Maintenance Manual - DRT 450 PDF

Reachstackers 45 tonnes
Publ. no UDRT02.02GB
Maintenance Manual in original MAINTENANCE MANUAL
DRT 450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DRT 450
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:8
Function descriptions ................................................................................. A:8
About the documentation ...............................................................................A:11
The documentation's parts ........................................................................A:11
Ordering of documentation........................................................................A:11
Feedback ...................................................................................................... A:12
Form for copying ...................................................................................... A:12
Maintenance Manual DRT 450 UDRT02.02GB

A:2
UDRT02.02GB Maintenance Manual DRT 450

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 customization 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:8.
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 Bromsar – Servobromssystem 5
5
B
P
13
7 D790-2
T
D
D797-R D797-F 2
11 10 8 C
Pa
12
C D
D
9
4
Pa 3 7
ACC
B
6
3
C
P
2
6
4
1
012931
1. Bromsoljepump 8. Slutkontakt bromsljus (S216)
5
2. Bromsoljefilte 9. Brytkontakt bromsoljetryck (S204)
3. Ackumulatorladdningsventil
10. Reglerenhet ram fram (D797 -F)
4. Ackumulatorer
11. Reglerenhet ram bak (D797 -R)
5. Bromsventil
6. Bromscylindrar 12. Bromsljus (H41 1L & H411R)
7. Hjulbromsar 13. Reglerenhet KIT (D790 -2), Varningslampa bromstryck
Underhållsmanual DR T 450 UDR T02.01SE

013914
Example of function description

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

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 Foreword – About the documentation A:11
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:12 A Foreword – Feedback
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.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................

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:10
Noise ........................................................................................................ B:10
Solvents ....................................................................................................B:11
Fire and explosion risks............................................................................ B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:18
Non-ionised radiation ............................................................................... B:19
Environment.................................................................................................. B:20
General .................................................................................................... B:20

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:10
• Noise, page B:10
• Solvents, page B:11
• Fire and explosion risks, page B:12
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:17
• Tyres and rims, page B:17
• Lifting equipment, page B:18
• Spare parts, page B:18
• 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.
012924
• Boom fully retracted and lowered to horizontal position.

• Engine off.
Machine with fully retracted and lowered boom
• System voltage off (with battery disconnector).

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

1 Machine in service position.
2 Depressurise the hydraulic system.

Turn the start key to position I and activate extension out, a loud
hissing sound is heard if there is pressure in the hydraulic system.
Activate lift, extension, and side shift several times.
3 Turn the start key to position 0 and turn off the system voltage.
4 Depressurize 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 top lift is closed before the
engine is started.
013400
The figure above shows open valve.
5 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.
NOTE
Keep the 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.

Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
Always completely depressurize the hydraulic and
brake systems before starting to work in these systems.
Hydraulic and brake systems are pressurized and the
oil can cause personal injuries.
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
authorized 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 authorized 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 jeopardized 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 anesthetizes, 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).
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.
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
irritation of mucous membranes with asthma-like symptoms as well as
impaired lung function. Even brief exposure to high levels may give
problems with permanent oversensitive.

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 pressurized 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 authorized 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 boom and attachment.
Therefore, always make a habit of having the boom fully lowered and
completely retracted 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
• If possible, do not start to work before the boom is completely
lowered and fully retracted.
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
• Lift cylinder
• 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-ionized 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:20 B Safety – Environment
Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialization. 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 Safety – Environment B:21
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.

B:22

C:1
Contents C Preventive maintenance

Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Wheel nuts, check-tightening.......................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:5
Service schedule............................................................................................. C:7
Washing ........................................................................................................ C:14
Lubrication 500 hours ................................................................................... C:15
Lubrication 1000 hours ................................................................................. C:16
Checking for cracks ...................................................................................... C:19

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 fulfill
warranty and service agreements!
Use spare parts and fluids approved by Cargotec to
fulfill the warranty.
Wheel nuts, check-tightening
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).
Preventive maintenance, work instructions
1 For a new machine, perform check actions after 50 operating

hours, see 50h-check, page C:5.
Note completed 50h-check in the service log, see Check and
service log, page C:4.
2 Regular service shall be performed according to service schedule,

see Service schedule, page C:7. 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
500h 500h service
1000h 1000 service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000 service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000 service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000 service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000 service
9500h 500h 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 YC6M360-30)
Leakage check oil, coolant, exhaust system
Fuel pre-filter, drain water Section 1 Engine, group 1.2.3 Fuel pre-filter
Air filter main cartridge, inspection Section 1 Engine, group 1.6.1 Air cleaning system
Air filter safety cartridge, inspection Section 1 Engine, group 1.6.1 Air cleaning system
Drive belt tension, checking Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Oil and oil filter, change Section 1 Engine, group 1.8 Lubrication system
Bolted joints, attachments, mountings, hose clamps,
wear and chafing of hoses, cable harnesses, etc.
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 Power transmission, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Power transmission, group 3.3 Drive axle
4 Brakes
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check
Leakage check
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Wheel suspension, group 6.3 Tyre system
Wheel nuts, check-tightening Section 6 Wheel suspension, group 6.3 Tyre system
7 Load handling
Hose connections, check-tightening
Chain tension spreading, checking and adjusting Section 7 Load handling, group 7.5.7 Spreader chains
Lower slide surfaces inner boom The lower glide surfaces of the inner boom should be lubricated
every 250 operating hours up to 1,000 operating hours, thereafter
Slide surfaces main beam attachment according to lubrication chart.
8 Control system
Check that there are no active error codes Section 8 Control and monitoring system, group 8.3 Error codes
Locking of the cab (mechanically movable), checking Section 9 Frame, body, cab and accessories, group 9.10.4
Sliding cab
Leakage check, retightening as required

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 electrical, group 11.3.1 Start battery

Service schedule
Service shall be performed every 500 operating hours. The actions are
divided into 500 h, 1,000 h, and 2,000 h 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
Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Object, action h, etc.. etc. etc. etc. Comment Reference
0 complete machine
Checking cleanliness and C C C Check and remove Section B Safety
leakage remains of flammable
materials in the engine
compartment, pay extra
attention to hot surfaces
such as exhaust system,
manifold, or turbo. If leaks
of oil, fuel, or coolant are
detected, find the cause
and solve the problem.
Attachments (stub axles) C C Visual check in connection
with greasing.
Checking for cracks C* C* * Check every 1000h or Checking for cracks,
every year. page C:19
Lubrication 500 hours L L L NOTE: only: Lubrication 500 hours,
page C:15
Brake pedal
Link arms
Wheel hub steering axle
Wheel spindle steering
axle
Lubrication 1000 hours L L Lubrication 1000 hours,
page C:16
1 Engine

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Engine oil (engine R R R R For volume and quality, Section 1 Engine, group
alternative Yuchai see section F F Technical 1.8 Lubrication system
YC6M360-30) data.
Engine oil (engine option R R R
Cummins QSM11 )
Engine oil filter (engine R R R R
alternative Yuchai
YC6M360-30)
Engine oil filter (engine R R R
option Cummins QSM11
)
Performance and exhaust C C C C
smoke, check (engine
alternative Yuchai
YC6M360-30)
Fuel tank C Clean if necessary.
Fuel pre-filter (engine R* R* R* R* Incl. draining of Section 1 Engine, group
alternative Yuchai condensation water. 1.2.3 Fuel pre-filter
YC6M360-30) Shall be done every 50
hours.
Fuel pre-filter (engine R* R* R*
option Cummins QSM11 * Change filter earlier if
error code is displayed.
)
Fuel filter (engine R* R* R* R* * Change filter earlier if Section 1 Engine, group
alternative Yuchai error code is displayed. 1.2.4 Fuel filter
YC6M360-30)
Fuel filter (engine option R* R* R*
Cummins QSM11 )
Valves and injectors C C C Section 1 Engine, group
(engine alternative 1.5.4 Valve mechanism
Cummins QSM11 )
Vibration damper (engine C* * Check every 6,000 h or Section 1 Engine, group
option Cummins QSM11 every 2 years. 1.5.6 Crank mechanism
)
Air filter main cartridge C/R C/R C/R Checking indicators, Section 1 Engine,
change when indicated. group 1.6.1 Air cleaning
system
Air filter safety cartridge C C /R C/R Changed every other time Section 1 Engine,
main cartridge is changed. group 1.6.1 Air cleaning
system
Turbo (engine alternative C C C Section 1 Engine, group
Yuchai YC6M360-30) 1.6.2 Turbo
Turbo (engine option C* * Check every 6,000 h or Section 1 Engine, group
Cummins QSM11 ) every 2 years. 1.6.2 Turbo
Exhaust system C C Check sealing and Section 1 Engine, group

suspension. 1.6.3 Exhaust system
Intercooler C C Check sealing and Section 1 Engine, group
suspension. 1.6.4 Intercooler

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Radiator C C C External cleaning.
NOTE
Do not use high
pressure wash.
Coolant filter (engine R R R Section 1 Engine, group

option Cummins QSM11 1.7.2 Coolant filter
)
Fan belt (engine C/R C/R C/R C/R Change when needed. Section 1 Engine, group
alternative Yuchai 1.7.5 Cooling fan
YC6M360-30)
Fan belt (engine option C/R C/R C/R
Cummins QSM11 )
Fan hub (engine option C C Check after 1000 h or Section 1 Engine, group
Cummins QSM11 ) every year. 1.7.5 Cooling fan
Coolant, level (engine C C R R For volume and quality, Section 1 Engine, group
alternative Yuchai see section F F Technical 1.7.7 Coolant
YC6M360-30) data.
Coolant, level (engine C C C / R* * Change after 5 000 h or
alternative Cummins once every two years.
QSM11 ) For volume and quality,
see section F F Technical
data.
Coolant, freezing point C C C For volume and quality, Section 1 Engine, group
see section F F Technical 1.7.7 Coolant
data.
Coolant quality, checking C C Check after 1000 h or Section 1 Engine, group
(engine option Cummins every year. 1.7.7 Coolant
QSM11 )
Bolted joints, C C C Checks and
attachments, mountings, check-tightening
etc.
Connectors (engine C C C C Visual check for damage
alternative Yuchai or corrosion.
YC6M360-30)
Connectors (engine C C C
option Cummins QSM11
)
2 Transmission
Breather filter, torque C C Clean, when needed. Section 2 Transmission,
converter group 2.2 Torque
converter/clutch
Transmission oil filter R R Section 2 Transmission,
group 2.6 Lubrication
Transmission oil R R For volume and quality, system
see section F F Technical
data.
3 Driveline/Axle

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Propeller shaft C C C Bolted joints and universal Section 3 Power
joint. transmission, group
3.2 Propeller shaft
Drive axle oil R R For volume and quality, Section 3 Power
see section F F Technical transmission, group
data. 3.3 Drive axle
Mounting drive axle C C Section 3 Power
transmission, group
3.3 Drive axle
4 Brakes
Brake pedal C C Section 4 Brakes, group
4.1.1 Brake pedal
Brake oil pump C C C Section 4 Brakes, group
4.3.1 Brake oil pump
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,
change when needed. 4.5.4 Parking brake unit
Oil cooler C C C Clean when needed.
NOTE
Do not use high
pressure wash.
Breather filter R Section 4 Brakes group,

4.8.11 Breather filter
Brake oil filter R R R Section 4 Brakes group,
4.8.12 Brake oil filter
Oil brake system R For volume and quality, Section 4 Brakes group,
see section F F Technical 4.8.14 Oil for brake
data. system
5 Steering
Link arms C/L C/L C/L Check bearings. Lubrication 500 hours,
page C:15
6 Suspension
Steering axle suspension C C Section 6 Wheel
suspension, group
6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel Section 6 Wheel
suspension shall be suspension, group
checked. Max. 1.5 mm. 6.2.2 Wheel spindle
Wheel hub steering axle, C Check bearing pre-load. Section 6 Wheel
check suspension, group
6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and Section 6 Wheel
pressure, change as suspension, group
needed. 6.3 Tyre system
Wheel nuts C C Check-tightening. Section 6 Wheel
suspension, group
6.3 Tyre system

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Rim C* * Checking for cracks, Section 6 Wheel
every 2,000 hours and suspension, group
in connection with tyre 6.3.2 Rim
changes.
7 Load handling
Servo filter R R R Section 7 Load
handling, group 7.2.2
Servo filter
Servo pressure C C C Section 7 Load
handling, group 7.2.3
Pressure reducer
Cable racks boom and C C Hose and cable damage.
attachment
Boom and attachment C C Damage.
Slide plates boom C C Check wear, change as Section 7 Load
needed. handling, group 7.3.10
Lift boom
Slide plates side shift C C Check wear, change as Section 7 Load
frame needed. handling, group 7.4.6
Sideshift frame
Slide plates main beam C C Check wear, change as Section 7 Load
attachment needed. handling, group 7.4.7
Main beam attachment
Chain spreading C C Tension chain when Section 7 Load
needed. handling, group 7.5.7
Spreader chains
Slide plates spreader C C Check wear, change as Section 7 Load
beam needed. handling, group 7.5.8
Spreader beam
Oil spreading motor unit R R For volume and quality, Section 7 Load
see section F F Technical handling, group 7.5.6
data. Spreader motor
Oil rotation motor unit R R For volume and quality, Section 7 Load
see section F F Technical handling, group 7.6.6
data. Rotation motor unit
Twistlocks C C C/R Checking that the parts Section 7 Load
are properly tightened handling, group 7.9.1.7
every 500 hours. Twistlocks
Check of float position
every 500 hours.
Check of vertical
movement every 2000
hours.
Check for cracks every
other year or every 4000
operating hours.
Replace every 10,000
operating hours. Reset
time counter for twistlocks
after replacement.
Sensor contact C C Checking and adjustment. Section 7 Load
handling, group 7.9.1.8
Sensor alignment

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Sensor twistlocks C C Checking and adjustment. Section 7 Load
handling, group 7.9.1.9
Sensor twistlocks
C Check that deviation Section 7 Load
Weight indicator without load is max. 0.5 handling, group 7.10.2
ton. Weight indicator
8 Control system
Overload system C C C Section 8 Control
system, group 8.2.1
Overload system
Instruments and controls C C C Checking function.
Fresh air filter R R R Dependent on external Section 9 Frame, body,
environment, at latest cab, and accessories,
every 500 operating group 9.4.1 Fresh air
hours. filter
C C C Clean when needed. Section 9 Frame, body,
Condenser cab, 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,

Moisture filter indication is grey. cab and accessories,
group 9.4.9 Moisture
filter
Windshield wipers C C C Incl. washer, top up when
needed.
Roof window C C Check damage, change Section 9 Frame, body,
when needed. cab, and accessories,
group 9.9.3 Roof
window
Lighting and audible C C C
signals
Cab undercarriage C C Check mountings,
isolators and bolted
joints.
Sliding cab C C Check locking. Section 9 Frame, body,
cab and accessories,
group 9.10.4 Sliding
cab
Doors C C Check doors' mounting
points.
Paint/coatings C Check the machine's Section 9 Frame,
painted surfaces for stone body, cab and
chips and scratches. accessories, group
9.15 Paint/coatings
Repair damage
immediately to avoid
corrosion.
Handles and hand rails C C Checking the mountings.

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Safety decals C C C Check that safety decals See Operator's manual
are legible, securely DRT450, section 3.2
fastened, and not Plates
damaged. Clean dirty
decals and replace decals
as needed.
Breather filter C/R R R Change at indication. Section 10 Common
hydraulics, group
hydraulic oil tank
Hydraulic oil filter R R Section 10 Common
hydraulics, group
10.6.7 Hydraulic oil
filter
Oil cooler C C Clean when needed.
NOTE
Do not use high
pressure wash.
Hydraulic oil R For volume and quality, Section 10 Common

see section F F Technical hydraulics, group
data. 10.6.8 Hydraulic oil
Fine filter hydraulic oil R R R Section 10 Common
hydraulics, group
10.6.9 Fine filter
hydraulic oil
11 Common electrics
Batteries C C C Section 11 Common
electrical, group 11.3.1
Start battery
Battery cable C C C Section 11 Common
electrical, group 11.3.1
Start battery
Fuses C C C Check that fuses are Section 11 Common
intact, change if needed. electrical, group 11.2.2
Fuses
Position sensors C C C Should be free from
grease and dirt, clean as
needed.
• Attachment
Test-run

Service
250 h, 500h, 1000h, 2000h,
750 h, 1500h, 3000h, 4000h,
1,250 2500h, 5000h 6000h
Test-run the machine and check:
• Instruments
• Brakes
• Gearshifting
• All load handling functions
• Steering
• Any noise
WARNING
The cab has manual sliding cab. The cab shall ALWAYS be in its rear position during operation.
Warning, risk of crushing!
Always make sure that the cab locks on both sides are locked in their rear positions before
operating, and that the locks are secured with the lock pins.
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 Clean the area around each grease cup before greasing.
2 Lubricate all points with grease, see section F Technical data.
Wheel hub and wheel spindle

3 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.
4 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.
Grease point wheel hub
5 Grease the wheel spindle's upper and lower bearings.
NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.
6 Lower the wheel.

7 Repeat steps 3 - 7 on the left steering wheel.
Lubrication points wheel spindle

1. Upper lubrication point
2. Lower lubrication point

Link arms
8 Lubricate both link arms' outer and inner bearings with grease.
1 2
003587
Lubrication points link arm

1. Outer bearing
2. Inner bearing
Brake pedal
9 Lubricate the brake pedal's hinge with grease.
10 Wipe off excess grease.
Grease points brake pedal
Lubrication 1000 hours
1 Lower and run out the boom completely and run out spreading
completely.
2 Turn off the engine and turn off the system voltage.

3 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
Visually inspect all stub axles in connection with
lubrication. Damaged stub axles must be changed.
1 2
10
5
9 8 7 6
11
1
2
4
8
9
10
013882
5
8
Grease points, lubricating grease
1. Mounting lift boom (2 pcs.) 1. Brake pedal inside cab (2 pcs)

2. Mounting attachment (2 pcs.) 2. Wheel spindles (4 pc)
3. Bearing rotation yoke (4 pcs., two per side) 3. Wheel hubs (2 pc)
brushing of ring gear
4. Slide beam mounting side shift frame
4. Chain and chain wheel spreading
5. Link arms (4 pc)
5. Twistlocks (4 pc)
6. Joint steering axle
6. Universal joints (2 pc)

4 Brush slide surfaces on the boom and attachment with white

lubrication paste as shown on the diagrams below, see section
F Technical data.
NOTE
The upper slide surfaces in the outer boom should be lubricated
at the same time as the other slide surfaces.
013883
004875
5 Operate the boom and spreading in and out, and side shift
attachment max. right - left, a few times without a load.
IMPORTANT
Wipe off excess lubrication paste.

Checking for cracks
DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
boom and attachment.
DANGER
All of the machine's welds shall be checked according
to recommended interval. 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, the machine
should be taken out of operation immediately and
contact Cargotec Support.
2 Clean every weld carefully before inspection.
3 Check for damage and cracks in the areas with high stress
concentration, see Checkpoints, page C:20. 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 powder method is used to determine if there's a
crack or not, and where it is. See Magnetic powder method,
page C:19.
b. Confirmed cracks are investigated further with penetrating
fluid. See Checking cracks with penetrating fluid, page C:20.
Magnetic powder method

1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic powder and the following equipment:

• Equipment:Yoke Tiede
• Method:
a Alternating current AC
b Contrast colour
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder 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
any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
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
Checkpoints
1 Park the machine with attachment lowered as far down as possible
and spreading in the 40-foot position.
Steering axle mounts

2 Check the welding joints at the steering axle's mountings to the
frame for damage and signs of cracking.

Lift boom
3 Check the lift boom's surfaces and welding joints for damage and
signs of cracking.
Pay particular attention to the grey-marked areas in accordance
with the illustration.
4 Check the mountings to the frame and the lift cylinders with regard
to wear.
010489
Attachment
5 Check the attachment's surfaces and welding joints for damage
and signs of cracking.
010488

Frame
6 Check the frame's surfaces and welding joints for damage and
signs of cracking.
7 Check the mountings to the boom and the lift cylinders with regard
to wear.
8 If the event of signs of damage, please contact Cargotec Support
for further instructions.
DANGER
Risk of reduced strength.
FATAL DANGER!
Damage to frame, boom, and attachment must be
repaired in the correct way. Incorrect repairs reduce
the strength.
013026

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 DRT 450 is a "Reachstacker" for container handling. The
machine has a lift capacity of 45 tons.
It is powered by a six-cylinder, four-stroke diesel engine with direct

injection.
The transmission is hydromechanical with gears in constant mesh. It

has four forward gears and four reverse gears. The engine's power is
transmitted using a torque converter.
The power transmission consists of a propeller shaft and a rigid drive

axle with hub reduction. The machine has front-wheel drive.
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 type
disc brake 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 frame.
The wheels are fastened on the hubs using clamps. The drive axle has
twin wheels, the steering axle has single wheels.
Load handling consists of components and functions for handling loads.

