User Manual 160ES-12 EN PDF

160 ES
OPERATING MANUAL
NOTES
The text and images of this document must not be copied or used in other publications without
a written permission of Mantsinen Group Ltd Oy!
All Rights Reserved.
Mantsinen Group Ltd Oy reserves the right to make technical changes.

The machine may differ from the instructions and images in this document.
Any warranty terms and responsibilities are defined in the sales contracts of Mantsinen Group Ltd Oy,
and they cannot be changed based on the information in this document!
The original language of this document is Finnish.

1 General about the machine..................................................................... 7
1.1 Main components...............................................................................................7
1.2 Configurations ...............................................................................................................8
1.3 Type plates.........................................................................................................11
2 Safety and environmental factors .......................................................... 12
2.1 The notations and symbols used in the operation manual.................................12
2.2 Warning and attention stickers...........................................................................12
2.3 General ..............................................................................................................18
2.4 Working conditions.............................................................................................18
2.5 Load handling.....................................................................................................19
2.6 Driving the machine ...........................................................................................19
2.7 Electric system ...................................................................................................20
2.8 Servicing the machine........................................................................................20
2.9 Working in thunderstorm ....................................................................................21
2.10 EmergencyStop buttons...................................................................................22
2.11 Cab safety gate ................................................................................................23
2.12 Safety gates of maintenance platforms / access bridges.................................23
2.13 Emergency cab lowering..................................................................................23
2.14 In case of fire....................................................................................................24
2.15 Emergency exit with rope.................................................................................25
2.16 Operating environment requirements set by operating the machine ...............27
2.16.1 Physical factors.......................................................................................27
2.16.2 Chemical agents .....................................................................................28
2.16.3 Biological elements.................................................................................28
2.16.4 Explosive operating environment............................................................28
2.17 Consequences of operating the machine to the operating environment..........29
2.17.1 Physical factors.......................................................................................29
2.17.2 Chemical agents .....................................................................................29
2.17.3 Biological elements.................................................................................30
2.18 Final termination and recycling of the machine................................................30
3 Operator's environment........................................................................... 31
3.1 Machine joysticks ...............................................................................................32
3.1.1 Left joystick ...............................................................................................32
3.1.2 Right joystick.............................................................................................33
3.1.3 Miniature joystick ......................................................................................34
3.2 Cab safety gate ..................................................................................................36
3.3 Cab EmergencyStop button ...............................................................................36
3.4 ignition switch.....................................................................................................36
3.5 Auxiliary power plugs .........................................................................................37
3.6 Cab power plug (230 V) .....................................................................................37
3.7 Cab heating and air conditioning system ...........................................................38
3.7.1 Adjusting blowing power ...........................................................................39
3.7.2 Changing the mode of heating and air conditioning system .....................39
3.7.3 Selecting cab air circulation ......................................................................40
3.7.4 Directing blown air through different nozzles............................................40
3.7.5 Changing display settings.........................................................................41
3.7.6 Cab preheat function (only diesel machine) .............................................41
Contents
3.7.7 Switching off the heating and air conditioning system ............................. 41
3.8 Multi-function control of the machine control system......................................... 42
3.9 One-touch switch panel of the machine control system .................................... 42
3.10 Rocker switch panel ........................................................................................ 44
3.11 Machine control system user interface ............................................................ 45
3.11.1 Machine control system starting display ................................................ 45
3.11.2 Main display of control system ............................................................... 46
3.11.3 Main menu of control system ................................................................. 48
3.11.4 Enter PIN code display........................................................................... 50
3.11.5 Driver settings menu .............................................................................. 50
3.11.6 Diagnostics menu................................................................................... 52
3.11.7 Transaction log....................................................................................... 52
3.11.8 Factory settings menu............................................................................ 52
3.11.9 Service settings menu............................................................................ 52
3.11.10 Hydraulics info menu............................................................................ 52
3.11.11 Engine info menu (electric motor) ........................................................ 54
3.11.12 Operating times menu.......................................................................... 55
3.11.13 Control system warning pop up windows............................................. 55
3.11.14 List of control system error messages ................................................. 56
3.11.15 Emergency stop view ........................................................................... 56
3.11.16 Menu to adjust windscreen wiper wiping interval ................................. 57
3.12 Load control user interface .............................................................................. 57
3.12.1 Main load control window ....................................................................... 57
3.12.2 Front attachment selection window........................................................ 60
3.12.3 Diagnostics window................................................................................ 60
3.12.4 Distance diagnostics window ................................................................. 60
3.12.5 Hydraulics diagnostics window .............................................................. 61
3.12.6 Load control alarm window .................................................................... 61
3.13 Seat adjustments............................................................................................. 63
4 Operating the machine ............................................................................ 64
4.1 Daily Inspections ............................................................................................... 64
4.1.1 Checking the general condition ................................................................ 64
4.1.2 Inspection of the level of hydraulic oil and adding of oil ........................... 65
4.2 Greasing equipment and filling them ................................................................. 65
4.3 Adding washer fluid ........................................................................................... 66
4.4 Starting up the machine..................................................................................... 67
4.5 Operating the machine at low temperatures...................................................... 67
4.6 Driving the machine........................................................................................... 68
4.7 Using the boom ................................................................................................. 69
4.7.1 Load control ............................................................................................. 69
4.7.2 HybriLift® system ..................................................................................... 69
4.7.3 Pressing with the boom ............................................................................ 70
4.7.4 Heavy lift function ..................................................................................... 70
4.7.5 Precision running ..................................................................................... 70
4.7.6 Swing brake ............................................................................................. 70
4.8 Use of cab elevator............................................................................................ 71
4.9 Ending the use................................................................................................... 71
5 Maintenance............................................................................................ 72
Contents
5.1 Electric system ...................................................................................................73
5.1.1 Checking the emergencyStop circuits ......................................................73
5.1.2 Fuses and relays 24 VDC.........................................................................73
5.1.3 Power current conductor connectors requiring retightening .....................74
5.1.4 Checking the load control function............................................................74
5.1.5 Cleaning the air filters of electrical cabinet +LCC1 ...................................75
5.1.6 Cleaning the air filter of the cooling unit of electrical cabinet +MCC2 ......76
5.2 Hydraulic system................................................................................................77
5.2.1 Pressure release of hydraulic system.......................................................77
5.2.2 General inspection of the hydraulic system ..............................................78
5.2.3 Draining water from hydraulic oil reservoir ...............................................78
5.2.4 Changing the drain filter............................................................................79
5.2.5 Replacement of return filters.....................................................................80
5.2.6 Changing the swing circuit filter ................................................................81
5.2.7 Changing the pilot circuit filter...................................................................82
5.2.8 Changing the auxiliary hydraulic filter .......................................................83
5.2.9 Replacing the CJCTM by-pass filter .........................................................84
5.2.10 Changing filters in front attachment line .................................................86
5.2.11 Changing the oil reservoir breather filter.................................................87
5.2.12 Changing the suction filters ....................................................................87
5.2.13 Changing the hydraulic oil and cleaning the oil reservoir .......................89
5.2.14 Cleaning the radiator element of hydraulic oil.........................................92
5.3 Mechanics ..........................................................................................................93
5.3.1 Checking the joints ...................................................................................93
5.3.2 Inspecting plate fields and weldings .........................................................93
5.3.3 Measuring the axial clearance of the slewing bearing ..............................94
5.3.4 Checking the fastening of components.....................................................95
5.3.5 Checking the cab elevator ........................................................................99
5.4 Lubrication points ...............................................................................................100
5.4.1 Changing the pump gear oil and filter.......................................................100
5.4.2 Servicing the swing planetary gears .........................................................101
5.4.3 Inspecting and changing the slewing ring grease.....................................103
5.4.4 Greasing the joints of the cab elevator .....................................................104
5.4.5 Greasing the electric motor bearings........................................................104
5.5 Bogies ................................................................................................................105
5.5.1 Greasing the wheel bearings ....................................................................105
5.5.2 Changing the drive gear oil.......................................................................106
5.5.3 Greasing the joint between bogey and bogey frame ................................107
5.6 Vertical collector.................................................................................................107
5.6.1 Greasing the bearings of circular coupler .................................................107
5.6.2 Checking the slip rings and brushes.........................................................108
5.6.3 Checking conductor connections..............................................................108
5.7 Cable reel...........................................................................................................108
5.7.1 Checking the electric motor ......................................................................109
5.7.2 Checking the cable guide .........................................................................109
5.7.3 Checking the power cable ........................................................................109
5.7.4 Checking the collector housing.................................................................110
5.7.5 Adjusting the reeling torque ......................................................................110
Contents
5.7.6 Changing the torque unit oil ..................................................................... 111
5.8 Maintenance inspections of the HybriLift® system............................................ 112
5.8.1 Checking the gas preload pressure of the pressure accumulators .......... 113
5.8.2 Inspecting the opening pressure of the pressure relief valve in the
energy storage system’s hydraulic circuit ................................................ 115
5.8.3 Replacing the flushing filter ...................................................................... 117
5.8.4 Replacing the pressure filter .................................................................... 118
5.8.5 Flushing the energy storage system ........................................................ 119
5.9 Inspection and service of air-conditioning system ............................................. 120
5.9.1 Visual inspection of air conditioning system and fault diagnostics ........... 121
5.9.2 Checking and replacing the air conditioning compressor belt .................. 122
5.9.3 Checking the condenser unit.................................................................... 123
5.9.4 Checking refrigerant level ........................................................................ 123
5.9.5 Checking the operation of air conditioning system................................... 123
5.9.6 Cleaning and replacing fresh air filter and circulation air filter.................. 124
Appendices
1. Torques
2. Fluids and lubricants
3. Service chart
4. Maintenance measurements of the energy storage system
5. Pressure relief valve of the hydraulic circuit of the energy storage system
6. Lifting capacity table
7. Cab relays and fuses
8. Base machine relays and fuses
9. Fastening of hydraulic hoses and pipes
10. Rescue card
11. Undercarriage relays and fuses
Contents
Mantsinen 160 ES HybriLift® OPERATING MANUAL
1 General about the machine
Mantsinen 160 ES HybriLift is a material handling machine on a tracks, with an electric motor, an energy
storage system and cab elevator. The machine is designed for the loading, unloading and moving of bulk
goods in lit ports, terminals and factory plants. The machine must not be used for lifting passengers unless
special arrangements are made.
Material and energy efficiency have been taken into consideration in machine engineering and manufac-
turing. The machine has been built for optimal energy efficiency, which is indicated by its marginal envi-
ronmental impact and low operating costs.
1.1 Main components

