . . . . . . . . . . . . . .. 0:3
Condenser . . . . . . . . . . . . . . . . . . . .. 9:25 I/O . . . . . . . . . . . . . . . . . . . . . . . . 8:23
Container counter. . . . . . . . . . . . . . . . .. 7:31 Ignition voltage (15) . . . . . . . . . . . . . . . . 11:12
Control system . . . . . . . . . . . . . . . . . .. 8:3 Ignition/heating . . . . . . . . . . . . . . . . . . . 1:44
Control system engine. . . . . . . . . . . . . . .. 1:43 Intercooler . . . . . . . . . . . . . . . . . . . . . 1:26
Control system transmission . . . . . . . . . . . .. 2:12
Control units . . . . . . . . . . . . . . . . . . . 11:16
Controls and instruments . .
Coolant . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4:3, 9:4
. . 1:34
L
Cooling fan . . . . . . . . . . . . . . . . . . . . 1:28 Levelling. . . . . . . . . . . . . . . . . . . . . . 7:22
Cooling system . . . . . . . . . . . . . . . . 1:27, 2:11 Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:4
Crank mechanism . . . . . . . . . . . . . . . . . 1:21 Lighting system. . . . . . . . . . . . . . . . . . . 9:28
LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:14
Link arm . . . . . . . . . . . . . . . . . . . . . . 5:4
D Load carrier . . . . . . . . . . . . . . . . . . . . 7:23
Load handling . . . . . . . . . . . . . . . . . . . 7:3
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:10 Lubrication system . . . . . . . . . . . . . . . 1:39, 2:8
Diagrams . . . . . . . . . . . . . . . . . . . . . E:1
Distribution of electricity . . . . . . . . . . . . . . 11:10
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:34 M
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:4
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3 Mast . . . . . . . . . . . . . . . . . . . . . 7:6, 7:21
Mechanical transmission. . . . . . . . . . . . . . . 2:7
Moisture filter . . . . . . . . . . . . . . . . . . . 9:26
E Monitoring . . . . . . .
MOVE-CAB . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 8:6
. . 8:22
EL-STEERING . . . . . . . . . . . . . . . . . . . 8:22
ELECTRIC SERVO . . . . . . . . . . . . . . . . . 8:20
Electrical distribution box . . . . . . . . . . . . . 11:15 O
Electrical protection . . . . . . . . . . . . . . . . . 11:3
Emergency stop switch voltage (15E) . . . . . . . . 11:13 OLS . . . . . . . . . . . . . . . . . . . . . . . 8:21
Engine . . . . . . . . . . . . . . . . . . . . . . 1:3 OPT . . . . . . . . . . . . . . . . . . . . . . . 8:22

G:6 G Terminology and index – Terminology
Other functions . . . . . . . . . . . . . . . . . . . 7:31 Spreader beam . . . . . . . . . . . . . . . . . . . 7:18