Load is lifted with an attachment mounted on a telescopic boom with
lift function. Load handling is divided into the functions lift and lower,
extension, side shift, spreading, rotation, tilt, levelling, and load carrier.
• Lifting/lowering is the function for lifting and lowering the boom.
• Extension is the function to extend the boom in and out.
• Side shift is moving the lift attachment laterally in relation to the
machine.
• Spreading is used to adjust the width between the attachment's
lifting points.
• Rotation is rotating the load in relation to the machine.
• The load carriers are designed to hold a load securely.
The control system includes functions to warn the operator of

dangerous situations and machine problems. The control system has
diagnostic possibilities 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
there are tanks for fuel, hydraulic oil, and oil for the brake system. The
cab has a central location and can be moved fore-aft.

0:4

1:1
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.2 Fuel system....................................................................................................1:10
1.2.3 Fuel pre-filter ............................................................................................. 1:11
1.2.4 Fuel filter ...................................................................................................1:13
1.5 Engine's mechanical parts .............................................................................1:15
1.5.4 Valve mechanism ......................................................................................1:15
1.5.6 Crank mechanism .....................................................................................1:19
1.6 Air intake and exhaust outlet..........................................................................1:20
1.6.1 Air cleaning system ...................................................................................1:20
1.6.2 Turbo .........................................................................................................1:21
1.6.3 Exhaust system .........................................................................................1:23
1.6.4 Intercooler .................................................................................................1:23
1.7 Cooling system ..............................................................................................1:25
1.7.2 Coolant filter ..............................................................................................1:25
1.7.5 Cooling fan ................................................................................................1:27
1.7.7 Coolant ......................................................................................................1:29
1.8 Lubrication system .........................................................................................1:36
1.9 Control system engine ...................................................................................1:39
1.10 Ignition/heating...............................................................................................1:40
1.11 Start/stop........................................................................................................1:41

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 new engines provide considerable improvement, not
only for exhaust emissions but also for the power and torque curve.
The following engine alternatives are available:

• Yuchai YC6M360-30
• Cummins QSM11
Engine alternative Yuchai YC6M360-30,

function description
Yuchai YC6M360-30 is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.
rpm ˚C
kph
0 . bar
P I
II
III
1
8
3 13
D 7 9 0 -2 D 795
D 7 9 0 -1 D 7 9 7 -F D 7 9 7 -R
2 14 12
4
D 794 11
5
H 2O H 2O
S E N S O R S 7 M 6
014135
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 rear (D797-R)
6. Starter motor (M654) 13. Control unit KID (D795)
7. Electric components engine 14. Control unit, frame front (D797-F)

1:4 1 Engine – Engine
Engine alternative Cummins QSM11,

Cummins QSM11 is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.
0 . bar
P I
rp m
II kph
III
1
7
3 11
D 7 9 0 -2 D 795
D 7 9 0 -1 D 7 9 7 -R
2 10
12 D 794 4
9
H 2O
S E N S O R S 6 M 5
014172
8
1. Ignition (S150) 7. Accelerator pedal (B690)

2. Control unit cab (D790-1) 8. Make-contact (closing switch) coolant level (B759)
3. Control unit KIT (D790-2) 9. Sensor fuel level (B757)
4. Control unit engine (D794) 10. Control unit frame (D797-1)
5. Starter motor (M654) 11. Control unit KID (D795)
6. Electric components engine 12. Relay coolant level (K322)

Engine alternative Yuchai YC6M360-30,

component position
9
2
3
8
7
4
013904
Engine right side (in machine's direction of travel)
1. Connection exhaust system 6. Connection radiator
2. Turbo 7. Transmission oil cooler
3. Connection air cleaner 8. Radiator
4. Oil filter 9. Intercooler
5. Connection intercooler

5
4
2
6
1
7
10
11
12
013905
15 14 13
Engine left side (in machine's direction of travel)
1. Preheating coil (E8000) 8. Alternator
2. Relay, preheating (K312) 9. Coolant pump
3. Thermostat housing 10. Connection radiator outlet
4. Make-contact (closing switch), low coolant level 11. Control unit engine (D794)
(B759) 12. Fuel filter
5. Expansion tank 13. Fuel pump
6. Connection cab heat 14. Starter motor (M654)
7. Connection intercooler 15. Relay, starter motor (K360)

Engine alternative Cummins QSM11,

component position
1 2 3 4 5
18
7
17
16
8
9
10
11
12
13
14
15
014167
Engine alternative Cummins, right side (in the machine's direction of travel)
1. Expansion tank 11. Fuel filter
2. Connection intercooler (intake) 12. Drainage condensation water fuel filter and sensor
water in fuel
3. Place for compressor air conditioning unit
13. Fuel pump
4. Connection intercooler (outlet)
14. Sensor oil pressure and oil temperature
5. Fuel connection (intake)
15. Sensor crankshaft position
6. Fuel connection (outlet)
16. Transmission oil cooler
7. Control unit engine (D794)
17. Water cooler
8. Starter motor
18. Intercooler
9. Drain plug engine oil
10. Sensor fuel pressure

7
5
8
4
9
3
10
11
12
13
14
15
014166
19 18 17 16
Engine alternative Cummins, left side (in the machine's direction of travel)
1. Connection air cleaner 10. Connection intercooler (intake)
2. Turbo 11. Thermostat housing
3. Sensor induction air temperature 12. Intake, intercooler
4. Connection intercooler (outlet) 13. Alternator
5. Connection radiator (outlet) 14. Sensor coolant temperature
6. Expansion tank 15. Coolant pump
7. Make-contact (closing switch), low coolant level 16. Connection exhaust system
(B759) 17. Oil filter
8. Sensor boost pressure 18. Coolant filter
9. Connection cab heat 19. Shut-off valve coolant

Components on the machine, component

location
0
1 2 P I 3 4 5
II
III
13
6
12
9 8
10
014137
11
1. Accelerator pedal (B690) 9. Sensor fuel level (B757)
2. Ignition (S150) 10. Fuel tank
3. Control unit KIT (D790-2) 11. Control unit, frame front (D797-F)
4. Control unit KID (D795) 12. Sensor water in fuel (B760) (engine alternative
Yuchai YC6M360-30)
5. Control unit cab (D790-1)
13. Fuel pre-filter (engine alternative Yuchai
6. Control unit frame rear (D797-R)
YC6M360-30)
7. Diagnostic socket drivetrain
8. Diagnostic socket engine (X281) (engine alternative
Yuchai YC6M360-30)

1:10 1 Engine – Fuel system
1.2 Fuel system

Fuel system, description
For position of components see Engine alternative Yuchai
YC6M360-30, component position, page 1:5.
012926
1 2 3
1. Fuel filler orifice
2. Fuel tank
3. Sensor, fuel level (behind air filter)
Fuel system, bleeding air (engine alternative

Yuchai YC6M360-30)
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
neccessary.
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 Engine – Fuel pre-filter 1:11
Fuel system, bleeding air (engine alternative

Cummins QSM11 )
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 Make sure that the fuel filter is filled with fuel.
3 Bleed the fuel system by running the starter motor until the engine
starts.
4 Check sealing integrity.
1.2.3 Fuel pre-filter

Fuel pre-filter, draining condensation water (engine
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

1:12 1 Engine – Fuel pre-filter
Fuel pre-filter, changing (engine alternative Yuchai

YC6M360-30)
NOTE

3 Drain the fuel pre-filter 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.
014134
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.
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 Engine – Fuel filter 1:13
1.2.4 Fuel filter

Fuel filter, changing (engine alternative Yuchai
YC6M360-30)
NOTE
2 Place a container under the fuel filter.

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.

turn.
7 Wipe off the fuel filter and remove the collection container.
fuel filter seals tight.

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

QSM11 )
NOTE

2 Disconnect the wiring from the sensor for water in fuel.
4 Change the seal at the filter's thread connection on the filter
bracket and lubricate it with engine oil.
5 Fill the new fuel filter with clean fuel.
6 Lubricate the seal on the new fuel filter with engine oil.
7 Install the new fuel filter.
Tighten the fuel filter to contact and then an additional one-half to
three-quarter turn.
fuel filter seals tight.

1 Engine – Engine's mechanical parts 1:15
1.5 Engine's mechanical parts

1.5.4 Valve mechanism
Adjusting valves and injectors, preparations (engine
alternative Cummins QSM11 )
Valves and injectors must be adjusted when the engine is cold (coolant
temperature under 60 ºC).
2 Place the cab in the front position.
TEMPERATURE
60˚C
(140˚F)
009721
3 Disconnect the crankcase ventilation hose from the crankcase

ventilation outlet on the valve cover.
4 Remove the 16 bolts with washers that attach the valve cover in
the cylinder head.
5 Remove the valve cover and the valve cover gasket.
6 Rotate the engine on the auxiliary shaft so that the setting mark
on the belt pulley stands in line with one of the markings on the
casing behind the belt pulley.
WARNING
Do not pull on or bend the fan blades to rotate the
crankshaft.
The fan blades may be damaged which may lead to fan
failure, which in turn may result in personal injuries
009722
or product damage.
Use the accessory drive axle to pull the crankshaft
around.

1:16 1 Engine – Valve mechanism
7 The crankshaft rotates clockwise, if viewing the engine from the

front.
The firing order is cylinder no. 1-5-3-6-2-4.
NOTE
Cylinder number 1 is the cylinder nearest the cooling fan.
8 Every cylinder has three valve lifters:

• Valve lifter (position E) is for the outlet valves.
• The centre valve lifters are for the injectors.
• The short valve lifters (position I) are for the intake valves.
See adjoining diagram for position of valve lifters for intake and
outlet valves.
9 One valve pair and one injector are adjusted at each adjustment
mark. The pulley is then rotated to the next adjustment mark.
Two full turns on the crankshaft are required to adjust all valves
and injectors.
NOTE
Valves and injectors for the respective cylinders are adjusted at
the same mark on the pulley.
NOTE
Carefully read the example in the text before beginning the
adjustment procedure.
10
Adjustment position for adjustment of valves and injectors
Turn the engine Position of Adjust valves / injectors
around in the the pulley on cylinder no.
direction of rotation.
Start A 1 1
Move ahead to B 5 5
Move ahead to C 3 3
Move ahead to A 6 6
Move ahead to B 2 2
Move ahead to C 4 4
The firing order cylinder no.: 1-5-3-6-2-4.
Adjustment can be started at any of the settings marks for

adjusting valves/ injectors. In the following example, adjustment
is started at setting mark A with the valves on cylinder 1 closed
and ready for adjustment.

1 Engine – Valve mechanism 1:17
11 Turn the engine around clockwise until the adjustment mark A for
the adjustment of valves / injectors on the pulley are aligned in
front of the mark on the cover behind the pulley.
12 When setting mark A stands directly opposite the marking on the

casing behind the belt pulley, the inlet and exhaust valves for
cylinder 1 must be closed (if the valves are not closed the engine
has been rotated a whole revolution too much and instead the inlet
and exhaust valves for cylinder no. 6 are ready for adjustment).
Adjust injectors and valves on the cylinder so that rocker arms for
both inlet and exhaust valves are unloaded and can be moved
from side to side.
Injectors, adjusting (engine alternative Cummins

QSM11 )
1 Work through preparations for adjusting injectors, see Adjusting
valves and injectors, preparations (engine alternative Cummins
QSM11 ), page 1:15.
2 Loosen the lock nut for the injector's adjustment.

3 Use a screwdriver and the adjuster bolt and push the injector
plunger in the bottom position three or four times to remove all
fuel in the injector.
4 Unscrew the adjuster bolt 1/3 turn (two of the flat sides of the nut
or 120 degrees).
Secure the adjuster bolt and tighten the lock nut, tightening
torque 61 Nm (45 ft-lb).
5 If valves do not have to be adjusted, install the valve cover. See
Valve cover, installing (engine alternative Cummins QSM11 ),
page 1:19.
NOTE
Only screw in the adjuster bolt until you feel that the injector plunger
has just pushed down in its bottom position.
NOTE
Do not use excessive force when pushing the injector plunger in
the bottom.

1:18 1 Engine – Valve mechanism
Valves, adjusting (engine alternative Cummins QSM11

)
1 Work through preparations for adjusting valves, see Adjusting
valves and injectors, preparations (engine alternative Cummins
QSM11 ), page 1:15.
2 With adjustment mark A positioned aligned in front of the mark on

the cover behind the pulley and both valves closed for the cylinder
to be adjusted, loosen the adjuster bolt's lock nut for both the
intake and outlet valve.
3 Choose a feeler gauge with a thickness that corresponds with the

valve clearance to be adjusted.
Valve clearance tolerance

mm in
Intake valves 0,36 mm 0,014
Outlet valves 0,69 mm 0,027
4 Place the thickness gauge between the top side of the push
rod the valve lifter's seat. Use a torque wrench and tighten the
adjuster bolt. Tightening torque 0.7 Nm (6 in-lb).
5 After the lock nut has been tightened with the correct tightening
torque, check that that feeler gauge can be moved back and forth
between the top side of the push rod and the valve lifter's seat
with only a slight resistance.
6 If injectors do not have to be adjusted, install the valve cover. See
Valve cover, installing (engine alternative Cummins QSM11 ),
page 1:19.

1 Engine – Crank mechanism 1:19
Valve cover, installing (engine alternative Cummins

QSM11 )
1
NOTE
If the valve cover gasket is not damaged when removing, it
can be re-used after it has been cleaned. If the valve cover
gasket was damaged when removing, it must be replaced with
a new gasket.
Reinstall the valve cover gasket.
14 10 6 2 4 8 12 16 2 Mount the valve cover with the 16 insulators, the washers and
the bolts.
Tighten the bolts according to the numbering on the diagram.
Tighten the bolts with 9 Nm.
3 Connect the crankcase ventilation hose to the crankcase
ventilation's outlet on the valve cover.
4 After finished adjustment, return the cab to the rear position and
secure both sides of the cab with the lock devices.
014174
13 9 5 1 3 7 11 15
DANGER
The cab is heavy and the machine may never be moved
without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.
1.5.6 Crank mechanism

Viscous vibration damper, checking (engine
alternative Cummins QSM11 )
CAUTION
The silicone fluid in the vibration damper hardens after
a long period of use, which means that the vibration
damper stops working. A non-functioning vibration
damper can cause serious damage to the engine or
drive.
008038
The vibration damper is located on the crankshaft's belt pulley.

Viscous vibration dampers have a limited service life.
Check the vibration damper for fluid loss, dents/damage, and that it
rotates without run-out. Check the vibration damper's thickness for
deformations or that the damper's cover plate has lifted.
If any of the above defects exist, contact your local authorised

Cummins workshop to replace the vibration damper.

1:20 1 Engine – Air intake and exhaust outlet
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air filter, changing
1 2 3 4 5 2 Clean the outside of the air filter housing.

3 Remove the cap from the air filter housing.
4 Remove the filter cartridge.
001357
1. Intake hose
2. Filter indicator
3. Air cleaner
4. Inlet
5. Dust reservoir
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.
10 Reset the indicator.

1 Engine – Turbo 1:21
1.6.2 Turbo
Turbo, checking (engine alternative Yuchai
YC6M360-30)
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 Return the cab to the rear position and secure both sides of the
cab with the lock devices.
DANGER

1:22 1 Engine – Turbo
Turbo, checking (engine option Cummins QSM11 )

3 Check tightening torque for the turbo's mounting bolts. Tighten

the bolts to 61 Nm.
009719
4 Check the turbo housing's sealing face on the exhaust side. If

leakage is discovered, tighten the bolt on the clamp (V-band).
Tighten the bolt with 9 Nm.
009718
5 Check the turbo housing's sealing face on the inlet side. If leakage
is discovered, tighten the bolt on the clamp (V-band). Tighten
the bolt with 9 Nm.
DANGER
009720


1 Engine – Exhaust system 1:23
1.6.3 Exhaust system
Exhaust system, checking
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, or muffler when the
machine is in operation or has recently been turned off!
2 Check the exhaust system's sealing and other wear.
3 Check that the exhaust system suspension is intact.
1.6.4 Intercooler
Intercooler, checking
3 Clean the intercooler with compressed air.
NOTE
Do not use high pressure wash.
4 Check that the intercooler suspension is intact.
5 Check the sealing and check that the intercooler's hoses and
clamps are in good condition.
DANGER

1:24 1 Engine – Intercooler
Charge-air pipe, checking (engine option Cummins

QSM11 )
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
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 1:25
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.
For position of components see:

• Engine alternative Yuchai YC6M360-30, component position,
page 1:5
• Engine alternative Cummins QSM11, component position ,

page 1:7
1.7.2 Coolant filter

Coolant filter, changing (engine alternative Cummins
QSM11 )
NOTE
Close the shut-off valve before loosening the filter. Coolant may run
out and cause environmental damage.

3 Close the shut-off valve on the filter holder.
4 Clean the area around the coolant filter.
5 Place a receptacle under the coolant filter.
6 Remove the coolant filter with the filter removal tool.
7 Lubricate the O-ring on the filter insert with engine oil.
8 Install the new filter.
turn.
9 Open the shut-off valve on the filter holder.
NOTE
Do not forget to open the valve after replacement. The coolant
does not pass through the filter and therefore it is not cleaned.
10 Turn on the system voltage and start the engine.

11 Check that the coolant filter seals tightly.
Filter left side, engine alternative Cummins
12 Remove the container. Handle the coolant as environmentally
1. Shut-off valve coolant hazardous waste.
2. Coolant filter 13 Place the cab in the front position.
3. Oil filter

1:26 1 Engine – Coolant filter
14 Check the coolant level in the expansion tank, fill if necessary.

1
2 cab with the lock devices.
3
DANGER
013827
1. Sight glass, checking level

2. Filling point
3. Coolant reservoir (expansion tank)

1 Engine – Cooling fan 1:27
1.7.5 Cooling fan

Drive belt, checking (engine alternative Yuchai
YC6M360-30)
1 Warm up the machine. Check after operating when the belts are
warm.
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.
It should be possible to press down the belts approx. 3-4 mm
between the belt pulleys.
NOTE
The belt tensioners are automatic.
DANGER
008011

1:28 1 Engine – Cooling fan
Drive belt, checking (engine alternative Cummins

QSM11 )
1 Warm up the machine. Check after operating when the belts are
warm.
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.
It should be possible to press down the belts approx. 3-4 mm
between the belt pulleys.
NOTE
The belt tensioners are automatic.
DANGER
008011

1 Engine – Coolant 1:29
Fan hub, checking (engine alternative Cummins

QSM11 )
3 Remove drive belt, see Drive belt, checking (engine alternative
Cummins QSM11 ), page 1:28. Check the fan hub, replace if
necessary.
NOTE
The fan hub must rotate without wobbling or excessive length
clearance.
008019
DANGER
1.7.7 Coolant
Coolant level, check
WARNING
The cooling system is pressurized. 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.
Coolant should be filled in the system's expansion tank (position 3).

The fluid level should be over the sight glass (position 1) on the
expansion tank.
NOTE
Open very carefully as hot coolant may jet up.
If the coolant level becomes too low, the warning lamp for low coolant
level lights up on the instrument panel.
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.

1:30 1 Engine – Coolant
3 If needed, top up with ready-mixed recommended coolant. For

1 volume and quality, see section F F Technical data.
2
3 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.
DANGER
013827

1. Sight glass, checking level Fatal danger! Risk of crushing!
2. Filling point Secure both sides of the cab with lock devices and
3. Coolant reservoir (expansion tank) pins before starting to operate.
Coolant quality, checking (engine alternative

Cummins QSM11 )
WARNING
The cooling system is pressurized. 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.


1
2
3 Check the coolant's quality with test equipment for coolant,
3 "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.
4 Change the coolant if the test equipment indicates poor coolant

quality, see Coolant, changing (engine alternative Cummins
QSM11 ), page 1:34.
013827
DANGER
2. Filling point The cab is heavy and the machine may never be moved
3. Coolant reservoir (expansion tank) without secured cab.
Coolant, changing (engine alternative Yuchai

YC6M360-30)
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
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.
6 Open the drain valve on the engine.

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

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

1 tank. For volume and quality, see section F F Technical data.
2
3 CAUTION

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. Do not operate the machine.
DANGER
013827

2. Filling point
12 Check the level in the expansion tank, fill if necessary.

DANGER
14 Check the coolant level again after 10 operating hours.

Coolant, changing (engine alternative Cummins

QSM11 )
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
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.
6 Open the drain valve on the engine.

7 When all the coolant has run out, close the drain taps.
1. Shut-off valve coolant

2. Coolant filter
3. Oil filter

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

1 tank. For volume and grade, see section F Technical data.
2
3 CAUTION

10 Turn on max. heat in the cab.
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.
013827
2. Filling point
DANGER

14 Check the coolant level again after 10 operating hours.

1:36 1 Engine – Lubrication system
1.8 Lubrication system

Lubrication system, description
The engine's lubrication system is completely closed and has no
connections to the machine.
For position of components see:

page 1:5

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

Yuchai YC6M360-30)
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1 Run the engine until warm.
3 Remove the drain plug from the engine and drain the engine of oil.
4 Remove the oil filters.