A. Stick cylinder. B. Main boom.
C. Hybrilift cylinder (HybriLift). D. Main boom cylinder.
E. Cab elevator. F. Uppercarriage.
G. Access bridge / maintenance platform. H. Counterweight.
I. Cable reel. J. Stick boom.
K. Cab. L. Horizontal beam.
M. Bogie body. N. Rail tong.
O. Bogie.
S/N: 160ES268113 Ver: 170203 1 General about the machine 7

OPERATING MANUAL Mantsinen 160 ES HybriLift®
1.2 Configurations
Main measurements
Total weight. 215000 kg.
Outreach. 31,8 m.
Main boom. 17,5 m straight.
Stick. 15,0 m.
Counterweight. 32100 kg.
Electrical system 160 E
Electric motor 160 E. - Cast Iron motor.
- IEC 315kW 1500 rpm / 50 Hz, (1800 rpm / 60 Hz).
- Energy efficiency class IE3.
- Soft starter.
Electric supply. - Power feed point in centre of rail length.
- Travel distance 110 m.
Supply voltages. Supply voltage range 380 V.
Additional voltages. - 24 V DC.
- 230 V AC.
- 4 outside the cabin.
Working lights - 4 in the stick.
- 1 above the cabin facing backwards.
Hydraulic system
Type. - Two main circuits for front equipment and travel.
- Separate closed loop swing circuit. HybriLift® energy
recovery system equivalent up
- to 260 kW engine power.
Main pumps. - Three variable displacement axial piston pumps.
- Oil flow 3 x 420 l/min.
Swing. - Variable displacement axial piston pump.
- Oil flow 540 l/min.
Auxiliary circuit. - Gear pump, rotator, cablift.
- Oil flow 65 l/min.
Working pressures. - Front equipment 330 bar.
- Heavy lift, drive 350 bar.
- 2 pcs.
- Piston / rod diameter 230 mm / 160 mm.
- Min / max length 3360 mm / 2290 mm.
Main boom cylinders.
- End cushioning.
- Load control valves.
- Hose rupture valves.
- 2 pcs.
Stick cylinder.
- End cushioning.
8 1 General about the machine S/N: 160ES268113 Ver: 170203