Spreading . . . . . . . . . . . . . . . . . . . . . 7:13
Start battery . . . . . . . . . . . . . . . . . . . . 11:7
P Start/stop . . . . . . . . . . . . . . . . . . . . . 1:45
Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:41 Steering axle cradle . . . . . . . . . . . . . . . . . 6:3
Parking brake pads . . . . . . . . . . . . . . . . . 4:12 Suspension . . . . . . . . . . . . . . . . . . . . 6:3
Parking brake system . . . . . . . . . . . . . . . . 4:9
Parking brake unit . . . . . . . . . . . . . . . . . 4:11
Position sensor mast . . . . . . . . . . . . . . . . 7:9 T
Power assisted system . . . . . . . . . . . . . . . 5:3
Power-assisted brake system . . . . . . . . . . . . 4:4 Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Preventive maintenance . . . . . . . . . . . . . . . C:3 Technical data . . . . . . . . . . . . . . . . . . . F:3
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:3 Temperature control, cleaning and hydraulic oil . . . . 10:10
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6 Terminology . . . . . . . . . . . . . . . . . . . . G:3
Terminology and index . . . . . . . . . . . . . . . G:3
Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:20
R Tilt cylinder . . . . . . . . . . . . . . . . . . . . 7:21
Torque converter/Clutch system . . . . . . . . . . . 2:6
Radiator and expansion tank . . . . . . . . . . . . . 1:27 TRANSM . . . . . . . . . . . . . . . . . . . . . 8:19
Reading instructions . . . . . . . . . . . . . . . . A:4 Transmission. . . . . . . . . . . . . . . . . . . . 2:3
Rearview mirror . . . . . . . . . . . . . . . . . . 9:33 Trolley. . . . . . . . . . . . . . . . . . . . . . . 7:10
Redundant CAN-bus . . . . . . . . . . . . . . . 11:18 Turbo . . . . . . . . . . . . . . . . . . . . . . . 1:24
Redundant voltage feed of control units . . . . . . . 11:12 Twistlocks . . . . . . . . . . . . . . . . . . . . . 7:23
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:14 Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:13
RMI . . . . . . . . . . . . . . . . . . . . . . . . 8:23 Tyres and rims . . . . . . . . . . . . . . . . . . . 6:6
Roof window . . . . . . . . . . . . . . . . . . . . 9:33
V
S Valve mechanism . . . . . . . . . . . . . . . . . . 1:17
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 VBFS . . . . . . . . . . . . . . . . . . . . . . . 8:22
Safety and emergency equipment. . . . . . . . . . . 9:9 Voltage converter . . . . . . . . . . . . . . . . . 11:14
Safety instructions . . . . . . . . . . . . . . . . . B:4 Voltage feed . . . . . . . . . . . . . . . . . . . 11:10
Safety valves. . . . . . . . . . . . . . . . . . . . 10:4
Seats . . . . . . . . . . . . . . . . . . . . . . . 9:10
Service indicator . . . . . . . . . . . . . . . . . . 8:7 W
Settings . . . . . . . . . . . . . . . . . . . . . . 8:24
Side shift . . . . . . . . . . . . . . . . . . . . . 7:11 Wheel brake . . . . . . . . . . . . . . . . . . . . 4:8
Signalling system . . . . . . . . . . . . . . . . . . 9:30 Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:5
Speed limitation . . . . . . . . . . . . . . . . . . 8:6 Wheel spindle . . . . . . . . . . . . . . . . . . . 6:4
Speed reduction . . . . . . . . . . . . . . . . . . 7:31 Wiper/washer system . . . . . . . . . . . . . . . . 9:27

G Terminology and index – Index G:7

last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

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9 Frame, body, cab and accessories

G Terminology and index

Maintenance Manual DCT 80–90 UDCT01.02GB

UDCT01.02GB Maintenance Manual DCT 80–90

The maintenance manual contains information about how the machine

Cargotec will not accept any responsibility for modifications performed

About the machine version

Cargotec reserves the right to change specifications and equipment

Duplication by any means such as copying, printing, etc., is prohibited.

Maintenance Manual DCT 80–90 UDCT01.02GB

Read operator's manual

Read the operator's manual

Read maintenance manual

refers to important information in the maintenance manual.

Read the maintenance manual

UDCT01.02GB Maintenance Manual DCT 80–90

Maintenance manual's content

For more information about function groups, see Function group

Maintenance Manual DCT 80–90 UDCT01.02GB

Function group structure

The maintenance manual and workshop manual contain different

References between sections in the same manual are indicated with

References are not given between Maintenance manual and Workshop

Product alternatives and optional equipment

Special equipment is not described in the manual. If you're uncertain

Product alternatives are such options that exclude certain standard

Equivalent information for different product alternatives is described

UDCT01.02GB Maintenance Manual DCT 80–90

Optional equipment are options that can be added to the standard

Information for optional equipment is described in separate sections

The machine card indicates of which drawings the machine consists,

The function descriptions describe the function in a logical flow from

Function descriptions use symbols to illustrate components such as

Maintenance Manual DCT 80–90 UDCT01.02GB

4:10 4 Bromsar – Parkeringsbromssystem

4.5 Parkeringsbromssy stem

Hydrauloljepump broms och styrning (frå n tanken). Ventilblock

1. Str ömst ä llare parkeringsbroms (S107) 7. Brytkontakt parkeringsbroms (S200)

6. Ventilblock ackumulatorladdnings - och 12. Indikeringslampa parkeringsbroms

UDCT01.02GB Maintenance Manual DCT 80–90

Symbol explanation function descriptions

Maintenance Manual DCT 80–90 UDCT01.02GB

About the documentation

Always specify publication number when ordering.

For publication number, see the machine card.

UDCT01.02GB Maintenance Manual DCT 80–90

Your feedback is important to be able to improve the information.

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: ......................................................................................................................................

Maintenance Manual DCT 80–90 UDCT01.02GB

UDCT01.02GB Maintenance Manual DCT 80–90

Maintenance Manual DCT 80–90 UDCT01.02GB

UDCT01.02GB Maintenance Manual DCT 80–90

Cargotec has in this publication documented and warned for situations

A near accident is a warning!

Maintenance Manual DCT 80–90 UDCT01.02GB

Service position is used for service, maintenance and other situations

Service position means:

Machine with trolley and attachment in completely

UDCT01.02GB Maintenance Manual DCT 80–90

Hydraulic and brake systems, depressurising