5 Install new oil filters.
Lube the O-rings on the filters with engine oil and install according
to instructions on the filter.
6 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.
7 Fill engine oil. For volume and quality, see section F Technical
data.
8 Start the engine, let it idle.
9 Turn off the engine and check the oil level, see Oil level, check,
page 1:38. Top up as needed.

1 Engine – Lubrication system 1:37
Oil and oil filters, changing (engine alternative

Cummins QSM11 )
NOTE
Safety.
1 Run the engine until warm.
3 Remove the drain plug from the engine and drain the engine of oil.
4 Remove the oil filter.

5 Fill the new filter with new engine oil and lubricate the O-ring on
the filter with engine oil.
6 Install the new oil filter.
Tighten the filter according to the instructions on the filter.
7 When the oil has drained, install the oil plug and torque-tighten
with 88 Nm.
8 Fill engine oil. For volume and quality, see section F Technical
data.
9 Start the engine, let it idle.
10 Turn off the engine and check the oil level, see Oil level, check,
page 1:38. Top up as needed.
Oil filter left side, engine alternative Cummins QSM11

1. Shut-off valve coolant
2. Coolant filter
3. Oil filter

1:38 1 Engine – Lubrication system
Oil level, check
NOTE
Safety.
Engine oil, general

The engine oil filling pipe (position B) and dipstick (position C) are
under the service hatch in front of the cab.
C 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.
B
NOTE
The oil dipstick is long. Wear gloves.
3 Fill engine oil (position B) if needed (for volume and grade, see
A section F Technical data).
4 Fill – wait awhile – check on the oil dipstick.
NOTE
013822
Work carefully when filling to prevent other fluids or particles

from contaminating the oil, which means risk of engine damage.
A Location of filler point and level check
B Filling point
C Dipstick

1 Engine – Control system engine 1:39
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.

1:40 1 Engine – Ignition/heating
1.10 Ignition/heating
Ignition/heating, description (engine alternative
Yuchai YC6M360-30)
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 Engine alternative Yuchai

YC6M360-30, component position, page 1:5
Ignition/heating, description (engine alternative

Cummins QSM11 )
The engine features preheating of the induction air, for faster start
at low temperatures. Preheating is activated by Control unit engine
(D794) as needed.
For position of components see, see Engine alternative Cummins

QSM11, component position , page 1:7.

1 Engine – Start/stop 1:41
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). Starter motor and stop device are controlled by Control unit
engine (D794).
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:

page 1:5

page 1:7

1:42

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 four

forward gears and four 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 pressurizing 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 21
D 7 9 0 -2 D 795
D 7 9 0 -1 D 7 9 7 -F
6 20
7 D 793 D 794 22
13 14 15
19
17 12 18
11
16 10
9
013845
8
1. Multi-function lever (S162) 12. Solenoid valve clutch forward (Y630)

2. Shifting program selector on Control unit KIT (D790-2) 13. Sensor oil pressure transmission (B765)
3. Control unit KIT (D790-2) 14. Sensor turbine speed (B751)
4. Accelerator pedal (B690) 15. Sensor oil temperature (B766)
5. Declutch pedal (S220-1) 16. Oil pump transmission
6. Control unit cab (D790-1) 17. Oil filter transmission
7. Control unit, transmission (D793) 18. Oil cooler
8. Solenoid valve clutch reverse (Y631) 19. Control unit engine (D794)
9. Solenoid valve clutch 1st gear (Y6067-1) 20. Make-contact declutch (S220-2)
10. Solenoid valve clutch 2nd gear (Y6069) 21. Control unit, frame front (D797-F)
11. Solenoid valve clutch 3rd gear (Y6067-3) 22. Control unit KID (D795)

2 Transmission – Transmission 2:5
Transmission, component position
3
2 4
1 6
7
8
9
10
15 14
16 11
17
013906
18
13 12
1. Oil pump transmission 10. Solenoid valve clutch 1st gear (Y6067-1)
2. Power take-off 11. Solenoid valve clutch reverse (Y631)
3. Sensor oil pressure transmission (B765) 12. Drain plug transmission oil
4. Transmission oil cooler 13. Valve block transmission control
5. Thermostat 14. Torque converter
6. Transmission 15. Oil filter transmission
7. Solenoid valve clutch forward (Y630) 16. Sensor oil temperature (B766)
8. Solenoid valve clutch 3rd gear (Y6067-3) 17. Sensor turbine speed (B751)
9. Solenoid valve clutch 2nd gear (Y6069) 18. Output shaft

2:6 2 Transmission – Torque converter/Clutch system
1 2 3 4 5
11
10
9
7
013847
8
1. Accelerator pedal (B690) 7. Control unit frame rear (D797-R)

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 front (D797-F)
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.
1. Breather filter, on top of torque converter.

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 pressurizing 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 four 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 at the bottom 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
KID (D795) and performance is reduced, if the oil temperature goes
above 125 ºC the transmission declutches.
page 2:5.
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 for transmission oil and let the oil drain
into the receptacle.
Draining transmission oil
4 Change oil filter.

Lubricate the O-ring on the new oil filters with transmission oil.
Tighten to contact and then another two-thirds turn.
5 When the transmission oil has drained, fit the drain plug.
Make sure that the washer for the oil plug is included.
013846
Oil filter transmission

2 Transmission – Lubrication system 2:9
6 Fill new transmission oil through the oil filler point (position B) to
the marking for low level on the oil dipstick.
C
For volume and quality, see section F F Technical data.
7 Start the engine and let the engine run at idle for at least two
minutes.
B 8 Check that the drain plug for transmission oil seals tightly.
9 Check the transmission oil level with the engine running at idle and
top up to the marking for low level.
013823
A. Position of oil filler point and oil dipstick

B. Oil filler point transmission oil
C. Oil dipstick transmission oil
10 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
11 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

2:10 2 Transmission – Lubrication system
Oil level, check
NOTE
Safety.
The transmission's oil filler pipe and oil dipstick (position C) are located
under the service hatch in front of the cab.
1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 85 ºC on the
C display). The oil dipstick has two markings, MAX and MIN, the oil
level should be at MAX.
Wipe off the dipstick before checking.
B NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if needed (for volume and grade,

see section F Technical data).
A
Fill – wait awhile – check on the oil dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
013823
fluids or particles from contaminating the oil, which means risk

of transmission damage.
A. Position of oil filler point and oil dipstick
B. Oil filler point transmission oil
C. Oil dipstick 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.
Propeller shaft, checking

• After 50h:
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission with 156 Nm.
• 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 with 156 Nm.

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 2 4 3 1
013141
1. Hub reduction
2. Drive shaft (internal)
3. Differential (internal)
4. Drive axle housing

3 Driveline/Axle – Drive axle 3:5
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 2820 Nm.

3 Check-tighten the wheel nuts with a torque of 400 Nm.
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.
Attaching bolts drive axle
Drive axle oil, changing
NOTE
Safety.
1 Position the machine so that the drain plugs on the hubs are
lowest vertically. This applies to both drive wheels.
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (raise the machine under
the drive axle by the wheel) and rotate it to correct position.
3 Remove the drain plugs in the wheel hubs (position 1) on both

1 2 sides. Also remove the level and filler plugs (position 2) to facilitate
draining.
Both sides shall be drained separately.
000592
Wheel hub, drive axle

1. Drain plug
2. Level and filler plug

3:6 3 Driveline/Axle – Drive axle
4 Remove the drain plug in the differential (position 3) (at bottom of

drive axle). Also remove the level and filler plug (position 2) to
facilitate draining.
5 Clean the drive axle's breather (position 1) while the oil is draining.
6 Fit the drain plugs.
7 Fill oil in the hubs until the oil level is flush with the level and
filler holes (position 2). For volume and quality, see section F F
Technical data.
NOTE
Differential drive axle The oil is very viscous, fill the oil slowly. Check the level in
1. Bleeding the drive axle (inside frame) stages so that the oil has time to settle.
2. Level and filler plug
8 Install the level and filler plugs on both hubs.
3. Drain plug
9 Fill oil in the differential until the oil level is flush with the level and
filler hole (position 2).
10 Install the level and filler plug on the differential.
11 Turn on the system voltage.
12 Check the oil level in the differential and hubs after a short
test-drive.

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
4.3.1 Brake oil pump ............................................................................................4:7
4.3.4 Accumulator ................................................................................................4:8
4.5 Parking brake system ......................................................................................4:9
4.5.4 Parking brake unit .....................................................................................4:10
4.8 Temperature control, cleaning and oil brake system......................................4:12
4.8.11 Breather filter.............................................................................................4:13
4.8.12 Brake oil filter ............................................................................................4:14
4.8.14 Oil for brake system ..................................................................................4:15

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 three functions:

• Power-assisted brake system, function description, page 4:4
• Parking brake system, function description, page 4:9
• Temperature control, cleaning and oil brake system, function
description, page 4:12
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 brake oil tank, brake oil
pump, brake oil filter, accumulator charging valve, accumulators, brake
valve, pressure sensors, brake cylinder and wheel brake units.
The brake oil pump pumps oil (from the tank) which is cleaned in
the oil filter. The accumulator charging valve directs pressure to the
accumulators that store the pressure or direct the oil through the wheel
brake for cooling of the brake discs. The brake valve directs pressure
from the accumulators to the brake cylinder. The brake cylinder
compresses the discs in the brake units that brake the machine.
Make-contact (closing switch) gives signal so that the brake light is
turned on when the brake cylinder is pressurized.
When the accumulators are charged, the accumulator charging valve

directs oil through the drive axle's brake units and cools the brakes. The
oil passes through the cooler back to the tank. An electric cooling fan
increases the air flow through the cooler when the temperature needs
to be reduced. A thermal bypass valve leads the hydraulic oil past
the cooler if the oil's temperature is too low. The temperature sensor
controls activation of the fan and temperature warning in the display.

4 Brakes – Power-assisted brake system 4:5
5
B
P
13 T
D790-2
D
D797-R D797-F
11 10 8 C
Pa
12
C D
D
9
4
Pa 3 7
B
ACC 6
C
P
012931
1. Brake oil pump 8. Make-contact brake lights (S216)
2. Brake oil filter 9. Break-contact brake oil pressure (S204)
3. Accumulator charging valve 10. Control unit, frame front (D797-F)
4. Accumulators 11. Control unit frame rear (D797-R)
5. Brake valve 12. Brake lights (H411L & H411R)
6. Brake cylinders 13. Control unit KIT (D 790-2) Warning lamp brake
7. Wheel brakes pressure

4:6 4 Brakes – Power-assisted brake system
Power-assisted brake system, component

position
2 3 4
1
6
8 7
1. Brake valve 5. Make-contact brake lights (S216) 004893
2. Brake oil pump 6. Wheel brake

3. Break-contact brake oil pressure (S204) 7. Accumulators brake system
4. Accumulator charging valve 8. Brake oil filter

4 Brakes – Brake oil pump 4:7
4.3.1 Brake oil pump

Brake oil pump, checking
NOTE
Safety.
Checking pump pressure

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

Safety.
4 Connect a pressure gauge (0–25 MPa) to the test outlet for pump
pressure on the accumulator charging valve.
5 Start the engine and let it idle.
Pressure check connection pump pressure
6 Close the drain valve on the accumulator charging valve and

check the pump pressure during charging.
During charging the pressure should increase to 22 MPa before
the accumulator charging valve switches to cooling. The pressure
drops when the accumulator charging valve switches to cooling.
7 Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8 Turn off the engine.
Safety.
10 Remove the pressure gauge and fit the protective cap on the
Close the accumulator charging valve
pressure check connection.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
Checking accumulator charging

Safety.

4:8 4 Brakes – Accumulator
13 Connect a pressure gauge (0–25 MPa) to the pressure check

connection for accumulator pressure on the accumulator charging
valve.
Pressure check connection accumulator pressure

16 Check that the pressure rises slowly to 20.5±1.0 MPa.
17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve shall switch to cooling at 15.5±0.5 MPa.
18 Depressurize the brake and hydraulic systems, see section B
Safety.
Close the accumulator charging valve NOTE

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

Parking brake system, function description
The parking brake consists of brake oil tank, brake oil pump, brake
oil filter, accumulator charging valve, pressure sensors and parking
brake unit.
the oil filter. The accumulator charging valve directs pressure to
the accumulators that store the pressure. The parking brake unit is
released with pressure from the accumulators by the parking brake
valve in the accumulator charging valve pressurizing the parking brake
caliper. Break contact (opening switch) parking brake gives signal so
that indicator light parking brake is turned on when the parking brake
is applied.
D 12
5
6 11
D790-1 D790-2
D797-F
7
4 C D D
8
C 9
ACC Pa 10
3
H
P
T
2
P
012932
1. Brake oil pump 7. Control unit, frame front (D797-F)
2. Brake oil filter 8. Solenoid valve, parking brake (Y642)
3. Accumulator charging valve 9. Brake caliper
4. Accumulators 10. Break-contact parking brake (S200)
5. Switch parking brake (S107) 11. Control unit KIT (D790-2)
6. Control unit cab (D790-1) 12. Indicator light parking brake (508)

4:10 4 Brakes – Parking brake unit
Parking brake system, component position
3 4
5
6
013819
1. Brake oil pump 4. Solenoid valve, parking brake (Y642)
2. Accumulator charging valve 5. Parking brake unit
3. Break-contact parking brake (S200) 6. Brake oil filter
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.

4 Brakes – Parking brake unit 4:11
5 Remove the cover from the brake caliper.
6 Loosen the lock nut.

7 Adjust the adjustment screw so that the brakes are applied.
8 Turn the adjuster bolt back 3/4 turn.
9 Tighten the lock nut.
NOTE
To avoid turning the adjustment screw as well, it must be held
still when tightening the lock nut.
10 Refit the cover on the caliper.

11 Check the function of the parking brake.

4:12 4 Brakes – Temperature control, cleaning and oil brake system
4.8 Temperature control, cleaning

and oil brake system
Temperature control, cleaning and oil brake
system, function description
The brake system is cooled with oil that is circulated through a cooler.
The cooler has a temperature-controlled electric fan that counteracts
overheating.
Temperature control consists of brake oil tank, brake oil pump, brake
oil filter, accumulator charging valve, wheel brake units, cooler, cooling
fan, sensor brake oil temperature and thermal bypass valve.
the oil filter. When the accumulators are charged, the accumulator
charging valve directs oil through the drive axle's brake units and cools
the brakes. The oil passes through the cooler back to the tank. An
electric cooling fan increases the air flow through the cooler when the
temperature needs to be reduced. A thermal bypass valve leads the
hydraulic oil past the cooler if the oil's temperature is too low. The
temperature sensor controls activation of the fan and temperature
warning in the display.
If the temperature in the brake system becomes too high, the machine's
speed is limited to protect the brakes.
11
D795
D797-F
D 9
D
C C
3
P 4
2 T
5
6 10
1 M
7
˚C
004274
8 ˚C
1. Brake oil pump 7. Thermal bypass valve

2. Brake oil filter 8. Temperature sensor (B762)
3. Accumulator charging valve 9. Control unit, frame front (D797-F)
4. Wheel brakes cooling 10. Cooling fan (M674)
5. Bypass valve in distribution block 11. Control unit KID (D795)
6. Cooler brake system

4 Brakes – Breather filter 4:13
Temperature control, cleaning and oil brake

system, control system
1 2 3
7 6
013418
1. Brake oil filter 5. Thermal bypass valve (in tank)
2. Brake oil tank 6. Oil cooler
3. Breather filter 7. Cooling fan (M674)
4. Sensor brake oil temperature (B762)
Brake oil pump, Accumulator charging valve, Drive axle
block, Wheel brake
See Power-assisted brake system, component position, page 4:6.
Breather filter, changing

1 Clean the area around the brake tank's breather filter.
2 Remove the cover from the filter holder.

Remove the bolt in the centre and lift away the cover.
3 Remove the old filter insert.
4 Clean the filter holder.
NOTE
Work carefully so that contaminants do not enter the tank.
5 Fit a new filter insert.

6 Refit the cover onto the filter holder.
1. Filling oil brake system

2. Breather filter, brake oil tank

4:14 4 Brakes – Brake oil filter
4.8.12 Brake oil filter
Brake oil filter, changing
NOTE
Safety.
IMPORTANT
The filter protects the brake system from impurities. It
is very important that new impurities do not enter the
brake system when changing filter.
2 Depressurise the hydraulic and brake systems, see section B

Safety.
NOTE
Leave the valves open when changing.
3 Remove the drain plug on the underside of the filter.

Let the oil drain. Wait a while since the oil drains slowly.
4 Remove the filter holder.
NOTE
The filter holder is heavy, loosen it carefully.
5 Remove the filter cartridge.
NOTE
Note the position of the O-rings.
6 Clean the filter holder.

7 Install the O-rings on the filter insert and filter holder. Lube the
O-rings with oil for the brake system.
8 Fit the new filter insert to the filter bracket.
9 Fit the filter holder and the drain plug.
10 Close the valves that were opened to drain the pressure in the
hydraulic system.
11 Start the engine and check that the filter holder does not leak.
000018

4 Brakes – Oil for brake system 4:15
4.8.14 Oil for brake system
Brake system oil, changing
NOTE
Safety.

Safety.
3 Remove the filler cap and drain the brake oil tank.
4 Remove the drain plug and let the last of the oil drain into a
receptacle.
5 Fit the drain plug, use a new sealing washer.
6 Fill oil brake system until the oil level is in the middle of the level
glass. For volume and quality, see section F Technical data.
7 Fit the filler cap.
1. Filling oil brake system

2. Breather filter, brake oil tank

4:16

5:1
5 Steering
Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.2 Power assisted system ....................................................................................5:3

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 pumps.
Steering consists of steering wheel, steering wheel shaft, steering

valve, hydraulic oil pumps, valve block servo pressure, priority valve,
steering cylinder, link arms, and wheel spindles.
The steering wheel acts on (via the steering shaft) the steering valve
which in turn directs oil pressure from the hydraulic oil pumps to the
steering cylinder. The priority valve, located between the hydraulic oil
pumps and the steering valve, gives priority to oil supply of the steering
valve before other functions, e.g., load handling. The steering cylinder
acts on the wheel spindles. The link arms are located between the
steering cylinder and wheel spindles. Valve block servo pressure
handles control signals to the hydraulic oil pumps.
LS P 1 A T H
LS P 2 LS P R
LS P 3 LS H Y
LS P 3X P T T P LS M
8
LS
4
LS P P
6
P
P
C F T
T L R
3 3
C C
7
1 2
013833
1. Hydraulic oil pump 3 5. Steering wheel

2. Hydraulic oil pump 4 6. Steering valve
3. Non-return valve 7. Steering cylinder
4. Priority valve 8. Valve block servo pressure

5:4 5 Steering – Power assisted system
Power assisted system, component position
1 2 3
013844
1. Pump working hydraulics 3 4. Valve block servo pressure
2. Pump working hydraulics 4 5. Priority valve
3. Steering valve 6. Steering axle

6:1
6 Suspension
Contents 6 Suspension
6 Suspension .........................................................................................................6:3
6.2 Suspension ......................................................................................................6:3
6.2.1 Steering axle cradle ....................................................................................6:4
6.2.2 Wheel spindle..............................................................................................6:5
6.2.3 Wheel hub ...................................................................................................6:5
6.3 Tyres and rims .................................................................................................6:7
6.3.1 Tyres .........................................................................................................6:15
6.3.2 Rim ............................................................................................................6:16

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 power transmission, see section 3 Power transmission, group
3.3 Drive axle.
6.2 Suspension
Suspension, description
Suspension refers to:
1 2 3 4 5 6 7
• Steering axle cradle
• Wheel spindle
• Wheel hub
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 journaled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journaled wheel hubs
where the wheels are mounted.
012947

6:4 6 Suspension – Steering axle cradle
6.2.1 Steering axle cradle
Steering axle cradle, checking
1 Check that the bushings in the suspension are intact.
The figure shows rear mounting
2 Measure the distance between the frame and the steering axle
cradle. Note the measurement.
3 Lift the machine under the rear counterweight.
NOTE
Do not lift under the steering axle.
NOTE
The rear mounting is flexible, make sure that the joint's
movement is blocked when measuring.
007842
4 Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
The figure shows front mounting 5 Calculate the difference between the two measurements. The
difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.

6 Suspension – Wheel spindle 6:5
6.2.2 Wheel spindle

Wheel spindle bearing, checking
2 Push the O-ring up carefully.

3 Measure with feeler gauge between axial bearing and axial
washer. Max. clearance: 1.5 mm.
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.
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.

6:6 6 Suspension – Wheel hub
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 Suspension – Tyres and rims 6:7
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 must 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.

6:8 6 Suspension – Tyres and rims
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 the tyre wear is abnormal, this may be
indicative of mechanical problems. Take action
immediately to repair any defects 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 tyres on the drive axle have uniform wear
and correct air pressure.