- 1 pcs.
HybriLift®cylinders.
- End cushioning.
- Main filter 10 microns.
- Bleed-off fine filter with water separator 3 microns.
- HybriLift® filter 10 microns.
Filtration.
- Swing circuit filter 10 microns.
- Pilot filter 3 microns.
- Drain line filter 10 microns.
- Hydraulically driven.
- Temperature control.
Hydraulic oil cooler.
- Cleaning with reversing function.
- Automatic and manual control.
Undercarriage, rail mounted
Height. 5,0 m.
Bogie gauge. 10 m.
Track gauge. 6,5 m.
- 8 pcs.
Track wheels. - Material 42CrMo4.
- Diameter 630 mm.
- 8 pcs driving gear.
Powertrain.
- 8 pcs of driving motors.
Travel length. 110 m.
Cable reel. Cavotec.
Cable. 2x150 mm2, Buflex.
Parking brake. 1 pcs of Mantsinen hydraulic rail tongs.
Swing
Slewing ring. - Heavy duty three-row roller type bearing.
- Internal gear, immersed in grease.
- Outer diameter 2700 mm.
Swing motors. Two axial piston motors.
Swing brakes. Automatic wet multiple disc brakes.
Swing drives. Planetary reductions in oil bath.
Swing speed. 0 to 5,2 rpm.
Swing torque. 350 kNm.
Cab elevator ant operators cabin
Cab elevator. N2-5000.
Cabin type. Harbour cabin.
- Fully wide curved.
Cabin windshield. - Tinted.
- Wiper with adjustable intermittent function.
- Tinted.
Cabin roof window. - Wiper.
- Sun shades.
- Heating and air conditioning.
Others.
- Folding instructor seat.

- Air suspended seat with automatic weight adjustment turn
table.
- Seat belt.
Operators seat. - Heating.
- Fully adjustable armrest, headrest back rest and height.
- Slide, front - back.
- Seat tilt.
- Ergonomic, adjustable multi-function joysticks.
- Travel, outrigger control and steering by one grip joystick.
- All front equipment and attachment functions are
proportional.
- Function speeds, ramps and control curves are adjustable.
- Electric end cushion boom, stick and cab elevator.
- Precision mode.
- Heavy lift mode.
- Remote MCS access (customers SIM-card).
Mantsinen Control System MCS
- Colour display 7,0” user interface.
- Operating data and gauges.
- Warning signals, illuminated pop up symbols.
- Acoustic signal for critical alarms.
- Settings.
- Diagnostics.
- Log function.
- Instant power consumption.
- Periodic fuel or electric power consumption.
- CANopen CAN-bus technology.
- Colour display 5,7” user interface.
- Overload and stability control with motion cut.
Mantsinen Safety System MSS - Cab collision prevention with motion cut.
- Animated machine operation.
- Attachment menu.
- Load, reach and height information.
- Central lubrications system Lincoln.
- Travel alarms beacon.
- Loudspeaker.
Others - Remote data access for diagnostic.
- Basic tool kit.
- Radio and CD player, MP 3 - compatible.
- Painting class of steel structures C4, cover plates C5.
10 1 General about the machine S/N: 160ES268113 Ver: 170203

1.3 Type plates

1. Cab elevator model.
2. Cab elevator serial number.
3. Cab elevator's weight A [kg]
4. Year of manufacture.
Safe cab working load in persons B
5.
[quantity] or as mass C [kg].
6. Machine model.
7. Machine serial number.
8. Engine power D [kW].
9. Weight E [kg]
10. Year of manufacture.
Maximum allowed load G [kg] the
machine can lift with the maximum boom
11.
reach F [m] when the outriggers are on
the ground.
Maximum allowed load H [kg] the
12. machine can lift with the minimum boom
reach I [m].

2 Safety and environmental factors
It is of utmost importance that all the instructions and regulations are followed, for the sake of the safety of
the operator and for the sake of general safety. Non-compliance with the safety instructions may lead to
serious personal injuries and / or damage to property.
The machine operator is always responsible for operating the machine and its front attachments safely and
appropriately in the operating environment. The machine manufacturer is not responsible for the applica-
bility and safety of attachments other than those of Mantsinen in the intended use and operating environ-
ment.
2.1 The notations and symbols used in the operation manual.
Warning!
Alerts of a risk of personal injury or major damage to property, when not operated correctly.
Note!
Draws attention to a correct and safe mode of operation.
Safety!
Instructs to protect the machine and its operating environment during its use or service.
Info!
Provides instructions in special circumstances.
2.2 Warning and attention stickers

The operators and service personnel of the machine must carefully study the meanings of the warning and
attention stickers, and their location on the machine. The warning stickers have been attached to locations,
in the vicinity of which extra caution must be exercised. The attention stickers are mostly normative or
provide advice.
There can be stickers of many different sizes, and they may come with a text or symbol related to the con-
text. They must be clearly readable, and they must not be covered. Damaged stickers must be replaced
with new, corresponding ones.
General attention symbol

An explanatory text always accompanies a symbol.
Life-threateningly high electric currents

The symbol warns of places where, or near which, when acting
carelessly, there is a danger of a life-threatening electric shock.
12 2 Safety and environmental factors S/N: 160ES268113 Ver: 170203

Life-threateningly high electric currents

The symbol warns of places where, or near which, when acting
carelessly, there is a danger of a life-threatening electric shock.
Danger of a burn
The symbol warns of potentially hot or burning surfaces.
Danger of a hydraulic leak

The symbol warns of high-pressure hydraulic fluid, which may
penetrate the skin causing a severe illness.
Crushing hazard
The symbol warns of places where, or near which, there is a danger
of getting squeezed or crushed to a life-threatening extent.
Danger of a falling load

of getting trapped under a falling load or getting crushed under it.
Cab elevator arms high

The symbol warns of cab elevator arms, which can be located high,
depending on the position of the elevator. When going under low
obstacles, it must be made absolutely sure that the elevator arms do
not come into contact with anything.
Danger of falling
of falling from a dangerous height.
S/N: 160ES268113 Ver: 170203 2 Safety and environmental factors 13

Laser beam
The symbol warns of a laser beam. A laser beam can damage eyes if
it is directed at them.
Danger of bruising
The symbol warns of places where there is a high likelihood of getting
bruised.
Falling under a machine

It is possible to get run over near the symbol.
Crushing hazard
Crushing hazard
Danger of getting crushed.

The symbol warns of places where body parts can get crushed or
become squeezed.
Danger of fire
Smoking, hot work and open fire are absolutely forbidden.
Max allowed load (Safe Working Load).

Used on Mantsinen front attachments. The safe working load the front
attachment is permitted to lift is given in connection with the SWL text.