Tyres and rims, check

Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.
DANGER
inflating! Lock ring and lock lugs may release and
The air must 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 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.
012021
1. Lock ring
2. Rim flange
3. Rim bead seat taper
2 Check the air pressure in the tyres, see section Tyres, inflating,
page 6:15.
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 6:16.
4 If the tyres and rims have no defects, check-tighten the wheel nuts.
Torque-tighten crosswise with 400 Nm (oiled bolt).
012827
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.
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 with max. Ø 5 mm.
005123
4 Loosen the wheel nuts.
5 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
005124
6 Remove the nuts, washers and clamps.

7 Remove the spacer ring.
Pull the wheel out a bit so that the spacer ring comes loose.
NOTE
The spacer ring is heavy.
8 Lift the wheel away and position it safely so that it does not fall or
move.

9 Secure the inner drive wheel with lifting equipment.

10 Remove the spacer ring between the outer and inner wheels.
NOTE
The spacer ring is heavy.
11 Remove the inner drive wheel and position it safely so that it does
not fall or move.
Installing
12 Fit the inner drive wheel. Turn the wheel so that the guide lug
enters the groove on the hub.
13 Fit the inner spacer ring.
NOTE
The inner spacer ring is not split.
14 Install the outer drive wheel. Turn the wheel so that the guide lug
enters the groove on the hub.
15 Fit the outer spacer ring.
NOTE
The outer spacer ring is spit. Turn the ring so that the opening
ends up directly opposite the groove on the hub.
16 Install clamps and wheel nuts. Tighten the wheel nuts crosswise
in turn with increasing torque:
• 400 Nm (oiled screw).
NOTE
Don not forget the bracket for the inner tyre's valve extender.
17 Inflate the tyres, see Tyres, inflating, page 6:15.

18 Lower the machine and remove the jack.
19 Test-drive the machine and check that the wheels are secure.
20 Check-tighten the wheel nuts crosswise to a torque of:
• 400 Nm (oiled screw).

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.
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 with 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 wheel nuts and clamps.
6 Remove the wheel and position it safely so that it does not fall or
move.
005124
Installing
7 Fit the wheel.
8 Install clamps and wheel nuts. Tighten the wheel nuts crosswise
successively with increasing torque to 400 Nm oiled screw.
9 Inflate the tyre, see Tyres, inflating, page 6:15.
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 400 Nm.
000383

6 Suspension – Tyres 6:15
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.
Wheels shall be inflated on the machine or in a
012827
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.
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 Move to the side and stay to the side of the tyre while inflation
is in progress.
4 Inflate the tyre to prescribed pressure, see specifications.

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

6:16 6 Suspension – Rim
Tyre, change
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre company.
The wheel rims must be checked when tyres are changed. See 6
Suspension, group 6.3.2 Rims.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimize 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.
Overdimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
1 Dismantle the rim, see Tyre, change, page 6:16.
2 Carefully clean the outside of the rim edge with a steel brush.
001703
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.
Max 0,5 mm
001715

6 Suspension – Rim 6:17
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
O Information about min. diameter can be obtained from Cargotec.
013854
O. Circumference
D. Diameter
5 Check for damage in the areas with high stress concentration.

Checking is done in two steps:
1. The magnetic powder 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 powder method

1 Blast clean the marked area around the entire rim so that it is
completely clean from all paint.
2 Test using magnetic powder and the following equipment:
001703
• Equipment:Yoke Tiede
• Method:
a. Alternating current AC
b. Contrast colour
• Checking medium:
a. Wet
b. Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,
checking is finished and the rim 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.
001704
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.

6:18 6 Suspension – Rim
6 Visually inspect the lock ring groove.

1 2
If the tested area does not indicate linear or point-shaped cracks
in the lock ring groove the rim is approved.
If the crack check indicates linear or point-shaped cracks the rim
should be discarded.
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
7.2.2 Servo filter ...................................................................................................7:7
7.2.3 Pressure reducer.........................................................................................7:9
7.3 Extension .......................................................................................................7:10
7.3.10 Lift boom ...................................................................................................7:13
7.4 Side shift ........................................................................................................7:14
7.4.6 Side shift frame .........................................................................................7:16
7.4.7 Main beam attachment..............................................................................7:17
7.5 Spreading.......................................................................................................7:18
7.5.6 Spreading motor........................................................................................7:22
7.5.7 Spreading chains ......................................................................................7:23
7.5.8 Spreader beam .........................................................................................7:24
7.6 Rotation..........................................................................................................7:26
7.6.6 Rotation motor unit ....................................................................................7:28
7.8 Levelling.........................................................................................................7:29
7.9 Load carrier....................................................................................................7:30
7.9.1 Twistlocks ..................................................................................................7:30
7.10 Other functions...............................................................................................7:38
7.10.2 Weight indicator.........................................................................................7:38
7.10.3 Container counter......................................................................................7:42
7.10.4 Synchronised lift ........................................................................................7:43

7:2

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The function load handling refers to, e.g. to lift, lower, rotate, angle
or hold loads.
Load handling is divided into different sub-functions.

• Lifting/lowering
012739
• Extension
Lifting/lowering • Side shift

• Spreading
• Rotation
• Load carrying (twistlocks)
012740
Load handling is primarily controlled with the control lever while

certain functions have separate switches.
Extension
012741
Side shift
012742
Spreading
012743
Rotation
012745
Load carrying (twistlocks)

7:4 7 Load handling – Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, function description
Lift and lower means to angle the boom up and down so that the
attachment is lifted and lowered. The lift boom is angled by two
lift cylinders that are pressurized by Control valve lift, lower and
extension. The lift function is controlled with the control lever (S815).
012739
Damping
Damping means that the speed of functions is reduced automatically

close to end-positions. 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.
Regeneration
Regeneration
1 2
To increase speed when lifting, oil from the rod side (2) is re-used
for the piston side (1), this is called regeneration. Engagement of
regeneration is controlled by the control system.
000455
Condition Reference value

Control switch Not activated
Twistlocks Locked or unlocked, not intermediate position
Overload system Boom up: passive
Boom down: passive or bypass activated
Contact Boom down: no alignment

7 Load handling – Lifting/lowering 7:5
1
D
2 24
D790-1 D797-R
23
D797-F D794
3
D D
4 4 D 17 18
14
P S S P S L
20
P S A 1 VA C -M
P a 22
B 1 T
P C -
P C +
LS
13 5 C +M P a
6 21
E F C F 19
LS P 1 A T H
15 P
LS P 2 LS P R
C
LS P 3 LS H Y
16
7
12 C
C 12 12 C
12
C
013834
8 9 10 11
1. Control lever (S815-P1) 16. Pressure limiting valve

2. Control unit cab (D790-1) 17. Servo valve blocking right (Y6001) and Servo valve
blocking left (Y6002)
3. Control unit, frame front (D797-F)
18. Solenoid valve regeneration right (Y6051) and
4. Servo valve lift (Y6005) or Servo valve lower (Y6004)
Solenoid valve regeneration left (Y6052)
5. Control valve lift, lower and extension
19. Valve block, lift cylinder
6. Solenoid valve pump shut-off boom in (Y6062)
20. Sensor, hydraulic pressure lift cylinder, rod side, left
7. Valve block servo pressure (B768-L2) and Sensor, hydraulic pressure lift cylinder,
rod side, right (B768-R2)
8. Hydraulic oil pump 1
21. Sensor, hydraulic pressure lift cylinder, piston side,
left (B768-L1) and Sensor, hydraulic pressure lift
10. Hydraulic oil pump 3 cylinder, piston side, right (B768-R1)
11. Hydraulic oil pump 4 22. Lift cylinder
12. Non-return valve 23. Sensor boom angle (B771)
13. Accumulator 24. Control unit frame rear (D797-R)
14. Servo filter
15. Priority valve

7:6 7 Load handling – Lifting/lowering
Lifting/lowering, component position
1 2 3 4
5 6
20
19
18
9 8
15 14
17 16 10
11 13
013851
12
1. Control unit frame rear (D797-R) 13. Servo valve lift (Y6004)
2. Control unit cab (D790-1) 14. Servo filter
3. Control lever (S815) 15. Sensor, hydraulic pressure lift cylinder, piston side,
left (B768-L1) and Sensor, hydraulic pressure lift
4. Hydraulic oil pump 1-4
cylinder, piston side, right (B768-R1)
5. Test outlet servo pressure
16. Servo valve blocking (Y6001) or (Y6002)
6. Accumulator servo circuit
17. Sensor, hydraulic pressure lift cylinder, rod side, left
7. Valve block servo pressure (B768-L2) and Sensor, hydraulic pressure lift cylinder,
rod side, right (B768-R2)
18. Solenoid valve regeneration (Y6051) or (Y6052)
19. Valve block, lift cylinder
10. Servo valve boom out (Y6006)
20. Sensor boom angle (B771)
11. Servo valve boom in (Y6007)
12. Servo valve lower (Y6004)

7 Load handling – Servo filter 7:7
1 2
001239
9 8 7 8 6 5 4 3
1. Outer boom 6. Extension cylinder

2. Inner boom 7. Lift cylinder
3. Tilt cylinder right side 8. Mounting, lift cylinder
4. Mounting, attachment 9. Rear boom mounting
5. Tilt cylinder left side
7.2.2 Servo filter
Servo filter, change
NOTE
Safety.

Safety.
3 Turn the start key to position 0 and turn off the system voltage.
4 Clean the outside of the filter housing and filter holder.
5 Remove the filter holder and remove the cartridge downward.
6 Clean the inside of the filter holder.
7 Place the new cartridge in the filter holder.

7:8 7 Load handling – Servo filter
8 Check that the O-ring on the filter holder is intact and in place.
9 Fit the filter and filter holder.
NOTE
11 Close 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 top lift is closed before the
engine is started.
013399
Relief valve top lift, figure shows open valve.
12 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The oil
should be in the middle of the level glass. Top up as needed, for
quality see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.

7 Load handling – Pressure reducer 7:9
7.2.3 Pressure reducer

Pressure reducer, checking servo pressure
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil

reaches operating temperature, at least 50 ºC.
3 Turn the start key to position 0.
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the

pressure reducer.
5 Start the engine and check the servo pressure. Compare to the
pressure plate.
Turn the steering wheel or activate a load handling function in
order to activate the hydraulic oil pumps. The servo pressure is
higher than the standby pressure of the hydraulic oil pumps.
013864

7:10 7 Load handling – Extension
7.3 Extension
Extension, function description
Extension means to slide the inner boom in and out in the outer boom.
The inner boom is pushed in and out by the extension cylinder which
is pressurized by Control valve, lift, lower, and extension. Extension is
controlled with the Control lever (S815).
012740
Damping

close to end-positions. This entails that mechanical parts are exposed
to less stress when stopping in end-positions.

Regeneration
Regeneration
1 2
To increase speed when extending, oil from the rod side (2) is re-used
for the piston side (1), this is called regeneration. Engagement of
regeneration is controlled by the control system.
000455

Overload system Boom out: passive

7 Load handling – Extension 7:11
1
D
2
D790-1 D794
23 Pa m 22
D797-F D797-R
3 21
4 4 D D 17 18
14
PSS PSL
PS A1 VA 20
A1 VA
P B1 D C-
P C+
LS
13 5
6 19
EF CF
LSP1 A T H
15 P
LSP2 LSPR
C
LSP3 LSHY 16
LSP3X PT T P LSM
7
12 C
C 12 12 C
12
C
013835
8 9 10 11
1. Control lever (S815-P1) 13. Accumulator

2. Control unit cab (D790-1) 14. Servo filter
3. Control unit, frame front (D797-F) 15. Priority valve
4. Servo valve boom in (Y6007) or Servo valve boom 16. Pressure limiting valve
out (Y6006)
17. Servo valve blocking boom in (Y6050)
18. Solenoid valve regeneration (Y6046)
6. Solenoid valve pump shut-off boom in (Y6062)
19. Valve block extension cylinder
7. Valve block servo pressure
20. Extension cylinder
22. Sensor boom length (B777)
23. Sensor hydraulic pressure loft cylinder piston side
11. Hydraulic oil pump 4 left (B768-L1)
12. Non-return valve

7:12 7 Load handling – Extension
Extension, component location
1 2 3 4 5 6
7 8
22
9
21
10
11
19
12
17
18 13
14 16
20
15
013876
1. Valve block extension cylinder 13. Servo valve boom out (Y6006)
2. Servo valve blocking (Y6050) 14. Servo valve boom in (Y6007)
3. Solenoid valve regeneration (Y6046) 15. Servo valve lower (Y6004)
4. Control unit cab (D790-1) 16. Servo valve lift (Y6004)
5. Control lever (S815) 17. Servo filter
6. Hydraulic oil pump 1-4 18. Pressure limiting valve
7. Test outlet servo pressure 19. Valve block, lift cylinder
8. Accumulator servo circuit 20. Sensor hydraulic pressure loft cylinder piston side
left (B768-L1)
9. Solenoid valve pump relief (Y6062)
Sensor boom length
See section 8 Control system, group 8.2.1 Overload system.

7 Load handling – Lift boom 7:13
7.3.10 Lift boom
Slide plates lift boom, checking
NOTE
When adjusting side-mounted slide plates, it is important to check
the clearance for the whole boom's stroke.
1 Place the boom in the lowest position (fully retracted).
2 Check wear of the side-mounted slide plates at the front edge

of the lift boom. If needed, remove the slide plate and measure
the thickness.
Thickness should be at least 25 mm.
NOTE
If the slide plate's thickness is less than 25 mm, the slide plate
may work loose from the bracket, which may result in boom
damage.
3 Check the clearance between the boom and slide plate, clearance
should be 1 mm. Adjust with spacer plates if required.
1. Side-mounted slide plates

NOTE
2. Lower slide plates The inner boom must be centred in the outer boom.
4 Check thickness of the lower slide plates at the front edge of the
lift boom. If needed, remove the slide plate and measure the
thickness.
5 Check the clearance between the boom and stop at the leading
edge/top edge of the boom, clearance must be max. 3 mm.
Adjust the slide plates with spacer plates if needed.
6 Check the wear of the lower and side-mounted slide plates at the
rear edge of the lift boom. If needed, remove the slide plate and
measure the thickness.
NOTE
If the slide plate's thickness is less than 25 mm, the slide plate
may work loose from the bracket, which may result in boom
damage.
7 Check the clearance between the boom and slide plate, clearance
should be 1 mm. Adjust with spacer plates if required.
8 Check thickness of the upper slide plates at the rear edge of the
lift boom. If needed, remove the slide plate and measure the
thickness.
1. Upper glide plates

2. Side-mounted slide plates
3. Lower slide plates

7:14 7 Load handling – Side shift
7.4 Side shift

Side shift, function description
Sideshift means moving the attachment sideways. The attachment
can be sideshifted ± 800 mm from the middle position.
Control valve attachment pressurizes the sideshift cylinders that push
012741
the attachment's main beam in relation to the lift boom. Sideshifting is
controlled with the Control lever (S815).

2
D790-1
D797-R D791-1
3 8
D D
9
C
P1 A
11
4
T1 B
LSP1 A T H
LSP2 LSPR 10
LSP3 LSHY 5
LSP3X PT T P LSM
7 C 013836
1. Control lever (S815-T1.1) 7. Non-return valve

2. Control unit cab (D790-1) 8. Control unit attachment (D791-1)
3. Control unit frame rear (D797-R) 9. Servo valve, side shift left (Y6020) or Servo valve
side shift right (Y6021)
4. Solenoid valve, engagement of hydraulics for top lift
(Y6003) 10. Control valve attachment
5. Valve block servo pressure 11. Side shift cylinder

7 Load handling – Side shift 7:15
Side shift, component position

2
10
3
4
8
7
5
013879
6
1. Side shift cylinder 7. Solenoid valve, engagement of hydraulics for top lift
(Y6003)
2. Control lever (S815)
8. Control valve attachment
9. Servo valve, side shift left (Y6020) and Servo valve,
side shift right (Y6021)
10. Control unit attachment (D791-1)

7:16 7 Load handling – Side shift frame
7.4.6 Side shift frame
Slide plates side shift frame, checking
1 Remove the cover plate, spacer plate and slide plate.

2 Measure the slide plate's thickness.
3 Check the slide plate's clearance by measuring the distance

between the slide plate and the edge for the cover plate.
The clearance should be 1 mm.
Fit or remove spacer plates until the distance is correct.
4 Fit the cover plate.
5 Repeat steps 1–4 on the other slide plates.
The illustration shows the measurement without slide

plate.
Lower slide plates side shift frame, checking

1 Position axle stands or similar under the attachment's spreader
booms and lower the attachment the stands so that the side shift
frame's lower slide plates are released.
3 Place spacers between the crossmember and the attachment's

main boom for both crossmembers.
4 Measure the slide plates' thickness.
Thickness should be at least 15 mm. Check that the slide plates
have the same thickness.
5 Remove the spacer.
7 Lift the attachment and remove the stands.

7 Load handling – Main beam attachment 7:17
7.4.7 Main beam attachment
Glide plates main beam attachment, checking
1 Park the machine with the attachment as far down as possible and
spreading run inward so that 40 cm remain to the 20-foot position.
3 Unload applicable slide plate.

Take the strain off the lower glide plates by lifting the spreader
beam at the outside edge or by using wedges to change the
spreader beam's position on the attachment's main beam.
4 Remove the attaching bolts from the slide plate console.
5 Remove the slide plate's guide bolts.
6 Pull out the slide plate together with spacer plates and console.
7 Measure the thickness of the slide plate, replace if needed.
8 Place the slide plate in the correct position.
Check the clearance between spreader beam and glide plate.
Clearance should be max. 1 mm with all slide plates installed.
Fit or remove spacer plates until the distance is correct.
NOTE
Excessive clearance may result in damage to the spreader
beam during load handling.
9 Install the slide plate console.

10 Install the slide plate guide bolt.
11 Repeat steps 3–10 on the other slide plates.
12 Start the machine and check the spreader's function. Try to lift a
container and check that there is no clearance in the spreader
beams.

7:18 7 Load handling – Spreading
7.5 Spreading
Spreading, function description
Spreading means changing the width between the twistlocks.
Spreading has two stops, 20-foot and 40-foot stops.
Control valve attachment pressurizes Valve block spreader motor that
012742
controls pressure to the spreader motor. The spreader motor pulls the
spreader chains which pull out the spreader booms.
Spreading is controlled with the Control lever (S815). Inductive

position sensors indicate the spreader units' position.
Damping

close to end-positions. Three 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.


Twistlocks Unlocked or bypass activated
Overload system Passive

7 Load handling – Spreading 7:19
+ 2
D790-1
D797-R D791-1
3 8
D
9 D
C
13
P1
4 12
T1
LSP1 A T H
LSP2 LSPR 10 11
LSP3 LSHY 5
LSP3X PT T P LSM
7 C
013837
6
1. Control lever (S815-T1.x and S815-T4) 8. Control unit cab (D790-1)

2. Control unit cab (D790-1) 9. Servo valve for spreading out (Y6018) or Servo valve
for spreading in (Y6019)
10. Control valve attachment
(Y6003) 11. Valve block spreading cylinder
5. Valve block servo pressure 12. Hydraulic motor spreading
6. Hydraulic oil pump 3 13. Sensor damping 20' and 40' (B769)
7. Non-return valve

7:20 7 Load handling – Spreading
Spreading, component position
1 2 3
11
10
5
7
013880
6
1. Control unit attachment (D791-1) 8. Control valve attachment

2. Control lever (S815) 9. Servo valve, spreading out (Y6018) and Servo valve,
spreading in (Y6019)
10. Hydraulic motor spreading
11. Valve block hydraulic motor spreading
(Y6003)

7 Load handling – Spreading 7:21
1 2 3 4 5
013881
1. Indicator plate 20' 4. Spreading motor
2. Sensor damping 20' and 40' (B769) 5. Spreading chains
3. Indicator plate 40'

7:22 7 Load handling – Spreading motor
7.5.6 Spreading motor
Oil spreading motor unit, changing
NOTE
Safety.
1 Remove the drain plug.

2 Remove and clean the sight-glass.
3 Fit the drain plug when all the oil has drained.
NOTE
Make sure that the drain plug's washer seal is also removed.
1. Filling point
2. Level glass
3. Drain plug
4 Fill oil until the level can be seen in the level glass (fill through
breather hole). For volume and quality, see section F F Technical
data.
013674

7 Load handling – Spreading chains 7:23
7.5.7 Spreading chains
Spreading chains, checking
1 Before adjusting, the clearance between the slide plates and

extension beams must be checked, as otherwise the chain's
mounts may be damaged, see Glide plates extension beam,
checking and adjusting, page 7:24.
2 Start the engine, move in the spreading to the 20-foot position

and turn off the engine.
3 Check the C-C measurement between the twistlocks.

C-C 20 foot: 5853±3 mm.
Check that both spreading beams move toward the 20-foot stop
and that the distance between the spreading beam and the
spreading motor's mount is at least 3 mm.
4 If necessary, adjust the distance by moving the washers between

high and left 20-foot stop. The number of washers must not be
changed.
NOTE
Note the distance that the stop is adjusted to.
Move out the spreading a bit in order to move the washers.
5 Remove the cover plates on the attachment's main beam.

7:24 7 Load handling – Spreader beam
6 If the 20-foot stop is adjusted, the spreader chains must be

adjusted by an equal amount.
NOTE
Check the vertical position of the chain tensioner to ensure that
the chain runs straight against the chain wheel.
7 Start the engine and move out the spreading to the 40-foot position
and turn off the engine.
8 Check the C-C measurement between the twistlocks.
C-C 40 foot: 11985±3 mm.
9 If needed, adjust the 40-foot stop.
10 Start the engine and move the spreading out to the 40-foot
postition.
11 Wait 2 minutes and then check the tension of the chains.
005105
Measure how much the chain can be pressed in by the hole closest
to the middle of the attachment. When the chain is pressed in with
a force of 250 N, it should move 20–40 mm from resting position.
12 If needed, adjust the tension of the chains.
Start the engine and run out the spreading until the chain
tensioners are visible in the inspection holes (approx. 250 mm).
Adjust the chains, hold the chain tensioner with a box-end wrench
so that the chain is not twisted while adjusting.
NOTE
Adjust the chain on the chain tightener max 2 mm at a time.
13 Repeat steps 9–11 until the tension of the chains is correct.

14 Apply lubricating grease to the spreading chains.
15 Fit the cover plates onto the attachment's main beam.
7.5.8 Spreader beam
Glide plates extension beam, checking and

adjusting
1 Park the machine with attachment lowered as far down as possible

and spreaders in their narrowest position.
3 Unload applicable slide plate.

The glide plates can be unloaded by lifting the extension beam
in the outer edge or by using wedges to change the extension
beam's position in the attachment's main beam.
The diagram shows inner slide plates in the attachment's

main beam.

7 Load handling – Spreader beam 7:25
4 Remove the attaching bolts from the slide plate console.

5 Remove the slide plate's guide bolts.
6 Pull out the slide plate together with spacer plates and console.
7 Measure the thickness of the slide plate, replace if needed.
8 Place the slide plate in the correct position.
Check the clearance between extension beam and slide plate.
Clearance should be less than 1 mm with all slide plates installed.
Use a spacer plate to adjust the clearance.
9 Install the slide plate console.
10 Install the slide plate guide bolt.
11 Lubricate the slide surface on the extension beam.
12 Start the machine and check the spreader's function. Try to lift
a container and check the extension beams' clearance in the
attachment's main beam.
The diagram shows inner slide plates in the attachment's

main beam.

7:26 7 Load handling – Rotation
7.6 Rotation
Rotation, function description
The attachment can be rotated +195º -105º in relation to the machine.
Control valve attachment pressurizes Valve block rotation motor.

Valve block rotation motor controls pressure to the rotation motors
that turn the attachment. Rotation is controlled with the Control lever
(S815). The voltage signal controls direction and speed (clockwise or
counter-clockwise).

1
2
D790-1
D797-R D791-1
3 8
D
9 D
C
P1
4 13
T1
LSP1 A T H
LSP2 LSPR 10
LSP3 LSHY 5 12
LSP3X PT T P LSM
7 C
013838
1. Control lever (S815-P3) 7. Non-return valve

2. Control unit cab (D790-1) 8. Control unit attachment (D791-1)
3. Control unit frame rear (D797-R) 9. Servo valve, rotation clockwise (Y6008) or Servo
valve, rotation anticlockwise (Y6009)
(Y6003) 10. Control valve attachment
5. Valve block servo pressure 11. Valve block hydraulic motor
6. Hydraulic oil pump 3 12. Rotation motor

7 Load handling – Rotation 7:27
Rotation, component location
1 2 3
11 10
5
7
013886
6
1. Control unit attachment (D791-1) 8. Control valve attachment

2. Control lever (S815) 9. Servo valve, rotation clockwise (Y6008) and
Servo valve, rotation counter-clockwise (Y6009)
10. Valve block hydraulic motor rotation
11. Hydraulic motor rotation
7. Solenoid valve, engagement of hydraulics for top
lift (Y6003)

7:28 7 Load handling – Rotation motor unit
7.6.6 Rotation motor unit
Oil rotation motor unit, changing
NOTE
Safety.
1 Remove the planetary gear's drain plug (position 6) and lead the
oil down into the container.
Remove the planetary gear's filler plug (position 3) for faster
draining.
2 Remove and clean the planetary gear's level glass (position 5)
while the oil drains.
3 Fit the level glass and drain plug.
1. Level glass, disc brake

2. Filling point, disc brake
3. Filling point, planetary gear
4. Draining, disc brake
5. Level glass, planetary gear
6. Draining, planetary gear
4 Fill new oil in the planetary gear through the filler point (position
3) until the level is directly opposite the level glass. For volume
and quality, see section F F Technical data.
5 Remove the disc brake's drain plug (position 4) and lead the oil
down into the container.
Remove the disc brake's filler plug (position 2) for faster draining.
6 Remove and clean the disc brake's level glass (position 1) while
the oil drains.
7 Fit the level glass and drain plug.
013674
8 Fill new oil in the disc brake through the filler point (position 2)
until the level is directly opposite the level glass. For volume and
quality, see section F F Technical data.

7 Load handling – Levelling 7:29
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the attachment is angled in the
horizontal direction. This enables the machine to handle loads on
uneven ground surfaces.
001117
The attachment's main beam is located in the sideshift frame. The
clearance between sideshift frame and the attachment's main beam
allow a movement of approx. 5º, which enables lifting of containers
that lean in relation to the machine. It is the dead weight of the
attachment that adapts the attachment's angle to the container.

7:30 7 Load handling – Load carrier
7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, function description
The container is held in place on the attachment with four twistlocks.
Twistlocks are controlled with the control lever and Switch twistlocks.
A section in Control valve attachment pressurizes two hydraulic
cylinders connected in parallel, one in each spreader boom. Each
012745
hydraulic cylinder affects a linkage that turns two twistlocks. Four
position sensors, two in each spreader boom, sense the position of
the linkage and indicate if twistlocks are open or locked. Control lights
on the boom and in the cab show status for twistlocks.
Four position sensors, one at each twistlock, indicate when the
attachment has alignment with the container. This is used to control
when twistlocks can be activated. An indicator light on the boom
and one in the cab indicate when the attachment has full alignment.
An event menu shows which twistlocks have alignment (1 - 4). To
000571
activate twistlocks, alignment is required at all four twistlocks.
When there is no alignment at any twistlock then Switch open

Event menu twistlocks
twistlocks on the control lever activates the horn.

Contact Full contact or bypass activated

7 Load handling – Twistlocks 7:31
18
17
2 1 D
D
3 15 16
D790-1 D790-2 D795
D
4 D797-R D791-1
9
D D
10 D
C 13 14
P1 D
5
T1
12
LSP1 A T H
LSP2 LSPR 11
LSP3 LSHY 6
LSP3X PT T P LSM
8 C
013839
7
1. Switch lock twistlocks (S1003) 11. Control valve attachment

2. Control lever (S815-T2) 12. Lock cylinder
3. Control unit cab (D790-1) 13. Sensor for unlocked twistlocks (B7204) or Sensor for
locked twistlocks (B7205)
14. Sensor for alignment left front (7202L), Sensor for
alignment right front (7202R), Sensor for alignment
(Y6003)
left rear (Y7203L) and Sensor for alignment right rear
6. Valve block servo pressure (Y7203R)
7. Hydraulic oil pump 3 15. Control unit KIT (D790-2)
8. Non-return valve 16. Control unit KID (D795)
9. Control unit attachment (D791-1) 17. Indicator lights boom twistlocks and alignment
10. Servo valve, open twistlocks (Y6039) or Servo valve, 18. Indicator lights cab twistlocks and alignment
lock twistlocks (Y6040)

7:32 7 Load handling – Twistlocks
Twistlocks, component position
1 2 3 4 5 6 7 9
10
17
15 11
16
14
013887
13 12
1. Sensor for unlocked twistlocks (B7204) or Sensor for 11. Control unit frame rear (D797-R)
locked twistlocks (B7205)
2. Lock cylinder
4. Control lever (S815-T2) (Y6003)
5. Indicator lights boom twistlocks and alignment 15. Control valve attachment
6. Switch lock twistlocks (S1003) 16. Servo valve, open twistlocks (Y6039) or Servo valve,
7. Indicator lights cab twistlocks and alignment lock twistlocks (Y6040)
8. Control unit KIT (D790-2) 17. Sensor for alignment left front (7202L), Sensor for
alignment right front (7202R), Sensor for alignment
9. Control unit KID (D795) left rear (Y7203L) and Sensor for alignment right rear
10. Control unit cab (D790-1) (Y7203R)

7.9.1.7 Twistlocks
Twistlocks, checking
WARNING
Dropped load.
Fatal danger!
Twistlocks hold the load during load handling and
therefore it is crucial that twistlocks are checked
according to instructions and replaced at the slightest
sign of damage or wear.
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 Check that the twistlocks function correctly.

1 Lock and open the twistlocks, check that the indicator lights work,
both in the cab and on the attachment.
2 Clean the twistlocks from any dirt.
3 Under the rubber cover for twistlocks: check pin, link arm and
2 lock nut.
4 Clean the area around sensor contact.
5 5 Press in the alignment pin so that the head is flush with the
spreader beam's underside. Check the distance to sensor
alignment, the distance should be 3-4 mm. Adjust as needed.
NOTE
4 3
The contact pin should move easily and spring back completely.
6 Check that the lock guide and lift pin can move freely.
7 Fit a pry bar between the lift pin (position 4) and the lock guide
(position 5) and check the clearance, max. clearance: 1.5–2 mm.
0 12 9 4 4
1. Lock mechanism
2. Sensor contact
3. Contact pin
4. Lift pin
5. Lock guide

8 Turn twistlocks to locked position and check wear of the lift pin.
Change the lift pin as needed.
M ax.4 m m
m
m
0
.7
in
M
013898
Wear limits lift pin.
9 Clean the area around the lubrication body.

10 Grease the lift pin's bearing with universal grease "EP2".
11 Repeat steps 1-10 on all twistlocks.
Twistlocks, checking for cracks
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.
013897
4 Install approved twistlocks.
Area for checking for cracks on lift pin.
NOTE
Use the new attaching nut and spherical bearing.
Twistlocks, checking vertical movement
WARNING
Dropped component.
Risk of crushing, product damage.
Twistlock weighs approx. 30 kg.
1 Check the vertical movement for twistlocks.

1
Press up the lift pin and check that the clearance is 1.5–2 mm.
2 Adjust twistlocks when needed. Step 3-6.
3 Remove the nut (position 1) from the lift pin and dismantle
twistlocks (position 2).
4 Replace the adjusting shim (position 3) with the most suitable from
the adjusting shim kit to obtain correct clearance for the vertical
movement. See Parts catalog for part number of the kit. See Parts
catalog for part number of the kit.
3
5 Assemble twistlocks. Tighten the nut to 700 Nm.
6 Check again the vertical movement for twistlocks.
1,5-2 mm
012582
2
1. Nut
2. Twistlocks
3. Adjusting shims

Twistlocks, checking float position
WARNING
In the event of irregular horizontal movement twistlocks
are exposed to fatigue.
Shortened life of twistlocks.
Check the float position every 500 hours of operation.
1 Check that the tightening torque on the nut (position A) is 700 Nm.
2 Move the lift pin around in the opening and check that the lift pin
A reaches all four corners and that the edges of the lift pin and the
opening are in contact with each other at the same time.
3 Adjust the vertical movement if the float position is not correct.
1 2
3 4
012583
Sensor contact, checking and adjusting

1 Check that the alignment pins in the corner boxes can move freely
up and down. The alignment 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
contact pins is needed to detect contact (light indicator on the
sensor is lit). The movement should be 3–4 mm.
7 If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the contact pin is 5±1 mm.

Sensor twistlocks, checking and adjusting

1 Check that the sensors are free of damage and dirt.
1 2 1 3
2 Turn the start key to position I and check that the light indicator
on the sensor is lit on those sensors that have indicator plates
positioned in front of the sensor. On the other two, the light
indicator should not be lit.
If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is 5±1 mm.
3 Check that indicator light twistlocks open is lit.
000635
4 Lower the attachment over a container and lock twistlocks.
5 Check that the light indicator on the sensor is on for the sensors
1. Sensor twistlocks with the indicator plate in position in front of the sensor. On the
2. Lock mechanism other two, the light indicator should not be lit.
3. Lock cylinder If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is 5±1 mm.
6 Check that indicator light twistlocks locked is lit.

7:38 7 Load handling – Other functions
7.10 Other functions

7.10.2 Weight indicator
Weight indicator, function description
The weight indicator shows the weight of the lifted load. The dynamic
scale shows the load regardless of position of boom and extension.
The weight indicator uses Sensor boom length (R777), Sensor boom
angle (R771) and Sensor hydraulic pressure lift cylinder (B768) to
calculate the weight of the load. For more information about sensors,
see section 8 Control and monitoring system, group 8.2.1 Overload
system.

a
b
OK
c
d
9 8
1 7
D790-1 D795
D797-F D797-R
6 4
D
D
5
013113
Pa Pa Pa Pa 2m <° 3
1. Control unit cab (D790-1) pressure lift cylinder piston side right (B768-R1) and
Sensor hydraulic pressure lift cylinder rod side right
(B768-R2)
4. Control unit frame rear (D797-R) 7. Control unit KID (D795)
5. Sensor hydraulic pressure lift cylinder piston 8. Operating menu for dynamic scale
side left (B768-L1), Sensor hydraulic pressure lift
cylinder rod side left (B768-L2), Sensor hydraulic 9. Operating menu for checking dynamic scale

7 Load handling – Weight indicator 7:39
Weight indicator, checking
1 Unload attachment, i.e. no load.
2 Check that the weight indicator shows OK. If OK is not shown,

a calibrate the weight indicator.
OK
3 Lift a known weight.
c
b
013114
Operating menu scale
a OK shown when attachment is unloaded, i.e.,
the load is 0 kg (±1,000 kg)
b Load centre measured from drive axle centre
c Use of load capacity at current load centre
4 Check that the weight indicator shows the right weight ±0.5 ton. If
deviation is greater, calibrate the weight indicator.
a
c
b
000357
Operating menu dynamic scale

a Measured weight of the load
b Load centre measured from drive axle centre
c Use of load capacity at current load centre
Weight indicator, calibration
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Warm the hydraulic oil to working temperature, min. 40 ºC.
2 Park the machine on level ground without load and centre the
attachment.
3 Navigate to the service menu and press ENTER.

000056
4 Enter the code for calibration.

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).

7:40 7 Load handling – Weight indicator
5 Scroll to SCALE with the arrow keys and press ENTER.

CALIBRATION
Each calibration consists of a sequence of menus. Scroll between
the menus with the arrow keys.
SCALE STEERING
DRIVE-TRAIN RETURN
NOTE
000062
Some options, such as height restrictions and load centre
restrictions, mean that bypass must be used to reach the
boom's end-positions.
6 CALIBR SCALE, menu 1.

CALIBR SCALE 1(X)
MINIMUM BOOM ANGLE 7 Lower the boom to the lowest position (0º).
8 Save the setting with ENTER.
STORED VALUE X.XXV
0 11 3 2 9
PRESENT VALUE X.XXV
9 Scroll to CALIBR SCALE, menu 2.

CALIBR SCALE 2(x)
MAXIMUM BOOM ANGLE 10 Lift the boom to its highest angle.
STORED VALUE X.XXV
0 11 3 3 0
PRESENT VALUE X.XXV

CALIBR SCALE 3(X)
BOOM FULLY RETRACTED 13 Retract the boom completely.
STORED VALUE X.XXV
0 11 3 3 1
PRESENT VALUE X.XXV

CALIBR SCALE 4(X)
BOOM FULLY EXTENDED 16 Extend the boom completely.
STORED VALUE X.XXV
011332
PRESENT VALUE X.XXV

CALIBR SCALE 5(X)
19 Retract the boom completely.
LOAD SENSOR BOOM
RETRACTED LE RI 20 Lower the boom and inch towards the end until 2-4 cm remains
STORED XXXX XXXX on the lift cylinders.
011333
PRESENT XXXX XXXX 21 Wait approx. five seconds to stabilise the pressure.

7 Load handling – Weight indicator 7:41

CALIBR SCALE 6(X)
24 Extend the boom completely.
LOAD SENSOR BOOM 0t
EXTENDED LE RI 25 Wait approx. five seconds to stabilise the pressure.
CALIBR XXXX XXXX
010454
PRESENT XXXX XXXX 26 Check that "LOAD SENSOR BOOM" is set to 0 t. If not, adjust
with the minus key to 0 t and save the setting with ENTER.
IMPORTANT
Check that the right weight is shown in the menu before
saving the setting. Incorrectly entered weight means
that the scales read wrong.
Checking calibration
CALIBR SCALE 7(X)
ALLOWED LOAD XXXXXKg 28 Lift a reference load and check that the control system calculates
the correct weight of the load that the machine is lifting.
PRESENT LOAD XXXXXKg
LOAD STR.AXLE XXXXXKg PRESENT LOAD = Reference load ± 450 kg. Weight is given in
006804
LOAD-CENTER XXX.XXm kg.

If the weight is not right, repeat calibration.
29 Operate the machine without load, stop the machine and check
that PRESENT LOAD = 00000 ± 450 kg.
Check in different working positions, see figure. The boom should
not reach end-positions when checking.
NOTE
Check when stationary. (Operation generates dynamic forces.)
010455
30 Back out of calibration with the R-key. When the code menu
appears, press Enter.

7:42 7 Load handling – Container counter
7.10.3 Container counter

Container counter, function description
Container counter counts the number of lifts performed with the

machine. 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 alignment disappears with locked twistlocks and twistlocks do
not open again within 8 seconds.
Condition

4
D795
1. Sensor for alignment left front (7202L), Sensor for alignment
right front (7202R), Sensor for alignment left rear (Y7203L) and
D791-1 Sensor for alignment right rear (Y7203R)
3 D
2. Sensor locked twistlocks left (B7205L)
D Sensor locked twistlocks right (B7205R)
1 2 3. Control unit attachment (D791-1)
4. Control unit KID (D795)
004297

7 Load handling – Synchronised lift 7:43
7.10.4 Synchronised lift

Synchronised lift, function description
Synchronized lift means means activating lift and extension at the

same time so that the lift is completely vertical. Synchronized lift is
activated by pressing in the trigger on the control lever at the same
time as lift is activated.
Synchronised lift is controlled by the control system with signals from

Sensor boom angle and Sensor boom length.
NOTE
The synchronised lift uses predetermined variables for speed. The
hydraulic oil pumps must be adjusted correctly for the function to
work well.
For details on lift and extension, see Lifting/lowering, function

description, page 7:4 and Extension, function description, page 7:10.

D
+
2
D 7 9 0 -1 D 795
5 D 7 9 7 -R D 7 9 7 -F
D
0 12 9 4 5
3 m <° 4
1. Control lever (S815) 4. Sensor boom length (B777)

2. Control unit cab (D790-1) 5. Control unit frame rear (D797-R)

7:44

8:1
8 Control system
Contents 8 Control system

8 Control system ...................................................................................................8:3
8.2 Monitoring ........................................................................................................8:5
8.2.1 Overload system .........................................................................................8:5
8.2.2 Bypass ........................................................................................................8:7
8.2.5 Speed limitation...........................................................................................8:7
8.3 Error codes ......................................................................................................8:8
8.4 Diagnostics ....................................................................................................8:10
8.4.1 CAN/POWER ............................................................................................8:12
8.4.2 LIGHTS .....................................................................................................8:13
8.4.3 CAB ...........................................................................................................8:14
8.4.4 CLIMATE ...................................................................................................8:15
8.4.5 HYD...........................................................................................................8:15
8.4.6 ENGINE ....................................................................................................8:16
8.4.7 TRANSM ...................................................................................................8:18
8.4.8 BOOM .......................................................................................................8:19
8.4.9 ATTACH ....................................................................................................8:20
8.4.10 OP .............................................................................................................8:21

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 case of any
dangerous situations.
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.
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

8:4 8 Control system – Control system
Function keys
Function keys
The function keys (A) are used to navigate in the menu system.
Also used to enter values in the system, change light contrast in the
keys/indicator panel, and to acknowledge warning.
000055
• Function key 1: Scroll counter-clockwise 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.
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 type "WARNING" and "STOP"). Scroll to other menus (see list
below) with function keys 1 (arrow left) and 2 (arrow right).
The following operating menus are available to aid the operator:

• Operating menu engine and transmission
• Operating menu engine
• Operating menu transmission and hydraulics
• Operating menu electrical system
• Service menu
• Operating menu heating and air conditioning
006762
• Operating menu statistics

Example of operating menus • Operating menu dynamic scale
• Operating menu checking dynamic scale
• Operating menu load handling
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.
Warnings are described in connection with each function. The following

event menus are available:
• Overload forward
• Overload on steering axle
• Alignment, top lift attachment
• Twistlock
• Open door
• Speed limitation at overload on steering axle
• Automatic spreading 20"-40"

8 Control system – Monitoring 8:5
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.
8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
• Overload system
• Load centre limitation
• Height limitation
• Speed limitation
• Service indicator
8.2.1 Overload system

Overload system, general
The machine features a warning system, LLMC (Longitudinal Load
Moment Control). Warning systems shall ALWAYS be enabled! The
system is used for stationary load handling in order to not jeopardize
the machine's forward stability.
The following takes place when the machine is close to the stability
limit:
• the buzzer in the cab is activated (indication for operator)
• warning figure is shown on display (indication for operator)
• the boom movement is interrupted
In this position the boom, and thus the load, can only be retracted
until the buzzer stops sounding and the display figure disappears.
LLMC is not intended to check lateral stability or stability when

operating. Nor does it take into account sloping ground conditions.
NOTE
Retract the boom before it is lowered! Applies to all load handling!
The overload system is activated when operators exceed the machine's

load handling capacity. All hydraulics are blocked, e.g., lift, when the
overload system is activated. With Switch bypass, certain parts of
the overload system can be bypassed. This enables lowering and
retraction of the boom to avoid danger.