Emergency lowering of the cab elevator

In machines equipped with a cab elevator. The machines have two
emergency lowering switches, one in the cab and one in the
uppercarriage of the machine.
Pressure accumulator
A large amount of energy is stored in the accumulators, even when
the machine is stopped.
See the instructions

There are related additional instructions.
Fuel tank
Fastening loop of the emergency rope

The loop is used in an emergency to fasten the rope.
Fastening loop of the emergency rope

The loop is used in an emergency to fasten the rope.
Lifting point of the machine

Mounting loop
The machine can be attached by the loop during transportation.
Machine lifting point

Indicates the point by which the machine can be lifted using a jack.
Emergency exit
Used in an emergency.
Authorized personnel only
General attention symbol

An explanatory text always accompanies a symbol.
Wear hearing protection
Doorbell
Optional.

Service light
Depending on the level of accessorising, fixed service lights have
been installed on the machine.
Service switch
Stops the engine from starting during service in machines equipped
with a diesel engine.
Main switch
Oil level indicator

Indicates the correct oil level in the hydraulic oil reservoir. Please note
that the boom and the possible cab elevator must be in a specific
position when checking the oil level.
Greasing point
Boom greasing point
Slewing ring bearing greasing point

2.3 General
• The machine can only be used for the purpose it is made for. Never use the machine for any work
that is not described in this document.
• Those working on the machine must not wear loose clothes and / or such jewellery which may get
caught in the moving parts of the machine.
• No components, equipment or systems may be removed from or added to the machine without the
prior approval of the manufacturer.
• Never lift heavy loads by hand. Use auxiliary lifting equipment.
• Never reuse broken lifting equipment, such as broken chains and cargo straps.
• Never store flammable liquids and / or materials in the machine or its vicinity.
• Never extinguish oil or grease fires with water. Hot oil and grease makes water volatilise explo-
sively, causing severe burns to people located nearby.
• Never extinguish high voltage electrical fires with water. Keep a safety distance of 1 m when ex-
tinguishing a high voltage electrical fire with a fire extinguisher.
2.4 Working conditions

• Protect yourself according to the working conditions. Use protective gear if needed.
• The machine and its environment must be kept clean.
• Never operate the machine in explosive operating environments.
• Never operate a diesel machine in a confined space.
• The machine must not be entered or exited during a thunder storm.
• Maximum allowed wind speed when working with the machine is 30 m/s.
• The maximum inclination of the base is 2°.
• Maintain a safety distance of at least 30 m to electrical power lines when operating the machine.
• Never use the machine in extremely cold or hot conditions. The lowest recommended operating
temperature of the machine is -35 °C and the highest +50 °C.
• Ensure the tolerance of the operating surfaces within the operating range of the machine with cal-
culations by experts. The surface pressures caused by the machine on the operating surface are
given in the specifications provided with the machine.
• With standard equipment, the machine cab does not provide protection against hazardous
substancesor biological pollution in the operating environment, such as dust, gases or mould.

2.5 Load handling

• Inspect the machine externally thoroughly before operating it.
• Before operating the machine, the operator must always make sure that there are no unauthorized
people within the hazardous area of the machine.
• Never operate the machine unless you have received appropriate orientation in it.
• It is strictly forbidden to operate the machine under the influence of narcotics, alcohol, or drugs.
• If the machine is damaged, it must not be operated.
• Never operate the machine when load control is switched off.
• Working or residing on defective access bridges and service platforms is forbidden.
• The machine must not be entered or exited while it is moving.
• When starting the machine, the operator must always make sure that there is no property that
could be damaged within reach.
• When the machine is in operation, personnel is allowed only in the cab.
• A seat belt must always be used when operating the machine.
• If the machine has outriggers, they must be firmly on the ground.
• It is forbidden to use the machine to hoist people or equipment with people inside.
• When finishing work, the stick of the machine must always be lowered onto a firm surface.
2.6 Driving the machine

• When operating the machine,make sure that the surface can take its weight.
• Only a front attachment without a load is allowed at the end of the boom when the machine is be-
ing driven.
• If the machine has a cab elevator, when moving under low obstacles, make sure that the cab eleva-
tor arms do not come into contact with anything.
• When driving the machine, the upper carriage and undercarriage must be pointing in the same di-
rection, and the boom must be as close to the base machine as possible!
• Always use a seat belt when operating the machine.
• The maximum longitudinal inclination of the machine is 10° and transversal inclination is 5°.
• When driving a machine with tracks, check the position of the drive motors in relation to the ma-
chine cab. The control chart is only accurate when the drive motors are behind the cab. When the
drive motors and cab are on the same side of the machine, the control chart is reverse.

2.7 Electric system

• Only a professional with adequate qualifications can carry out electrical work.
• The electric system of an electric machine has life-threateningly high voltage and electric cur-
rents!
• Nothing extra must be connected to the electrical system of the machine.
• Never replace a smaller fuse with a larger one.
• No moisture must enter the electric parts.
• Wear protective clothing and a face mask when servicing the batteries of a diesel machine. The
batteries contain sulphuric acid.
• Never charge the batteries of a diesel machine in a confined space, because particularly at the fi-
nal stage of charging, hydrogen is formed in the batteries and it is extremely explosive when it
mixes with the oxygen in the air.
• Never charge a frozen battery of a diesel machine, because it may explode.
• Hot work, open fire and smoking are prohibited near the batteries of a diesel machine.
2.8 Servicing the machine

• Only an authorized, person trained in the task may service and repair the machine.
• Before starting the maintenance procedures, a sign informing of the ongoing maintenance work
must be placed in a visible place on the machine.
• Wear correct personal protection while servicing. Avoid skin contact with different chemicals.
• Great care must be exercised when locating hydraulics leaks, because pressurised hydraulic oil
may penetrate the skin and create a serious health hazard.
• The main power switch of the diesel machine must be turned to the zero position for the duration
of the maintenance. The key lever of the main power switch is removed if possible. However, if
servicing the machine requires that the engine is running, never leave the machine without super-
vision.
• The main power switch of an electric machine must be turned to OFF position and locked for the
duration of the maintenance. If possible, cut the power also at the power supply point. However, if
servicing the machine requires that the motor is live, never leave the machine without supervision.
• Release the pressure from the hydraulic system through the pressure release tap of the hydraulic
oil reservoir before removing components from the system. If the machine has HybriLift system,
pressure must also be released from the hydraulic circuit of the energy storage system by opening
the pressure release tap in the valve block of the HybriLift system.
• Great care must be exercised when locating hydraulic oil leaks, because pressurised hydraulic oil
may penetrate the skin and create a serious health hazard.
• If the machine has been operated recently, its oils, greases, liquids, hydraulic and electric compo-
nents and the diesel engine are extremely hot.
• Working on a defective access bridges and service platforms is forbidden.
• Only spare parts and supplies approved by the manufacturer must be used when servicing the ma-
chine.