8:6 8 Control system – Overload system
Overload system, function description

This overload system is a part of the control system and performs
1 2 calculations of the load with sensor values for boom length, boom
angle and cylinder pressure in the lift cylinders.
The calculated load and the measured distance from the machine is
compared to a load curve, if the load is outside the permitted distance
the overload system is activated.
• In case of overload forward, the control system disables the
functions lift and lower as well as extension. Using bypass
it is possible to activate lower and extension in to escape the
overload situation.
• In the event of overload on the steering axle, the control system
activates a warning for overload on the steering axle.
The machine's speed is limited, depending on how high the load
is on the steering axle. A bar in the event menu shows the scope
of the limitation.
NOTE
In case of overload on the steering axle, it is up to the operator
to operate carefully, no functions are disabled. To reduce the
load and regain full manoeuvrability the boom shall be lowered
or extended out.
3
000582
1. Sensor boom angle (R771)

2. Sensor boom length (R777)
3. Sensor hydraulic pressure lift cylinder (B768-10,
-11, -12, -13)
6
D 795
D 7 9 7 -R D 7 9 7 -F D 793
3 4 2 7
D
1
014112
D 5 D D
1. Sensor hydraulic pressure lift cylinder left (B768-10 4. Control unit frame rear (D797-R)
and B768-11) and Sensor hydraulic pressure lift
5. Sensor boom angle (R771)
cylinder right (B768-12 and B768-13)
2. Control unit, frame front (D797-F) 6. Control unit KID (D795)
3. Sensor boom length (R777) 7. Control unit, transmission (D793)
Overload system, checking

1 Lift a loaded container approx. 1 m.
2 Run out the boom and check that the overload system is activated.
000358
Display warning overload forward

8 Control system – Bypass 8:7
8.2.2 Bypass
Bypass, description
When the overload system engages and turns off the hydraulic
controls, it may take place in a situation where it is necessary to bypass
the safety system.
By-pass is activated with a switch, there is one to three switches

depending on the machine's equipment:
• Switch bypass
Bypassing the safety system makes it possible to:

• lower load at overload
• lock and open twistlocks without full contact
• Spread 20'-40' with locked twistlocks
• bottom lift without full alignment
• manual steering of recirculation damper by ECC or EHC
• releasing parking brake in case of defective switch parking brake
or Sensor operator in seat
• lift, lower and extend with active error on the overload system
• selection of travel direction in case of defective Sensor operator in
seat, speed is limited to 10 km/h
DANGER
Bypassing the safety system results in a risk of tipping
forward, and is done at your own risk.
Risk of fatal accidents and property damage
Only use bypass of the safety system in emergency
situations.
8.2.5 Speed limitation

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

value by limiting gear position and engine rpm.

8:8 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).
002207
When the error code has been acknowledged the display returns
to previously selected menu. If the error code is active, it is stored
Example of automatic display figure in the error code list under operating menu for service.
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
DIAGNOSIS diagnostic test. The diagnostic test consists of several menus that are
CAN/POWER LIGHTS CAB shown in the display. The menus are grouped for faster access.
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH The following pages show compilations of the diagnostic menus. The
006853
workshop manual has a more detailed description of each diagnostic
OP EXTRA RMI
menu.
The diagnostic test is divided into the following groups:

• CAN/POWER, menu overview, page 8:12
• LIGHTS, menu overview, page 8:13
• CAB, menu overview, page 8:14
• CLIMATE, menu overview, page 8:15
• HYD, menu overview, page 8:15
• ENGINE, menu overview (engine alternative Yuchai
YC6M360-30), page 8:16
• ENGINE, menu overview (engine alternative Cummins QSM11),
page 8:17
• TRANSM, menu overview, page 8:18
• BOOM, menu overview, page 8:19
• ATTACH, menu overview, page 8:20
• OP, menu overview, page 8:21
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(10) output signals are sent by the control unit.
FRONT WIPER
SWITCH (1-3) 2 Signal values (position 5) in the menu indicate measured values by
6 the relevant control unit. The control units have internal voltmeters
OUTPUT 11 5
004856
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 figure shows an example of a menu, here for diagnostics of
5. Signal value windshield wiper. The table below indicates what you can read out
6. Variable from the menu figure.
7. Menu heading

8 Control system – Diagnostics 8:11
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.
BOOM - for diagnosis of lift, lower and extension.
ATTACH - for diagnosis of attachment.
OP - for diagnosis of overload system.
EXTRA - not used.
RMI - not used.
3 2 Number of current menu (menu group CAB contains several menus in a loop).
4 (10) Total number of menus in the group CAB.
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.
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 BOOM ATTACH arrow keys (1 and 2) to change menu.
000084
OP EXTRA HIST

8:12 8 Control system – CAN/POWER
8.4.1 CAN/POWER
CAN/POWER, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CAN/POWER 1(21) DIAG CAN/POWER 2(21) DIAG CAN/POWER 3(21)

PRESENT REDCAN STATUS PRESENT REDCAN STATUS PRESENT DRIVE-TRAIN
COMMUNICATION MODE X CONNECTED CITIES CAN BUS STATUS
NUMBERS OF UNITS X X Y X Y X ENGINE X
SEGMENT ERROR X 1-2-R-F-D TRANSMISSION X

IGNITION EMERGENCY STOP, SW X 790-1 CAB
KEY IN X RELAY K3009-1 XY POWER XX.XXV
RELAY K315-1 XY FEEDBACK X 5V REF X.XXV
RELAY K315-2 XY RELAY K3009-2 XY

790-1 CAB 797-F FRAME 797-F FRAME
24V SENSOR SUPPLY XY POWER XX.XXV 24V SENSOR SUPPLY XY
24V SUPPLY,RPM>500 XY RED.POWER Le X Ri X 5V REF X.XXV
EME STOP POWER X

797-R FRAME 797-R FRAME NOT USED
POWER XX.XXV 24V SENSOR SUPPLY XY
RED.POWER Le X Ri X 5V REF X.XXV

NOT USED 795 DISPLAY 793 TRANSMISSION
POWER XX.XXV
RED.POWER Le X Ri X IGNITION POWER XX.XXV
SENSOR SUPPLY XX.XXV

791-1 ATTACHMENT NOT USED NOT USED
EME POWER XX.XXV
RED.POWER LE X RI X
EME POWER 2 X

NOT USED 24V SENS.SUP 791-1 XY REDCAN STATUS CHECK
PRESS ENTER
014109
SEGMENT ERROR X

8 Control system – LIGHTS 8:13
8.4.2 LIGHTS
LIGHTS, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG LIGHTS 1(13) DIAG LIGHTS 2(13) DIAG LIGHTS 3(13)

WORKING LIGHT CAB WORKING LIGHT ATTACH WORKING LIGHT BOOM
SWITCH X SWITCH X SWITCH X
OUTPUT LE XX RI XX OUTPUT LE XY RI XY OUTPUT LE XY RI XY
OPT OUTPUT (2X) XY

MAIN LIGHT PRESENT OUTPUT SIGNAL HEAD LIGHTS
SWITCH X SIDE-F LE XY RI XY SWITCH X
SIDE-R LE XY RI XY HEAD LE XY RI XY
REAR LE XY RI XY DIMMED XY

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL ROTATION BEACON
HAZARD SWITCH X HAZARD/FLASHER SWITCH X
FLASH.SW. LE X RI X FRONT LE XY RI XY OUTPUT XX
REAR LE XY RI XY

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL CAB LIGHT
BRAKE LIGHT SWITCH X BRAKE LIGHT LEXY RIXY MANUAL SWITCH X
REVERSE LIGT SIGNAL X REVERSE LGT LEXY RIXY DOOR SWITCH X
REVERSE ALARM XY OUTPUT XXX
DIAG LIGHTS 13(13)

SWITCH LIGHTS
OUTPUT XXX
0 1 4 11 0

8:14 8 Control system – CAB
8.4.3 CAB
CAB, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CAB 1(10) DIAG CAB 2(10) DIAG CAB 3(10)

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

ROOF WIPER HORN BUZZER XY
SWITCH X SWITCH X SWITCH SEAT X
OUTPUT XY OUTPUT XY ALARM X
FEEDBACK X OP X

FUEL SEAT HEATER NOT USED
SENSOR VALUE XXXOHM SWITCH X
PROC XXX OUTPUT XY
DIAG CAB 10(10)

NOT USED
014103

8 Control system – CLIMATE 8:15
8.4.4 CLIMATE
CLIMATE, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CLIMATE 1(8) DIAG CLIMATE 2(8) DIAG CLIMATE 3(8)

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(8) DIAG CLIMATE 5(8) DIAG CLIMATE 6(8)

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(8) DIAG CLIMATE 8(8)

OUTPUT WATER VALVE OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
0 1 4 111
8.4.5 HYD
HYD, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG HYDRAULIC 1(6) DIAG HYDRAULIC 2(6) DIAG HYDRAULIC 3(6)

HYDRAULIC OIL BRAKE COOLANT OIL PRESSURE LIFTING CYL
TEMP XXX TEMP XXX Le Ri
FAN XY FAN XY C- XXX XXX
SET OUTPUT +/- X SET OUTPUT +/- X C+ XXX XXX
DIAG HYDRAULIC 4(6) DIAG HYDRAULIC 5(6) DIAG HYDRAULIC 6(6)

PRESSURE SWITCHES P-BRAKE PRESENT OUTPUT SIGNAL
BRAKE PRESSURE X SWITCH X/Y PRESSURE TO ATTACHM.
BRAKE LIGHT PRESS. X FEEDBACK SWITCH X VALVE XY
014104
DECLUTCH PRESSURE X VALVE XY SET OUTPUT +/- X

8:16 8 Control system – ENGINE
8.4.6 ENGINE
ENGINE, menu overview (engine alternative Yuchai
YC6M360-30)
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
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 XXX
CRANK ENGINE SWITCH X CRANK ENGINE X BOOST PRESSURE XXX
D+ X

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
014105
COOLANT LEVEL SW. X

8 Control system – ENGINE 8:17
ENGINE, menu overview (engine alternative Cummins

QSM11)
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI

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

PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT INPUT SIGNAL
PREHEAT SWITCH X PREHEAT X OIL PRESSURE XXX
CRANK ENGINE SWITCH X CRANK ENGINE X BOOST PRESSURE XXX
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
0 11 0 9 1
INTAKE MAIN.TEMP XXX FMI XX

8:18 8 Control system – TRANSM
8.4.7 TRANSM
TRANSM, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
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
014106
TIME AGO XXXXX (+/-)

8 Control system – BOOM 8:19
8.4.8 BOOM
BOOM, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG BOOM 1(8) DIAG BOOM 2(8) DIAG BOOM 3(8)

PRESENT INPUT SIGNALS BLOCK VALVES BOOM HIGH SPEED
BOOM UP/DOWN XX.XXV UP/DOWN LE XY RI XY UP LE XY RI XY
BOOM IN/OUT XX.XXV IN/OUT XY OUT XY
RELIEVE PRESS. IN XY
DIAG BOOM 4(8) DIAG BOOM 5(8) DIAG BOOM 6(8)

OUTPUT BOOM UP OUTPUT BOOM DOWN OUTPUT BOOM IN
REFERENCE XY REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX REQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX FEEDBACK XXX
DIAG BOOM 7(8) DIAG BOOM 8(8)

OUTPUT BOOM OUT NOT USED
REFERENCE XY
REQUIRED VALUE XXX
014108
FEEDBACK XXX

8:20 8 Control system – ATTACH
8.4.9 ATTACH
ATTACH, menu overview
DIAGNOSIS DIAG ATTACHMENT 1(22)

CAN/POWER LIGHTS CAB PRESENT INPUT SIGNALS
CLIMATE HYD ENGINE ROT CW/CCW XX.XXV
TRANSM BOOM ATTACH TILT IN/OUT XX.XXV
OP EXTRA RMI
DIAG ATTACHMENT 2(22) DIAG ATTACHMENT 3(22) DIAG ATTACHMENT 4(22)

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS NOT USED
SIDE SHIFT LE X RI X LOCK TW X
PISTOL X UNLOCK TW X
30/35 STOP X BY-PASS HEIGHT X

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
LOW SPEED 20/40 X ALIGNMENT LE RI LE RI
30/35 STOP X FRONT X X LOCKED TW X X
REAR X X UNLOCKED TW X X

PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
SIDE SHIFT LEFT XY LOCK TW XY IND. LOCKED TW XY
SIDE SHIFT RIGHT XY UNLOCK TW XY IND. UNLOCKED TW XY
IND. ALIGNMENT XY

OUTPUT ROTATION C.W. OUTPUT ROTATION C.C.W. OUTPUT SPREADER OUT
REFERENCE XY REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX REQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX FEEDBACK XXX

OUTPUT SPREADER IN NOT USED NOT USED
REFERENCE XY
REQUIRED VALUE XXX
FEEDBACK XXX


014107

8 Control system – OP 8:21
8.4.10 OP
OP, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG OP 1(6) DIAG OP 2(6) DIAG OP 3(6)

NOT USED PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
LIFT CYL LE RI
BY-PASS X C- X.XXV X.XXV
C+ X.XXV X.XXV
DIAG OP 4(6) DIAG OP 5(6) DIAG OP 6(6)

PRESENT INPUT SIGNAL ALLOWED LOAD XXXXXKg BOOM ANGLE XXX
BOOM ANGLE X.XXV PRESENT LOAD XXXXXKg BOOM EXTENSION XXX
BOOM EXTENSION X.XXV LOAD STR.AXLE XXXXXKg BOOM HEIGHT XXX
011098
LOAD-CENTER XX.XXm BOOM HEIGHT NOSE XXX

8:22

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
9.10 Cab structure and suspension .......................................................................9:34
9.10.4 Sliding cab.................................................................................................9:34
9.11 Cab interior ....................................................................................................9:35
9.12 Frame.............................................................................................................9:36
9.13 Body structure................................................................................................9:37
9.15 Paint/coatings ................................................................................................9:38

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. Operator'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 features a heating and ventilation
system. Air conditioning is available as optional equipment.

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
010906
14
1. Left instrument panel

2. Gear and multi-function lever (S162)
3. Steering wheel panel
4. Steering wheel
5. 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. Operator’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
Instrument panel
Instrument panel
16. Switch for fan (S118)
17. Switch for heat (S139)
29 30 31 18. Switch for air distribution (S117)
24..28
19. Switch for work lights cab roof (S105-1)
19..23 20. Switch for work lights attachment (S105-2)
18 21. Switch for work lights boom (S105-3)
17
010907
22. Switch for rotating beacon (S110)
16
23. Switch for hazard lights (S109)
Instrument panel
24. Switch for headlights (S100)
25. Switch for seat heating (S143)
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 light 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 in engine
42..46 39. Indicator light for preheating
47 48 40. Warning lamp for low coolant level engine
41. Warning light for high oil temperature in 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 direction indicators
46. Indicator light for parking brake
47. Indicator light for locked twistlocks (secured load)
48. Indicator light for contact (attachment / load)
49. Indicator light for unlocked twistlocks (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 (S150)
55
62 54. Switch for defroster
56
55. Switch for windshield wiper roof, interval
005073
61 60 59 58 57
56. Switch for windshield wiper roof, continuous
Steering wheel panel with panel for warning and indicator 57. Switch for interior lighting
lights
58. Switch for windshield wiper rear, interval
59. Switch for windshield wiper rear, continuous
60. Function keys for control and monitoring system
61. Travel direction indicator, Forward Neutral Reverse
62. Switch for shifting program A, automatic shifting
63. Switch for shifting program 1, locked to 1st gear
64. Switch for shifting program 2, locked to 2nd gear

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

Panel for hydraulic functions
65 66 67 68
65. Spare
66. Spare
67. Spare
68. Spare
6 9 ..7 2
69. Switch for twistlocks, automatic/manual locking (S1003)
70. Spare
71. Spare
73 72. Spare
74 73. Spare
76
75 74. Spare
014162
75. Spare
Panel for hydraulic functions 76. Switch for by-pass of hydraulic functions (S1005)
Operating menus, overview

Operating menus, overview
1 2 3 4
O K
10 5
014142
9 8 7 6
1. Operating menu engine and transmission
2. Operating menu dynamic scale
3. Operating menu dynamic scale
4. Operating menu engine
5. Operating menu transmission and hydraulics
6. Operating menu electrical system
7. Operating menu container counter
8. Operating menu checking dynamic scale
9. Operating menu service
10. Operating menu heating and air conditioning

Event menus overview

Event menus overview
1 2 3 4
014143
5
1. Event menu overload forward
2. Event menu overload on steering axle
3. Event menu, top lift alignment
4. Event menu twistlocks
5. Event menu start interlock

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 protective and warning equipment to
make the operator's work safer.
The machine may be equipped with the following:
1,7,8 6
10
013832
4 5 3 9
1. Reverse alarm 7. Camera with monitor
2. Rotating beacon Used to give better visibility to the front and rear when
operating the machine. The monitor is located inside
3. Horn
the cab on the left side.
4. Fire extinguisher
8. Back-up lights
Fire extinguishers can also be located externally.
9. External rear view mirrors
If the machine is supplied with a fire extinguisher, it
Used to provide increased visibility for operating and
should be of the type ABE according to EN3 pt. 1, 2,
load handling. One rear-view mirror on each side.
4 and 5. With such a fire extinguisher, it is possible
to extinguish fires in both solid organic materials and 10. Control breaker for hydraulics.
fluids. Adapted fire extinguishing equipment can be
Breaks all transmission of power and control signals
ordered from Cargotec.
to the hydraulics.
5. Seat belt
11. Emergency exit, right door
6. Buzzer in the cab to indicate an alarm, overload or
(not shown on diagram)
forgotten action, e.g., if the operator leaves the cab
without applying the parking brake.

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 ECH)
The heating and ventilation unit (ECH) 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)
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)
16. Switch defroster on Control unit KIT (D790-2)
8. Engine
17. Operating menu on Control unit KID (D795)
9. Sensor engine temperature

9:14 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
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. The refrigerant is evaporated in the evaporator in the
cab. When the refrigerant is evaporated, cold is 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
D D 6
7 D790-1 D790-2 D795
D
15 D D797-R D794
M 16
D 12 D
14 22 23
5 ˚C Pa ˚C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
10
˚C
8 11
004302
1. Switch temperature (S117) 15. Damper motor (Y672)
2. Switch fan (S118) 16. Control unit frame rear (D797-R)
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. Motor 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 position
Components in cab
Components in cab
1 2 3
16
15
14
13
6
7
12
8
11
010619
10 9
1. Operating menu on Control unit KID (D795)
2. Switch defroster on Control unit KIT (D790-2)
3. Sensor outdoor temperature (B774)
5. Sensor cab temperature (B775-1) (inside of the left control panel, behind a grating)
6. Switch air distribution (S139)
7. Switch temperature (S117)
8. Switch fan (S118)
9. Expansion valve
10. Fan motor heat (M657)
11. Actuator recirculation (M612)
12. Fresh air filter
13. Heat exchanger (cold and heat)
14. Sensor temperature refrigerant circuit (B775-3)
15. Damper motor (Y672)
16. Sensor temperature outlet fan (B775-2) (in air distributor)

Components in engine compartment (engine alternative Yuchai YC6M360-30)

Components in engine compartment (engine alternative
Yuchai YC6M360-30)
2
1
014121
6 5 4
1. Condenser
2. Water valve (Y673)
3. Pressure switch (S246)
4. Moisture filter
5. Compressor
6. Magnetic clutch compressor (M645)

Components in engine compartment (engine alternative Cummins QSM11)

Components in engine compartment (engine alternative
Cummins QSM11)
1 2
4 3
013117
1. Condenser
2. Water valve (Y673)
3. Pressure switch (S246)
4. Moisture filter
5. Compressor
6. Magnetic clutch compressor (M645)

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.
Risk of personal injury.
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 cooling plant 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 gas
cylinder. Open the valve on the cylinder and then the valve 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 valve on the cylinder.
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 valve on the suction side
very carefully, otherwise the oil will be blown out of the vacuum
pump. Then open the valve on the pressure side, vacuum 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
1 Remove the cover and change the fresh air filter.

The fresh air filter is located at the front of the cab.
9.4.8 Condenser
Condenser, cleaning

2 Blow clean the condenser's cooler with compressed air.
1. Radiator
2. 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 Check for leaks 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 lights are turned on automatically when the
operator sits in the set, selects a gear, or if the accelerator pedal is
pressed down.
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 2 3 5 4
D
D D
D D 8
9
13 10
D
6 D 14 D
D
D 15 12 D
16 M D
D 7 9 0 -1 D 7 9 0 -2
23 7 17 11 30
D D D 7 9 7 -R D 7 9 7 -F D 7 9 1 -1
D 18 D D D
D Pa D D
D D D 31
29 32
013902
D
24 25 26 27 28 19 20 21 22
1. Switch work lighting cab (S105-1) 18. Make-contact brake lights (S216)
2. Switch work lighting attachment (S105-2) 19. Running lights front (H416-1 & H417-1)
3. Switch work lighting boom (S105-3) 20. Direction indicators front (H422 & H423)
4. Switch headlights (S100) 21. Headlights low beams (E400L & E400R)
5. Switch rotating beacon (S110) 22. Headlights high beam (E402L & E402R)
6. Break-contact door (S266-LE & S266-RI) 23. Control unit frame rear (D797-R)
7. Control unit cab (D790-1) 24. Tail lights (H412L & H412R), red
8. Multi-function lever (S162) 25. Brake lights (H411L & H411R)
9. Lever direction indicator (S161) 26. Running lights rear (H416-2 & H417-2)
10. Switch interior lighting on Control unit KIT (D790-2) 27. Direction indicators rear (H426 & H427)
11. Control unit KIT (D790-2) 28. Back-up lights (E405L & E405R), white
12. Work lighting cab (E404-1L & E404-1R) 29. Work lighting boom (E404-3L & E404-3R)
13. Relay extra work lights boom (K304) 30. Control unit attachment (D791-1)
14. Extra work lighting boom (E404-5L & E404-5R) 31. Work lighting attachment (E406-L & E406R)
15. Interior lighting 32. Extra work lighting, attachment (E404-4L &
E404-4R)
16. Rotating beacon (H428)

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

The function of the lighting is to increase safety during operation and
load handling. The machine has the following lights:
NOTE
F Technical data.
1 2 3 4 5 6 7
18, 19, 20, 21
013840
17 16 15 14 13 12 11,10,9 8
1. Rotating beacon (H428) Headlights high beam (E402L & E402R)
2. Interior lighting 12. Make-contact brake lights (S216)
3. Control unit KIT (D790-2) 13. Control unit, frame front (D797-F)
4. Multi-function lever (S162) 14. Switches, see Controls and instruments, overview,
page 9:4
5. Work lighting cab (E404-1L & E404-1R)
15. Break-contact door (S266-LE & S266-RI)
6. Work lighting boom (E404-3L & E404-3R)
Extra work lighting boom (E404-5L & E404-5R)
18. Running lights rear (H416-2 & H417-2)
8. Work lighting attachment (E406-L & E406R)
19. Back-up lights (E405L & E405R), white
Extra work lighting, attachment (E404-4L &
E404-4R) 20. Tail lights (H412L & H412R), red
9. Direction indicators front (H422 & H423) Brake lights (H411L & H411R)
10. Running lights front (H416-1 & H417-1) 21. Direction indicators rear (H426 & H427)
11. Headlights low beams (E400L & E400R)

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
D 5
D D 6
16
D
D D D
D 17
14
15 M
7 18
D D 7 9 0 -1 4 D 7 9 0 -2 D 795
8
D 7 9 7 -R D 7 9 7 -F
D D 12
9 10 D
D 13
11
013901
1. Switch rotating beacon (S110) 10. Back-up lights (E405L & E405R), white
2. Switch hazard lights (Hazard) (S109) 11. Back-up alarm (H965)
3. Switch parking brake (S107) 12. Control unit, frame front (D797-F)
4. Control unit cab (D790-1) 13. Direction indicators front (H422 & H423)
5. Multi-function lever (S162) 14. Horn (H850)
6. Lever direction indicator (S161) 15. Rotating beacon (H428)
7. Control unit KIT (D790-2) 16. Break-contact operator in seat (S230)
8. Control unit frame rear (D797-R) 17. Buzzer cab (H853)
9. Direction indicators rear (H426 & H427) 18. Control unit KID (D795)

9 Frame, body, cab and accessories – Signalling system 9:31
Signalling system, component position
1 2 3 4
13,14
013841
12 10,11 9 8 7 6 5
1. Rotating beacon (H428) 9. Horn (H850)
2. Control unit KIT (D790-2) 10. Break-contact operator in seat (S230)
3. Buzzer cab (H853) 11. Control unit cab (D790-1)
4. Control unit KID (D795) 12. Control unit frame rear (D797-R)
5. Control unit attachment (D791-1) 13. Direction indicators rear (H426 & H427)
6. Direction indicators front (H422 & H423) 14. Back-up alarm (H965)
8. Switches, see Controls and instruments, overview,
page 9:4

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 position
The function of the window panes is to enclose the cab and to give
C the operator good visibility. The window panes are tinted.
The rear-view mirrors are of the type convex mirror. Outside rear-view
D
mirrors are located on the frame and an inside rear-view mirror is
located in the cab.
As an option the machine can be equipped with a back-up

(reversing) camera and a screen in the cab to improve visibility to
the rear. The back-up camera is located on the counterweight. The
monitor is installed on an adjustable stand on the left door pillar.
001512
A E 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.
CAUTION
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
The strength of the roof window is affected!
Only use clean water with anti-freeze, e.g., washer fluid.

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 minimize 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.
2 The cab suspension is of the type Manual sliding cab, description,

page 9:34.
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.4 Sliding cab

Manual sliding cab, description
Manual sliding cab means that the cab can be moved forward
to facilitate access for service and maintenance in the engine
compartment.
The cab is slid fore and aft by hand. Two cable chains on each side
protect hoses and cables to and from the cab when the cab is moved.
The cab is secured in the rear position during operation with two lock
devices at the cab's trailing edge.
A
DANGER
The cab is heavy and the machine may never be
moved without secured cab.
WARNING
012760
B C
A Position, lock device It is important that the lock devices are intact!
B Lock pin They should be checked regularly. However, this is
C Lock handle for securing cab not included as a part of the service schedule for
preventive maintenance!

9 Frame, body, cab and accessories – Cab interior 9:35
9.11 Cab interior

Cab interior, description
The cab is designed for best operator comfort. On the instrument
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

9:36 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:
4
6
013122
1
1. The rear section of the frame with drive axle mounts 5. Boom mounting
2. Cab mounts (4 points) 6. Engine compartment with engine and transmission
mounts
3. Steering axle mounts
4. The rear section of the frame with counterweights

9 Frame, body, cab and accessories – Body structure 9:37
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.
3
2 1
013123
1. Fenders
2. Hood engine compartment
3. Counterweight

9:38 9 Frame, body, cab and accessories – Paint/coatings
9.15 Paint/coatings
Paint and surface finish, description
The machine is painted using primer and a top coat in chosen colour
that can be applied with a brush or sprayed on. 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.

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
10.4.2 Axial piston pump with variable displacement...........................................10:7
10.5 Hoses, pipes and valves ................................................................................10:9
10.6 Temperature control, cleaning and hydraulic oil...........................................10:10
10.6.6 Breather filter hydraulic oil tank ............................................................... 10:11
10.6.7 Hydraulic oil filter .....................................................................................10:12
10.6.8 Hydraulic oil.............................................................................................10:13
10.6.9 Fine filter hydraulic oil..............................................................................10:14

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 that supply load handling, steering,
and certain cab functions with hydraulic pressure.
The brake system is completely separate, and is found in section 4

Brakes.
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 pressures, these should correspond
to the values on the pressure plate.
1
7
013865
6 5 4 3 2
The appearance of the pressure plate may vary but the symbols are the same.
1. Gas pressure brake accumulators 5. Steering pressure
2. Max. brake pressure 6. Max pressure hydraulic oil pumps
3. Servo pressure lift and extension 7. Hydraulic oil pressure accumulator brake system
4. Gas pressure servo accumulator

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

Safety valves, component position
1 2
013127
1. Relief valve attachment (figure shows open valve)
2. Accumulator drain valve
3. Pressure limiting valve

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

Tanks and accumulators, component position
1 2 1 3 4 Tank
1. Filler plug hydraulic oil
2. Cap for hydraulic oil filter
3. Level glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs hydraulic oil
5 5
013128

10:6 10 Common hydraulics – Pumps
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from six pumps. Four of
1 them are for the working hydraulics, one for cooling and filtering
of the hydraulic oil, and one for the brake system. The pumps are
2 assembled to 2 pump banks. Each pump bank consists of two axial
piston pumps with variable displacement and a gear pump with fixed
5 displacement. The pump banks are mounted on the transmission's
power take-off.
The axial piston pumps are connected mechanically and hydraulically

in pairs and can be regarded as one pump (hydraulic oil pump unit).
Non-return valves make sure that the pumps do not interfere with
each other.
The left hydraulic oil pump unit (position 1 and 2) supply the control
3 valve for lift and extension, pump 2 also supplies the attachment's
control valve. For boom in, pump 1 and 2 are disengaged.
4 The right hydraulic oil pump unit (position 3 and 4) supply the
steering system as well as the control valve for lift and extension.
The priority valve makes sure that there is always pressure for the
6
001450
steering system, the residual flow goes to the control valve for lift
and extension.
The left fixed pump (position 5) feeds the brake system's brake and
2. Hydraulic oil pump 2 cooling circuit across an accumulator charging valve, see section 4
3. Hydraulic oil pump 3 Brakes, group 4.3.1 Brake oil pump.
The right fixed pump (position 6) continuously circulates the hydraulic
5. Brake oil pump oil through the cooler and hydraulic oil filter.
6. Hydraulic oil pump cooling and filtering

10 Common hydraulics – Axial piston pump with variable displacement 10:7
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
15
D 7 9 0 -1 14
16 P S
D 7 9 7 -R 18 19
P 1 20
P P
D LS
LS
D P
13 21
11 12 E F C F
P P
17
C P LS
LS P 1 A T H
LS P 2 LS P R
LS P 3 LS H Y
10
6 7
8 9
5 C C C
C
N o 1 N o 2 N o 3 N o 4
1
013842
2 3 4
1. Hydraulic oil pump 1 12. Solenoid valve top lift hydraulics (Y6003)
2. Hydraulic oil pump 2 13. Accumulator servo circuit
3. Hydraulic oil pump 3 14. Servo filter
4. Hydraulic oil pump 4 15. Control valve lift and extension
5. Non-return valve 16. Control valve attachment
6. Non-return valve 17. Priority valve
7. Non-return valve 18. Pressure limiting valve
8. Non-return valve 19. Steering valve
9. Non-return valve 20. Control unit frame rear (D797-R)
10. Valve block servo pressure 21. Adjusting valve pilot pressure
11. Solenoid valve, unloading main pump (Y6062)

10:8 10 Common hydraulics – Axial piston pump with variable displacement
Hydraulic oil pump, checking
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil

reaches operating temperature, approx. 50 ºC.
3 Connect a pressure gauge to the pressure check connection on

hydraulic oil pump 1.
5 Check the standby pressure for one pump at a time as follows:
Hydraulic oil pump 1: 1.8 MPa
Settings apply to standard machine, certain machines may have
higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
1. Hydraulic oil pump 1 different pumps must always be maintained.
6 Increase engine speed to approx. 1,100 rpm and move the
3. Hydraulic oil pump 3 extension function to relief (overflow).
4. Hydraulic oil pump 4 Run out the boom to max. and continue to request max. extension
with the control lever. This will move the extension function to
relief.
7 Check the max. pressure for hydraulic oil pump 1, the pressure
should match the stated value on the pressure plate.
All pumps should give the same pressure. The order between
pumps is not important.
9 Move the pressure gauge to the next pump and repeat steps 3–8
on all four pumps.
013863

10 Common hydraulics – Hoses, pipes and valves 10:9
10.5 Hoses, pipes and valves

Hoses, pipes and valves, component position
013867
1. Valve block servo pressure 2. Priority valve

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 with a separate pump
that circulates the oil through a cooler and filters. The cooler has a
temperature-controlled electric fan that counteracts overheating.
Temperature control consists of hydraulic oil tank, hydraulic oil pump,

hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, hydraulic
oil temperature sensor and bypass valve.
The hydraulic oil pump pumps oil (from the tank) that is cooled in the
hydraulic oil cooler and is cleaned by the oil filters in the tank. 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. A bypass valve leads the oil past the cooler directly to tank if
the resistance through the cooler and filters becomes too high. The
temperature sensor controls activation of the fan and temperature
display in the display.
˚C 2. Cooler hydraulic system
9 ˚C 3. Temperature sensor (B776)
D795 4. Control unit frame rear (D797-R)
5. Cooling fan (M668)
D D797-R 6. Hydraulic oil filter

4 D
7. Fine filter
8. Bypass valve
5 M 9. Control unit KID (D795)
2
8
1 6
7
005111
˚C 3

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

component position
013868
6
5
1. Cooling fan and cooler hydraulic oil 5. Breather filter hydraulic oil tank
2. Hydraulic oil filter 6. Sensor hydraulic oil temperature (B776)
3. Fine filter hydraulic oil 7. Bypass valve
10.6.6 Breather filter hydraulic oil tank
Breather filter hydraulic oil tank, changing
2 Clean the area around the filter housing.
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 counter-clockwise.
1. Cover plate for oil filter
6 Reset the filter indicator by pressing down the button in the middle
2. Filling point hydraulic oil
on the glass centred on the filter cartridge.

10:12 10 Common hydraulics – Hydraulic oil filter
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.
2 Remove the cover plates over the hydraulic oil filters.

3 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter
cartridge as environmentally hazardous waste. Note position of
the parts.

5 Clean the filter holder's parts. Be especially thorough with the

magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and cover plates. Tighten the bolts crosswise.
Magnetic rod

10 Common hydraulics – Hydraulic oil 10:13
CAUTION
Do not overfill!
10.6.8 Hydraulic oil

Hydraulic oil, level check
NOTE
The oil level is checked with the boom fully lowered and fully
retracted.
1 Machine in service position, section B Safety.
CAUTION
Do not overfill!
Hydraulic oil, changing
NOTE
Safety.
IMPORTANT

10:14 10 Common hydraulics – Fine filter hydraulic oil
2 Remove the filler cap and pump out the hydraulic oil in a collection
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
Make sure that the drain plug's washer seal is also removed.
5 If the hydraulic oil filters are to be changed, change them before
2. Filling point hydraulic oil filling the tank with oil, see Hydraulic oil filter, changing, page
3. Level glass 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 level glass. For
volume and quality, see section F F Technical data.
CAUTION
Do not overfill!
10.6.9 Fine filter hydraulic oil
Fine filter hydraulic oil, changing
NOTE
Safety.
IMPORTANT

10 Common hydraulics – Fine filter hydraulic oil 10:15
2 Remove the cover.

3 Lift up the filter cartridge and place it in the receptacle. Let the
hydraulic oil drain.
4 Install the new filter cartridge and put the cover on the fine filter.
013131
CAUTION
Do not overfill!

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 position
2 3 4 1. Main fuses, boom nose
1 2. Control switch
3. Circuit fuses, electrical distribution box cab
4. Main fuses, boom mounting
5. Main fuses, electrical distribution box frame
6. Circuit fuse, transmission (F51-3)
7. Circuit fuses, electrical distribution box frame
8. Battery disconnector
6
013871
8 7

11:4 11 Common electrics – Fuses
11.2.2 Fuses
Fuses, description
IMPORTANT
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.
Main fuses
Main fuses
1 2
The main fuses divide the machine's voltage feed into smaller parts
to maintain as many functions as possible in case of damage to
cables harnesses.
By the cab's and frame's electrical distribution boxes there are fuse
plates that describe the different fuses.
3
4
5
6
013874
Main fuses
1. Control breaker voltage (15E) to control units on
boom and attachment, (25 A)
2. Ground connections for boom and attachment,
(25 A)
3. Electric power feed relay K1, electric power to
ignition voltage (15), (50 A)
4. Battery voltage (30) to cab, engine, and
transmission, (50 A)
5. Electric power feed relay K2, power to control
breaker voltage (15E), (50 A)
6. Ignition voltage (15) to control units on frame,
engine, and transmission, (50 A)

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.
5 8 -4 By the fuse holders there are fuse plates with information about fused
function and fuse rating.
S U P P LY P O W E R
A 1 10A K C U (K A L M A R C A B U N IT )
B 2 5A K C U ,S T A R T U P (K A L M A R C A B U N IT ) 9 2 3 9 3 5 .0 1 8 5
5 8 -5
F 5 8 -4 1 5
C 3 10A S E R V IC E
C A B
D 4 10A O P T C U S TO M E R
E 5 10A O P T R A D IO
M A IN P O W E R
F6 25A O P T S E AT H E AT E R ,T U R N A B LE S E AT
F 5 8 -4 3 0
G 7 15A O P T W O R K L IG H T
C A B
H 8 15A O P T A IR C U S H IO N E D S E A T
A 1 25A K C U (K A L M A R C A B U N IT )
F 5 8 -5 1 5 S U P P L Y P O W E R C A B
B 2 10A K IT (K A L M A R IN F O R M A T IO N T E R M IN A L )
C 3 15A E C C , F A N (E L E C T R O N IC C L IM A T E C O N T R O L )
D 4 5A E C C , R E C IR C (E L E C T R O N IC C L IM A T E C O N T R O L )
E 5 10A S E R V IC E
F6 5A O P T M A P R E A D IN G L IG H T
G 7 10A O P T C O N V E R TE R 12V
014170
H 8 10A O P T C O M P R E S S O R H O R N
Circuit fuses electrical distribution box cab
A1 30A CAB
A42174.0200
B2
F58-1 30 MAIN POWER
C3 15A ENGINE
D4 10A ENGINE
E5 5A TRANSMISSION
F6
G7 30A OPT ENGINE/EATS VOLVO
H8
5 1 -3 A1 25A KDU, FRONT (KALMAR DISTRIBUTION UNIT)
5 8 -1 B2 5A ENGINE, ECC
F58-2 15 SUPPLY POWER
C3 25A KDU, REAR (KALMAR DISTRIBUTION UNIT)

5 8 -2
0 14 1 2 7
D4 10A KDU, OPT (KALMAR DISTRIBUTION UNIT)
5 8 -3 E5 5A TRANSMISSION
F6
Fuses on frame G7
H8 5A ENGINE
51-3. 0.5-fuse (control unit transmission)
58-1. 30-fuses (battery voltage) A1 25A ATTACHMENT
B2 10A KDU,FRONT (KALMAR DISTRIBUTION UNIT)

58-2. 15-fuses (ignition voltage)
F58-3 15E SUPPLY POWER
C3
58-3. 15E-fuses (control breaker voltage) D4 10A KDU,OPT (KALMAR DISTRIBUTION UNIT)
E5
EMERGENCY
Fuses in cab F6
G7
F58-4. Circuit fuses cab battery voltage (30) and ignition
014128
H8 5A FEEDBACK K2
voltage (15)
58-5. Circuit fuses cab ignition voltage (15)
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 battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
4 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 shall be checked for clamping, chafing

risk, and damage to the battery cables. Repair or replace defective
clamps and eliminate chafing risks. 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 position (engine
The alternator is located on the engine's left side.
013870
Alternator, component position (engine

alternative Cummins QSM11)
The alternator is located on the engine's left side.