• Hot work, open fires and smoking are forbidden in the machine and near it.
• Used oils, greases, liquids, filters, batteries and other debris must be disposed of appropriately fol-
lowing official regulations.
• The machine or its parts may only be lifted from the marked lifting points.
• Never remove parts of the fuel system of a diesel engine immediately after use. You must wait for
at least five minutes to allow the pressure of the fuel system to drop.
• Never open the expansion tank cap of the cooling system of a diesel engine at running tempera-
ture. The cap can be opened safely only when the coolant temperature has dropped under 50 °C.
• If the machine has a separate service hoist, it must never be used to hoist people or equipment
with people inside.
• Never repair the machine by welding it independently. Contact the manufacturer or authorised re-
pair shop whenever repairs require welding.
• Never disconnect the air conditioning hoses. Only a professional with adequate qualifications can
service the air conditioning system.
2.9 Working in thunderstorm
Warning!
Walking or staying on the structures of the machine is lethally dangerous in thunder!
Warning!
Do not connect electric devices to the power plug in the cab in thunder!
Working with both an electric and diesel-powered materials handling machine is safe during thunder.
However, it is good to stop working and turn off the machine if the thunder is directly above the machine.
Do not leave the cab of the machine. In thunder, the cab is the safest place, because the metal shell of the
cab forms a Faraday cage around the driver.
It is possible that lighting breaks the electric devices of the machine. This is a particular risk for the elec-
tric motors if the overvoltage comes through the power grid. The best way to protect against such power
surges is to install an overvoltage protection at the power feed end.

2.10 EmergencyStop buttons

Pressing the button switches off the machine, after which only emergency lowering of the cab is possible.
The EmergencyStop button is freed by turning it anticlockwise; the button will pop up. The Emergency-
Stop buttons of the machine are located in the upper and lower carriages and in the control panel of the cab
(Figure 2784).
When one of the EmergencyStop buttons has been

pushed down, an EmergencyStop window is shown
on the display of the machine's control system inter-
face (Figure 2536) and the acoustic alarm of the cab
goes off. It is not possible to exit the window until
all EmergencyStop buttons have been released.

2.11 Cab safety gate

The left arm support acts as the safety gate of the
cab (Figure 2580). Lifting the arm rest up (open)
switches off the pilot control hydraulic circuit,
which prevents unintentional movements of the ma-
chine. The cab safety gate must never be left down
(closed) when leaving the machine's cab while the
machine is running.
2.12 Safety gates of maintenance platforms / access bridges

The machine's access bridges have spring-operated
safety gates which prevent persons from falling out
of the machine (Figure 2141). If defects are detect-
ed in the operation of the gates, the machine must
not be operated until the gates have been repaired.
2.13 Emergency cab lowering

The cab of the machine can be lowered even if the engine switches off. There are two emergency cab low-
ering switches, and they are located in the uppercarriage (Figure 2753) and in the rocker switch panel of
the cab (Figure 2629).

2.14 In case of fire
Warning!
Do not use water to extinguish oil or grease fire!
Note!
Find out in advance where the portable fire extinguishers are located and read their operat-
ing instructions!
Info!
See Appendix 10, Rescue Card.
1.Turn off a running machine using the EmergencyStop button (see section EmergencyStop buttons).
• Depending on the situation, swing the uppercarriage to a position where using the access bridges /
maintenance platforms is possible.
2.If the machine is equipped with a fire extinguishing system, the system is triggered (see section on fire
extinguishing system).
3.Rescue the persons in immediate danger and get help for them.
4.If possible, see that the machine is rendered dead (has no power).
• In a diesel machine, switch off power at the main power switch (see the location of main power
switch in the maintenance manual).
• In an electric machine, power is primarily switched off at the main power input and secondarily at
the main power switch (see the location of main power switch in the maintenance manual).
• Note that if the power of an electric machine is switched off only at the main power switch of the
machine, a part of the machine will still be live.
5.If the machine is equipped with a fire extinguishing system, and the fire has been extinguished, con-
tinue with fire suppression procedures. If the extinguishing system has not put out the fire or the
machine does not have one, try extinguishing the fire using the fire extinguishing equipment in the
machine.
• Ensure an escape route before starting to extinguish the fire.
• The combustion gases generated by a fire in the machine are toxic. Avoid by all means breathing
in the combustion gases.
• Do not extinguish high voltage electrical fires with water.
• Keep a safety distance of 1 m when extinguishing an electric power current fire with a fire extin-
guisher.
• No water must be used for extinguishing oil or grease fires, because hot oil makes water volatilise
explosively, causing severe burns to people located nearby.
• In case of a fire in machines with a HybriLift system, it is possible that the pressure accumulators
of the machine generate a dangerously high pressure. Therefore, the accumulators are equipped
with rupture discs, the purpose of which is to release overpressure in a controlled manner, before
the battery case breaks.
6.If extinguishing fails or it is impossible to carry out, leave the machine using the safest route possible.
7.Prevent the fire from spreading into the surroundings.
8.Alert the fire department and guide it when it arrives.

2.15 Emergency exit with rope
Warning!
We recommend that all machine operators are given separate training on how to safely use
the emergency exit equipment. Erroneous use of the emergency exit equipment may cause
serious injuries!
Note!
The fibre materials of the emergency exit equipment must be replaced every ten years!
Info!
See more detailed instructions on specific emergency exit equipment in the emergency exit
equipment box.
The emergency exit equipment must only be used when no other way of exiting the machine is possible.
• The machine has a cab elevator, but using the cab elevator or emergency lowering it is not possi-
ble.
• The machine has a cab elevator, but the cab cannot be lowered sufficiently for some reason.
• Swinging the uppercarriage into the correct position fails so that the access bridges or mainte-
nance platforms cannot be used.
• It is unsafe to use the access bridges / maintenance platforms.
• More than 2 m to jump down.
• There is no safer way to exit the machine. Basket cranes are not available or there is no time to
make one available.
The emergency exit equipment sets are located in a box in the cab. The box contains a rope and lowering
device (A and B 2695), two carabiners (C Figure 2695), harness (D Figure 2695) and operating instruc-
tions. The machine operator must get acquainted in advance with the emergency exit equipment and the
operating instructions delivered with them. We recommend that all machine operators are given separate
training on how to safely use the emergency exit equipment. Erroneous use of the emergency exit equip-
ment may cause serious injuries!
1.If the machine is equipped with a cab elevator, if possible, lower the elevator as close to the ground as
possible either using the joystick or the cab elevator emergency switch.
2.The emergency exit equipment is inspected visually for damages and other defects.
3.The harness is worn so that the fastening loops are on the chest (Figure 2696 left side). Open the leg
buckles for easier dressing. Once the harness is in place, fasten the leg buckles and waist buckle.
Tighten the harness straps on the shoulders and thighs by pulling the strap ends. The harness must be so
tight that you cannot fall out of it even if hanging upside down.

4.Fasten the lowering device with a carabiner to the loops on the chest and the other end of the rope to the
emergency lowering boom of the machine (Figure 2697). If the machine does not have an emergency
lowering boom, the rope is attached to the cab railing. Open the carabiner by pulling and turning the
carabiner locking cylinder. The carabiners lock automatically so they cannot accidentally remain open.
Take special care that the lowering device is the right way around as indicated in Figure 2697). If the
lowering device is the wrong way around and the wrong end of the rope is attached, the operator will
fall straight down.
5.Test the equipment before lowering. Pull the rope tight through the lowering device (Figure 2698).
Then lean back so that the rope is taking the load. In the situation depicted in Figure 2698, the rope
must not slip through the lowering device.
6.Then, go near the cab railing, pull the rope tight once more through lowering device (Figure 2699). At
this point, the operator must once more check the condition and correct attachment of the emergency
lowering equipment.
7.When everything is in order, climb over the railing and remain suspended by the lowering device.
8.You can lower yourself by gently pulling the lowering device lever while you guide the rope into the
lowering device. Note that the rope must go through the side of the lowering device (Figure 2700). Ths
increases friction on the rope as it passes through the lowering device, which makes it easier to regulate
the lowering speed. Never let go of the lowering rope, but make sure to guide and control it so it goes
through the lowering device. Under no circumstances must the lowering speed exceed the speed of
walking.

2.16 Operating environment requirements set by operating the machine

The materials handling machine sets certain requirements to its operating environment. Taking into con-
sideration the requirements set by the machine and meeting these requirements ensures the safety and
functionality of the machine and its operating environment in the most efficient way possible. The ma-
chine sets physical, chemical and / or biological requirements to its operating environment.
2.16.1 Physical factors
• Weight: Machines with tracks, rails and wheels set different requirements to the operating surfac-
es. Ensure the tolerance of the operating surfaces within the operating range of the machine with
calculations by experts. This is particularly the case with quays, jetties and outskirts of harbours.
Take into consideration possible changes in weather conditions, because the bearing capacity of
the operating surface may vary quickly if the soil get soaked, for example. The surface pressures
caused by the machine on the operating surface, to be used in the calculations, are given in the
specifications provided along with the machine.
• Dimensions: The machine must have sufficient room to move and operate in materials handling
in its entire operating area. The operating environment must be closed from unauthorized traffic
and persons. The cabling, pipes and other such structures in the area must be located so that nor-
mal use of the machine does not damage them. The minimum distance to power lines is 30 metres.
• Stability: The maximum inclination of the operating surface during lifting is 2 ° with maximum
wind speed of 30 m/s. If the wind speed exceeds 30 m/s, the work is interrupted and the boom and
possible cab elevator are lowered as far down as possible. Make sure the machine stays in place in
all circumstances, also when the surface may be slippery. When moving on slanted surfaces, the
maximum longitudinal inclination of the machine is 10° and transversal inclination 5°. When driv-
ing the machine the uppercarriage and undercarriage must always be kept parallel, and the stick as
close to the base machine as possible. Only a front attachment without a load is allowed at the end
of the boom. When working on slippery surfaces, make sure the machine cannot slide.
• Noise: When closed, the cab provides the driver sufficient protection against the noise of the ma-
chine. If the operating environment is particularly noisy, hearing protection must be worn in the
cab.
• Dust: If the operating environment is particularly dusty, the persons working outside the machine
must wear appropriate protection against the dust generated by the machine, if needed. The closed
cab and cab fresh air filters protect the driver from dust.

• Lighting: The machine is equipped with adequate lights for operating it. If necessary, additional
lights must be used in the entire operating area to light the points / areas requiring special atten-
tion. The additional lights may not blind the driver but they must be adequate to ensure safe oper-
ation of the machine.
• Ionising radiation: The cab of the machine does not protect from the radioactive substances in
the environment.
• Electric and magnetic fields: Powerful electric and magnetic fields may cause disturbances in
the electric and control systems of the machine and may hinder its operation.
• Temperature, humidity and air pressure: The lowest operating temperature of the machine is -
35 °C and the highest is +50 °C. Operating the machine in low temperatures is discussed in more
detail in the instructions for operating the machine. The machine is designed to operate in humidi-
ty and air pressure conditions that are hospitable to humans.
• Thunderstorm: It is safe to operate an electric or diesel materials handling machine in a thunder-
storm. However, it is good to stop working and turn off the machine if the thunder is directly
above the machine. In that case, the boom and possible cab elevator are lowered as far down as
possible. Do not reside or walk on the maintenance platforms / access bridges during thunder.
2.16.2 Chemical agents

With standard equipment, the machine cab does not provide protection against hazardous substances in the
operating environment, such as dust or gases. Such quantities of exhaust gas or other noxious substances
that are hazardous to health are not allowed in the operating area of the machine.
2.16.3 Biological elements

The cab of the machine is not equipped with biological filters, so it must not be used in premises contami-
nated with dangerous microbes (mould, fungi, bacteria, viruses). If the machine is exposed to biological
pollution during operation, it must be thoroughly washed and disinfected, if needed, in accordance with of-
ficial regulations.
2.16.4 Explosive operating environment
Warning!
The machine may not be used in an explosive operating environment!
The machine is not built or intended to be operated in an explosive environment.