007444

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
D791-1
The following takes place at start-up:
Startup signal
1. Start-up signal to Control unit cab (D790-1).
2. Control unit cab (D790-1) initiates connection of redundant
D790-1 D790-2 D795 voltage feed. See Redundant voltage feed of control units,
description, page 11:12.
013420
D797-R D797-F
Start-up signal is sent
3. Control unit cab (D790-1) activates ignition voltage (15). See
D791-2 Ignition voltage (15), description, page 11:13.
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
D790-1 D790-2 D795 CAN-bus drivetrain, description, page 11:18.
6. Control unit cab (D790-1) activates control breaker voltage (15E).
See Control switch voltage (15E), description, page 11:14.
013421
D797-R D797-F
Redundant CAN-bus communication

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 0, hold circuit's run time has expired 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 Control switch voltage (15E), description, page 11:14.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:13.
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

A The redundant voltage feed only feeds the control units' control logic
D791-1 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-R D797-F
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

D791-1 illustration.
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
D790-1 D790-2 D795 other control units, see B in illustration.
Control unit cab (D790-1) has 4 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.
013422
D797-R D797-F
A Start-up signal is sent

B All control units are supplied with voltage

11 Common electrics – Voltage feed 11:13
11.5.1.3 Ignition voltage (15)
Ignition voltage (15), description

The ignition voltage feeds the power electronics.
S ta r tu p
2 The ignition voltage is activated by:
• Start key in position I
D 7 9 0 -1 • Flashing hazard lights (Hazard) activated
1 D 1 D 2
When ignition voltage is activated the following takes place.
D 795 1. Battery disconnector in position 1. Voltage feed to Control unit
3 cab (D790-1), ignition, switch flashing hazard lights, door switch
K 3 1 5 -1 and interior lighting.
2. Switch for start-up signal gives pulse to Control unit cab (D790-1).
- + 4 CAN bus communication is established (not drive-train).
D 7 9 7 -F 3. Start key in position I or flashing hazard lights activated.
D 3
4. Control unit cab (D790-1) feeds voltage to power relay ignition
D 4 (K315-1) and relay ignition key lock (K315-2) in electronic box
D 7 9 7 -R frame.
5. Ignition voltage supplies control units, relays, solenoid valves and
D 5 other electronics.
D 793
Drivetrain’s CAN bus establishes communication.
K 3 1 5 -2
0 11 3 0 2
D 794
Power feed ignition circuit
D1. Diagnostic menu CAN/POWER 4
D2 Diagnostic menu CAN/POWER 6

11:14 11 Common electrics – Voltage feed
11.5.1.4 Control breaker voltage
Control switch voltage (15E), description

S250 The control switch voltage supplies functions which require a control
D1 switch, e.g. working hydraulics.
1 The control switch is activated with Switch control switch.
D790-1
2 4 Condition for activating control switch voltage is that Switch control
switch is not pressed in.
D6 D5 D2 • Start key in position I
D3 • Ignition voltage (15)
K3009-1 K3009-2
D797-F • Switch, control switch not activated.
- + 5 When control switch voltage is activated the following takes place.
3 1. Ignition voltage is connected to Control unit cab (D790-1).
013423
D791-1 2. Control unit cab (D790-1) activates control breaker (K3009-1) in

D4 electronic box frame and control breaker voltage (15E) feeds the
circuit until relay (K3) in electronic box frame.
Power feed, control breaker circuit
3. 15E-feed sends a voltage signal to Control unit cab (D790-1) and
verifies that Power relay control breaker (K3009-1) is active but
D2. Diagnostic menu CAN/POWER 5 that Power relay control breaker (K3009-2) is inactive.
D3 Diagnostic menu CAN/POWER 5 This verifies that the control breaker is working.
D4 Diagnostic menu CAN/POWER 8 4. Control unit cab (D790-1) activates power relay control breaker
(K3009-2) in the electrical distribution box and the control breaker
voltage supplies voltage to the control units (not drivetrain).
5. When Switch control breaker (S250) is pressed down the ignition
voltage to Control unit cab (D790-1) is cut off, and thus the control
current to Power relay control breaker (K3009-1) and Power relay
control breaker (K3009-2). Power supply to the control units is
cut off and the functions stop.
As extra safety the cab control unit (D790-1) also sends status
for Switch, control breaker (S250) on the CAN bus. In this way
functions are also cut off at signal level.

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

Electrical distribution box, component position
5
4
3
2 12
1 6
13
14
15
7
8 16
9
10
11
014129
1. Circuit fuses battery voltage (30) F58-3 9. Power relay ignition K315-1
2. Circuit fuses ignition voltage (15) F58-2 10. Power relay control switch K3009-1
3. Circuit fuses control switch voltage (15E) F58-3 11. Power relay control switch K3009-2
4. Diagnostic socket engine (loose in electrical 12. Diagnostic socket machine
distribution box) 13. Circuit fuses cab battery voltage (30) and ignition
5. Main fuses voltage (15) F58-4
6. Main fuses 14. Diagnostic socket drivetrain
7. Circuit fuse control unit transmission (0.5 A) (F51-3) 15. Circuit fuses cab ignition voltage (15) F58-5
8. Relay ignition K315-2 16. Voltage converter

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 4
013869
9 8 7 6 5
1. Control unit attachment (D791-1) 7. Control unit engine (D794) (engine alternative
2. Control unit KID (D795) Cummins QSM11)
3. Control unit KIT (D790-2) 8. Control unit, transmission (D793)
4. Control unit cab (D790-1) 9. Control unit, frame front (D797-F)

6. Control unit engine (D794) (engine alternative Yuchai
YC6M360-30)

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.
D791-1
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.
D797-R 1 D797-F
2
013425
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
D791-1 connections for communication. The CAN-bus is connected in series
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
limited capacity to perform their task.
D790-1 D790-2 D795
CAN R CAN L CAN R CAN L
Signals can be checked with diagnostic menu.
CAN L CAN R CAN L CAN R

013424
D797-R D797-F
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
Error codes
See Workshop manual DRT 450, section D Error codes.

D:2

E:1
E Diagrams
E Diagrams
Diagrams
See Workshop manual DRT 450, section E Diagrams.

E:2

F:1
F Technical data
Contents F Technical data

Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Lift capacity and dimensions............................................................................F:6
Oils and lubricants, recommendation...............................................................F:7
Tightening torques, recommendations.............................................................F:9
Tightening torque, ORFS connections ...........................................................F:10
Tightening torque, connections for air conditioning unit.................................F:11
Unit explanations ...........................................................................................F:12
Conversion SI-units........................................................................................F:13
Conversion table, length ................................................................................F:14
Conversion table, area...................................................................................F:14
Conversion table, volume ..............................................................................F:14
Conversion table, weight................................................................................F:14
Conversion table, pressure ............................................................................F:15

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 Engine Yuchai YC6M360-30

Cummins QSM11
Power acc. to ISO 3046 (net power) 243 kW at 2,000 rpm 224 kW at 2000 rpm
Torque ISO 3046 1550 Nm at 1100 rpm 1575 Nm at 1400 rpm
Max. rpm 2,000 rpm 2,000 rpm
Number of cylinders 6 cylinders 6 cylinders
Alternator 1960 W (28 V / 70 A) 2400 W (24 V / 100 A)
System voltage 24 V (2 x 12 V / 135 Ah) 24 V (2x12 V / 135 Ah)
2 Transmission Dana HR36000

No. of gears forward - reverse 4 – 4
3.3 Driveline/Axle, drive axle Merritor PRC7534
4 Brakes Wet Disc Brakes - Drive wheels

Parking brake Spring brake - Drive wheels
5 Steering Hydraulic servo
6 Suspension
Dimensions, front-rear 18.00x25, PR40 E4
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 in cab LpAZ 73 dB(A)
according to EN12053 with measurement
uncertainty σR = 2.5 dB. Measuring value with
standard engine.
Whole-body vibration in accordance with 0.5 m/s2
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 tube. The cartridge
Work light, Xenon and ballast are replaced complete.
Rotating beacon 70 PK22s (H3)
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
1.2 Engine, fuel system Yuchai YC6M360-30

Cummins QSM11
Fuel tank 550 l
Fuel quality Diesel according to EN590
1.7 Engine, cooling system Yuchai YC6M360-30

Cummins QSM11
Cooling system 35 l 40 l
Coolant, filling and changing Volvo Penta Coolant VCS, ES Compleat, Premix
ready-mixed.
See Oils and lubricants, recommendation, page F:7.
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 Yuchai YC6M360-30

Cummins QSM11
Engine oil, volume 28 l 34 l
Oil type, quality See Oils and lubricants, recommendation, page F:7.
2.6 Transmission, lubrication system Dana HR36000

Transmission oil, volume 50 l

3.3 Driveline/Axle, drive axle Merritor PRC7534

Differential 50 l
Hub reduction 2x10 l
4 Brakes
Brake system 140 l
7 Load handling Spreading motor Rotation motor

Planetary gear hydraulic motor 2.3 l 2.45 l
Brake hydraulic motor - 0.6 l
9 Frame, body, cab and accessories Yuchai YC6M360-30

Cummins QSM11
Refrigerant, volume 2000 g
Refrigerant air conditioning (cooling plant) R134a
Air conditioning, lubricant Zexel PAG-oil (Pre-filled with 1.7 dl ZXL100 PAG oil
correct volume.)
Washer fluid 5 l
Hydraulic oil tank, volume 600 l
Hydraulic system, volume 940 l (total, including tank)

Lift capacity and dimensions
9 '6 "
(8 '6 " )
42
(3 1 )
(4 3 )
45 31 (1 5 )
(4 5 ) (3 1 )
45 31 15
(4 5 ) (3 1 ) (1 5 )
45 31 15
(4 5 ) (3 1 ) (1 5 )
5=18100
4=15100
3=4600
2=3925
H 8=2575
45 31 15
(4 5 ) (3 1 ) (1 5 )
H
H
H
H
L3=6250 L4=1965
L 3= 11450 L5=3815
L6=6315
A 1
A 2
6250 1600
V M IN -M A X = 6 0 5 5 -1 2 1 8 5
B =4150
R 1=830
0
9400
R 3= 100
50
200
0
=4
R4
R 2=1
014133
100

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 YC6M360-30 SAE 15W-40 (engine oil)
API CH-4 or ACEA E5 SAE 15W-30 (engine oil)
SAE 10W-30 (engine oil)

Cummins QSM11
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
4 Brakes (UTTO-oil) *)
GM Allison C-4 SAE 5W-30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Planetary gear hydraulic motor, hypoid oil SAE 80W-140
API GL-5
SAE 75W-90
Disc brake hydraulic motor, see "10
Common hydraulics" below.
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, 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
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.

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

F:16

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.
Boom Lift beam can be moved vertically and longitudinally. Mounting for attachment.
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 authorized 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.
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: DRT 450. 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.
OP Overload Protection. Overload system to warn in case of overloading of machine.
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.
Reachstacker Machine with special lift boom and top lift attachment for containers.
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 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.
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 Four lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when 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.
UTTO-oil Universal Tractor Transmission Oil.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.
Wet brakes Brake discs in oil-bath.
Valve slide Moving part in the valve. Decides the oil's path.
Rotation yoke Rotating unit on attachment, rotates attachment in relation to lift boom.
Overload system A warning system, LLMC (Longitudinal Load Moment Control). The system is used for
stationary load handling, in order to not jeopardize the machine forward stability. LLMC
is not intended to control lateral (side) stability or stability when operating.

G Terminology and index – Index G:5
Index Entertainment and communication

Environment . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 9:32
. B:20
Error codes . . . . . . . . . . . . . . . . . . 8:8, D:1
Exhaust system . . . . . . . . . . . . . . . . . . 1:23
A Extension . . . . . . . . . . . . . . . . . . . . . 7:10
About the documentation . . . . . . . . . . . . . . A:11
About the maintenance manual . . . . . . . . . . . . A:3
Accumulator . . . . . . . . . . . . . . . . . . . . 4:8 F
Air cleaning system . . . . . . . . . . . . . . . . . 1:20 Feedback . . . . . . . . . . . . . . . . . . . . A:12
Air intake and exhaust outlet . . . . . . . . . . . . . 1:20 Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:14
Alternator . . . . . . . . . . . . . . . . . . . . . 11:9 Foreword . . . . . . . . . . . . . . . . . . . . . A:3
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:20 Frame . . . . . . . . . . . . . . . . . . . . . . . 9:36
Axial piston pump with variable displacement . . . . . . 10:7 Frame, body, cab and accessories . . . . . . . . . . 9:3
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:25
Fuel filter . . . . . . . . . . . . . . . . . . . . . 1:13
B Fuel pre-filter . . . . . . . . . . . . . . . . . . . . 1:11
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:7 Fuel system . . . . . . . . . . . . . . . . . . . . 1:10
Battery voltage (30) . . . . . . . . . . . . . . . . 11:11 Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:4
Body structure . . . . . . . . . . . . . . . . . . . 9:37
BOOM . . . . . . . . . . . . . . . . . . . . . . 8:19
Brake oil filter . . . . . . . . . . . . . . . . . . . 4:14 G
Brake oil pump . . . . . . . . . . . . . . . . . . . 4:7 General safety information . . . . . . . . . . . . . . B:3
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:3 Glass/windows/mirrors . . . . . . . . . . . . . . . 9:33
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3
Breather filter . . . . . . . . . . . . . . . . . . . 4:13
Breather filter hydraulic oil tank . . . . . . . . . . . 10:11
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:7 H
Heating, ventilation and air conditioning . . . . . . . . 9:13
Hoses, pipes and valves . . . . . . . . . . . . . . . 10:9
C HYD . . . . . . . . . . . . . . . . . . . . . . . 8:15
CAB . . . . . . . . . . . . . . . . . . . . . .. 8:14 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:13
Cab interior . . . . . . . . . . . . . . . . . . .. 9:35 Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:12
Cab structure and suspension . . . . . . . . . . .. 9:34
CAN bus . . . . . . . . . . . . . . . . . . . . 11:18
CAN-bus drivetrain . . . . . . . . . . . . . . . . 11:18 I
CAN/POWER . . . . . . . . . . . . . . . . . .. 8:12 Ignition voltage (15) . . . . . . . . . . . . . . . . 11:13
CLIMATE . . . . . . . . . . . . . . . . . . . .. 8:15 Ignition/heating . . . . . . . . . . . . . . . . . . . 1:40
Common electrics . . . . . . . . . . . . . . . .. 11:3 Intercooler . . . . . . . . . . . . . . . . . . . . . 1:23
Common hydraulics . . . . . . . . . . . . . . . .. 10:3
Communication. . . . . . . . . . . . . . . . . . 11:18
Complete machine . . . . . . . . . . . . . . . .. 0:3
Condenser . . . . . . . . . . . . . . . . . . . .. 9:25
L
Container counter. . . . . . . . . . . . . . . . .. 7:42 Levelling. . . . . . . . . . . . . . . . . . . . . . 7:29
Control breaker voltage . . . . . . . . . . . . . . 11:14 Lift boom . . . . . . . . . . . . . . . . . . . . . 7:13
Control system . . . . . . . . . . . . . . . . . .. 8:3 Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:4
Control system engine. . . . . . . . . . . . . . .. 1:39 Lighting system. . . . . . . . . . . . . . . . . . . 9:28
Control system transmission . . . . . . . . . . . .. 2:12 LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:13
Control units . . . . . . . . . . . . . . . . . . . 11:16 Load carrier . . . . . . . . . . . . . . . . . . . . 7:30
Controls and instruments . . . . . . . . . . . . 4:3, 9:4 Load handling . . . . . . . . . . . . . . . . . . . 7:3
Coolant . . . . . . . . . . . . . . . . . . . . . . 1:29 Lubrication system . . . . . . . . . . . . . . . 1:36, 2:8
Coolant filter . . . . . . . . . . . . . . . . . . . . 1:25
Cooling fan . . . . . . . . . . . . . . . . . . . . 1:27
Cooling system . . . . . . . . . . . . . . . . 1:25, 2:11 M
Crank mechanism . . . . . . . . . . . . . . . . . 1:19
Main beam attachment . . . . . . . . . . . . . . . 7:17
Mechanical transmission. . . . . . . . . . . . . . . 2:7
D Moisture filter . . . . . . . . . . . . . . . . . . . 9:26
Monitoring . . . . . . . . . . . . . . . . . . . . . 8:5
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:10
Diagrams . . . . . . . . . . . . . . . . . . . . . E:1
Distribution of electricity
Drive axle . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
11:10
. 3:4
O
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3 Oil for brake system . . . . . . . . . . . . . . . . . 4:15
OP . . . . . . . . . . . . . . . . . . . . . . . . 8:21
Other functions . . . . . . . . . . . . . . . . . . . 7:38
E Overload system . . . . . . . . . . . . . . . . . . 8:5
Electrical distribution box . . . . . . . . . . . . . 11:15
Electrical protection . . . . . . . . . . . . . . . . . 11:3
Engine . . . . . . . . . . . . . . . . . . . . . . 1:3
P
ENGINE . . . . . . . . . . . . . . . . . . . . . . 8:16 Paint/coatings . . . . . . . . . . . . . . . . . . . 9:38
Engine's mechanical parts . . . . . . . . . . . . . . 1:15 Parking brake system . . . . . . . . . . . . . . . . 4:9

G:6 G Terminology and index – Terminology
Parking brake unit . . . . . . . . . . . . . . . . . 4:10 Start battery . . . . . . . . . . . . . . . . . . . . 11:7

Power assisted system . . . . . . . . . . . . . . . 5:3 Start/stop . . . . . . . . . . . . . . . . . . . . . 1:41
Power-assisted brake system . . . . . . . . . . . . 4:4 Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Pressure reducer . . . . . . . . . . . . . . . . . . 7:9 Steering axle cradle . . . . . . . . . . . . . . . . . 6:4
Preventive maintenance . . . . . . . . . . . . . . . C:3 Suspension . . . . . . . . . . . . . . . . . . . . 6:3
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:3 Synchronised lift . . . . . . . . . . . . . . . . . . 7:43
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6
T
R Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Reading instructions . . . . . . . . . . . . . . . . A:4 Technical data . . . . . . . . . . . . . . . . . . . F:3
Redundant CAN-bus . . . . . . . . . . . . . . . 11:18 Temperature control, cleaning and hydraulic oil . . . . 10:10
Redundant voltage feed of control units . . . . . . . 11:12 Temperature control, cleaning and oil brake system . . . 4:12
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:16 Terminology . . . . . . . . . . . . . . . . . . . . G:3
Roof window . . . . . . . . . . . . . . . . . . . . 9:33 Terminology and index . . . . . . . . . . . . . . . G:3
Rotation . . . . . . . . . . . . . . . . . . . . . . 7:26 Torque converter/Clutch system . . . . . . . . . . . 2:6
Rotation motor unit . . . . . . . . . . . . . . . . . 7:28 TRANSM . . . . . . . . . . . . . . . . . . . . . 8:18
Transmission. . . . . . . . . . . . . . . . . . . . 2:3
Turbo . . . . . . . . . . . . . . . . . . . . . . . 1:21
S Twistlocks . . . . . . . . . . . . . . . . . .
Tyres . . . . . . . . . . . . . . . . . . . .
7:30, 7:33
. . . 6:15
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 Tyres and rims . . . . . . . . . . . . . . . . . . . 6:7
Safety and emergency equipment. . . . . . . . . . . 9:9
Safety instructions . . . . . . . . . . . . . . . . . B:4
Safety valves. . . . . . . . . . . . . . . . . . . . 10:4 V
Seats . . . . . . . . . . . . . . . . . . . . . . . 9:10
Servo filter . . . . . . . . . . . . . . . . . . . . . 7:7 Valve mechanism . . . . . . . . . . . . . . . . . . 1:15
Side shift . . . . . . . . . . . . . . . . . . . . . 7:14 Voltage feed . . . . . . . . . . . . . . . . . . . 11:10
Side shift frame. . . . . . . . . . . . . . . . . . . 7:16
Signalling system . . . . . . . . . . . . . . . . . . 9:30
Sliding cab . . . . . . . . . . . . . . . . . . . . . 9:34 W
Speed limitation . . . . . . . . . . . . . . . . . . 8:7
Spreader beam . . . . . . . . . . . . . . . . . . . 7:24 Weight indicator . . . . . . . . . . . . . . . . . . 7:38
Spreading . . . . . . . . . . . . . . . . . . . . . 7:18 Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:5
Spreading chains . . . . . . . . . . . . . . . . . . 7:23 Wheel spindle . . . . . . . . . . . . . . . . . . . 6:5
Spreading motor . . . . . . . . . . . . . . . . . . 7:22 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

Maintenance Manual - DRT 450 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maintenance Manual - DRT 450 PDF

Uploaded by

Copyright:

Available Formats

Reachstackers 45 tonnes

9 Frame, body, cab and accessories

G Terminology and index

Maintenance Manual DRT 450 UDRT02.02GB

UDRT02.02GB Maintenance Manual DRT 450

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 DRT 450 UDRT02.02GB

Read operator's manual

Read the operator's manual

Read maintenance manual

refers to important information in the maintenance manual.

Read the maintenance manual

UDRT02.02GB Maintenance Manual DRT 450

Maintenance manual's content

For more information about function groups, see Function group

Maintenance Manual DRT 450 UDRT02.02GB

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

UDRT02.02GB Maintenance Manual DRT 450

Optional equipment are options that can be added to the standard

Information for optional equipment is described in separate sections

Maintenance Manual DRT 450 UDRT02.02GB

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

UDRT02.02GB Maintenance Manual DRT 450

Underhållsmanual DR T 450 UDR T02.01SE

Example of function description

Maintenance Manual DRT 450 UDRT02.02GB

Symbol explanation function descriptions

UDRT02.02GB Maintenance Manual DRT 450

About the documentation

Always specify publication number when ordering.

For publication number, see the machine card.

Maintenance Manual DRT 450 UDRT02.02GB

Your feedback is important to be able to improve the information.

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: ......................................................................................................................................

UDRT02.02GB Maintenance Manual DRT 450

Maintenance Manual DRT 450 UDRT02.02GB

UDRT02.02GB Maintenance Manual DRT 450

Cargotec has in this publication documented and warned for situations

A near accident is a warning!

Maintenance Manual DRT 450 UDRT02.02GB

Service position is used for service, maintenance and other situations

Service position means:

• Boom fully retracted and lowered to horizontal position.

UDRT02.02GB Maintenance Manual DRT 450

Hydraulic and brake systems, depressurising

2 Depressurise the hydraulic system.

4 Depressurize the attachment.

The figure above shows open valve.