2.17 Consequences of operating the machine to the operating environment

The materials handling machine causes certain consequences to its operating environment. Taking into
consideration the consequences caused by the machine and proceeding accordingly ensures the safety and
functionality of the machine and its operating environment in the most efficient way possible. The ma-
chine has physical, chemical and / or biological consequences to its operating environment.
2.17.1 Physical factors
• Weight: The weight of the machine may cause the ground to compress within it operating area,
which may result in a need to reinforce the ground or structures. The surface pressures caused by
the machine on the operating surface, to be used in the calculations, are given in the specifica-
tions provided along with the machine.
• Dimensions: The dimensions of the machine may require modifications in the buildings, electric
grid, pipes and other equivalent structures within the operating area of the machine.
• Noise: In accordance with official regulations, the noise generated by operating the machine may
require persons working in its operating area or vicinity to wear hearing protection.
• Dust: In a dusty operating environment, the dust generated by operating the machine may require
persons working within or near its operating environment to protect themselves from the hazard of
dust.
• Lighting: The lighting of the machine may cause glare within or near the machine's operating en-
vironment.
• Ionising radiation: The machine does not emit harmful radiation to the environment.
• Temperature: The machine's surrounding temperature goes up when it is operated in a confined
space. In this case, ensure adequate ventilation of the operating environment.
• Laser radiation: If the measurement / control system of the machine uses laser beam, it may
damage the vision if it hits the eyes. No persons or animals are allowed within the hazard area of
the machine when it is operated.
• Vibration: The machine does not generate dangerous levels of vibration in the environment.
2.17.2 Chemical agents
Safety!
Never leave or dispose of oils or chemical waste in the nature!
Diesel machines do not emit concentrations of harmful substances of exhaust gas that exceed the limit val-
ues. However, if the machine is operated in a confined or poorly ventilated space, ensure adequate ventila-
tion and removal of exhaust gases.
The manufacturer makes available the material safety data sheets on the chemicals, such as oils, liquids,
greases and fuels, used in the machine. The material safety data sheet gives instructions on handling the
substances and disposing of them when the machine is services.
If e.g. an oil leak occurs when the machine is operated, the oils is removed appropriately, such as with oil
absorbing material. The contaminated soil must be cleaned or replaced in compliance with the official reg-
ulations.

2.17.3 Biological elements
The machine does not emit biological pollution. Regularly tend to the cleanliness of the machine and cab
to prevent the entry of external pollution.
2.18 Final termination and recycling of the machine
Note!
The final termination of the machine is done in accordance with official regulations!
All the oils, liquids, greases and other possible chemicals of the machine shall be collected and taken to a
hazardous waste plant for disposal. The machine is disassembled and the parts sorted based on their mate-
rial. The materials are recycled or taken to a hazardous waste plant in accordance with official regulations.
• Various metals.
• Electronics.
• Plastics.
• Glass.
• Rubber.
• etc.

3 Operator's environment
A. Left joystick. B. Display for control system.

C. Right joystick. D. Miniature joystick
E. Display for load control. F. Air nozzle.
G. Air conditioning control panel H. CD / MP3 player.
I. Speaker. J. Fuse box.
K. Storage cabinet. L. Control panel of the machine.
S/N: 160ES268113 Ver: 170203 3 Operator's environment 31

3.1 Machine joysticks

On the right-hand cab window there is a sticker with a concise description of the joystick functions.
3.1.1 Left joystick
FORWARD
- Stick boom away from the machine.
BACKWARD
- Stick boom toward the machine.
RIGHT
- Uppercarriage swing clockwise.
TO THE LEFT
- Uppercarriage swing anticlockwise.
A. No function.
B. No function.
C. Swing brake.
D. No function.
E. No function.
F. Heavy lift.
G. Auxiliary hydraulics 1, + motion.
H. Auxiliary hydraulics 1, - motion.
I. Precision running.
32 3 Operator's environment S/N: 160ES268113 Ver: 170203

3.1.2 Right joystick
FORWARD
- Main boom down.
BACKWARD
- Main boom up.
RIGHT
- Opening movement of a grab or a grapple.
LEFT
- Closing movement of a grab or a grapple.
J. Horn.
K. Front attachment rotation clockwise.
L. Front attachment rotation anticlockwise.
M. No function.
N. No function.
O. No function.
P. No function.
Q. No function.
R. No function.

3.1.3 Miniature joystick
All functions are proportionally controlled, so the speed of the motions depends on the size of the joystick
motion. The functions are selected using joystick pushbuttons A - B. The button does not need to be de-
pressed continuously, but a single push is enough. Only one function in the joystick can be selected at a
time. Selecting a new function always deactivates the previous function. The last selected function is deac-
tivated automatically when the joystick has been inactive for approximately ten seconds.
The drive is switched on from the joystick button A. The machine's steering system is designed so that the
machine is steered according to the control charts even when the uppercarriage is turned 180 degrees in re-
lation to the undercarriage. There are two driving speeds: slow and fast. When the drive selection button is
pressed, the slow drive is switched on. The fast drive is switched on when the button is pressed again.
A (+A) + FORWARD
- The machine moves forward.
A (+A) + BACKWARD
- The machine moves backward.
A + TO THE RIGHT
- No function.
A +TO THE LEFT

- No function.

The cab elevator is selected by pressing button B of the joystick.
B + FORWARD
- Cab elevator's main boom down.
B + BACKWARD
- Cab elevator's main boom up.
B + TO THE RIGHT
- Cab elevator's stick boom down.
B +TO THE LEFT

- Cab elevator's stick boom up.

3.2 Cab safety gate

The left arm support acts as the safety gate of the
cab (Figure 2580). Lifting the arm rest up (open)
switches off the pilot control hydraulic circuit,
which prevents unintentional movements of the ma-
chine. The cab safety gate must never be left down
(closed) when leaving the machine's cab while the
machine is running.
3.3 Cab EmergencyStop button

The cab EmergencyStop button is located in the
control panel (Figure 2581). Pressing the button
switches off the machine, after which only emergen-
cy lowering of the cab is possible. The Emergen-
cyStop button is released by turning it
anticlockwise; the button will pop up.
3.4 ignition switch

The ignition lock is located in the control panel of
the machine. Turning the ignition key to position I
starts the control system and load control interfaces
of the machine.

3.5 Auxiliary power plugs

Direct voltage of 12 V can be received from one
auxiliary power plug (Figure 2661). A power con-
sumer of maximum 5 amperes can be connected to
the plug.
3.6 Cab power plug (230 V)

The power plug is located behind the driver's seat in
the right corner of the cab (Figure 2660). In a diesel
machine, the plug receives power only when the
heating plug of the machine is connected. In an
electric machine, the plug receives continuous pow-
er.

3.7 Cab heating and air conditioning system

When the fresh inlet air function is activat-
ed, the blown air is taken from under the
cab. When indoor air circulation is activat-
ed, the air blown is taken from behind the
driver's seat through a filter (Figure 2598).
There are three air nozzles (Figure 2598) in
the front of the floor and eight in the col-
umns. All air nozzles can be shut and
opened manually.
When the fresh inlet air function is activat-
ed, air is removed through valves in the rear
wall of the cab (Figure 2598).
The operating panel for cab heating and air conditioning (Figure 2599) is located in the ceiling panelling
on the right. The operating panel functions as a display, control device and diagnostics unit. When the op-
erating panel is activated, its main view is displayed.
A. Cab air circulation icon.

Cab target temperature: The cab target
B. temperature is adjusted in the main view
by turning the screen wheel.
Screen wheel: The screen wheel is turned
in increments. The screen wheel also
C.
functions as a selection button when
pressed.
D. Power button.
E. System status.
Blower icon: The blower icon is replaced
F. with an exclamation mark if there is a
malfunction in the system.
G. Blowing power.

3.7.1 Adjusting blowing power
The screen wheel is pressed once in the main view and the icon indicating blowing power appears in the
operating panel display. Adjust blowing power by turning the screen wheel. Turning clockwise increases
blowing power and turning anticlockwise decreases it. The selection is made by leaving the icon of the de-
sired function on the display. The operating panel goes to the main view automatically when the screen
wheel has not been used for approximately ten seconds.
Display view indicating blowing power:
The columns indicate blowing power volume. Blowing power can be adjusted by
increments of half a column. The latest setting is kept even though the system is
turned off.
3.7.2 Changing the mode of heating and air conditioning system

The screen wheel is pressed twice in the main view and the system icon appears in the operating panel dis-
play. The desired function is selected by turning the screen wheel until the icon of the desired function ap-
pears in the operating panel display. The selection is made by leaving the icon of the desired function on
the display. The operating panel goes to the main view automatically when the screen wheel has not been
used for approximately ten seconds.
Views of the system status display:
When the automatic function is activated, the system maintains the cab's target
temperature. This is the default setting and the status changes automatically
every time the heating system is switched off.
When the cooling function is activated, the cab temperature is regulated using
the air conditioning system. The status changes automatically after the system is
switched off.
When the heating function is activated, the cab temperature is regulated only
using the heating system. In this case, the air conditioning compressor is not in
use. The status changes automatically after the system is switched off.
When the defroster function is activated, cab heating and air conditioning func-
tion simultaneously at their highest volume. The status changes automatically
after the system is switched off.

3.7.3 Selecting cab air circulation
Press the screen wheel three times in the main view to show the cab air circulation ícon in the operating
panel display. The desired function is selected by turning the screen wheel until the icon of the desired
function appears in the operating panel display. The selection is made by leaving the icon of the desired
function on the display. The operating panel goes to the main view automatically when the screen wheel
has not been used for approximately ten seconds.
Views of the cab air circulation display:
When the fresh inlet air function is activated, the blown air is taken from outside.
The latest setting is kept even though the system is turned off. The fresh inlet air
function must be used as default in all circumstances so that cab ventilation func-
tions in the best possible manner.
When indoor air circulation is activated, blown air is taken from inside the cab.
The function is used temporarily to reach faster the target temperature of the cab.
Using indoor air circulation may cause the windows to fog up in cold weather
because humidity cannot exit the cab. The latest setting is kept even though the
system is turned off.
3.7.4 Directing blown air through different nozzles

Press the screen wheel four times in the main view to show the blown air control ícon in the operating pan-
el display. The desired function is selected by turning the screen wheel until the icon of the desired func-
tion appears in the operating panel display. The selection is made by leaving the icon of the desired
function on the display. The operating panel goes to the main view automatically when the screen wheel
has not been used for approximately ten seconds.
Views of the blown air display:
Blown air is directed through the cab column nozzles.
Blown air is directed through all air nozzles in the cab.
Blown air is directed through the windscreen nozzles in the cab.

3.7.5 Changing display settings
Press the screen wheel five times in the main view to show the display settings in the operating panel dis-
play. Contrast is automatically selected for adjustment. Adjust contrast by turning the screen wheel.
Pressing the screen wheel once moves the selection forward to display background light adjustment .
Adjust the background brightness by turning the screen wheel. When you press the screen wheel again, the
selection moves to temperature unit selection and by turning the screen wheel you can select the dis-
played temperature unit to be Fahrenheit or Celsius. When you press the screen wheel again, the main dis-
play appears.
Display settings view:
Display contrast is temperature compensated.
3.7.6 Cab preheat function (only diesel machine)

The cab preheating function requires that the machine is equipped with an auxiliary fuel-powered engine
heater. When a signal from the auxiliary heater reaches the heating and air conditioning operating panel,
the background light of the display turns off and a heating icon appears on the display. In this situation, the
heater valve is fully open. The blown air is taken from outside and the blower runs at 15% efficiency. The
blower runs at this efficiency until the blown air temperature after the heating element reaches 20 °C (68
°F). After this, the blower operates at its preset efficiency.
Display view when the fuel-powered auxiliary heater is activated:
When the fuel-powered auxiliary heater is activated, manual operation of the sys-
tem is not possible.
3.7.7 Switching off the heating and air conditioning system

The system is switched off when the power button is pressed in the main view. When the defrost function
is activated, the power button must be pressed twice. Pressing it once restores the system status to auto-
matic. When the power button is pressed again, the system switches off.
Display view after the system has been switched off:
When the system is switched off, the display show only the cab temperature at
the given moment. The background light of the display is off. The power button
switches off the system only in the main view.

3.8 Multi-function control of the machine control system

The machine control system display is controlled using a multi-function control (Figure 2475). The multi-
function control has five buttons with icons and a scroll wheel to move within the menus. The following
table lists all the symbols of the multi-function control and their functions.
PDF button: (In the future, you can

access pdf files using this button).
MENU button: Press this to access

the menu view.
F2 button: No function at operator

level.
ESC button: Press ESC to return to

the previous view.
Wiper button: Press this to open the

menu to adjust windscreen wiper
wiping interval.
Scroll wheel: Press this to access

the selected menu and turn the
wheel to scroll the menu. Diesel
engine rpms are adjusted by turning
the scroll wheel in the main display
of the machine control system.
3.9 One-touch switch panel of the machine control system

The one-touch switch panel (Figure 2478) is used to
control the different functions of the machine. The
one-touch switch panel has 20 buttons to select the
desired function.
In some of the functions, you can select the level of
the function indicated by lights on the top edge of the
button . These functions are turned off by
keeping the button pressed for 2 seconds.

The following table lists all the symbols of the one-touch switch panel buttons and their functions
Work lights: Press this to switch on the work light / light assembly. Depending on the
level of equipment, the machine has a varying number of working lights. * Work light
assembly is always switched on when one indicator light is lit .
Beacons: Press to switch on the beacons.
Pressure release of the front attachment line: Press this to remove pressure from the
front attachment line. Pressure release must always be done before detaching the
hydraulic hoses of the attachment. Pressure release is only successful when the move-
ment of the machine has been prevented by opening the cab safety gate. The push but-
ton must be kept down for at least two seconds to activate the function. The
pressure release function ends when the safety gate is again lowered down.
Windscreen and skylight wiper: Push to switch on the wiper.
Window washer: Press to switch on windscreen washer.
Fuel transfer pump: Press to start / stop fuel transfer from auxiliary tank to the actual
tank.
Cooler cleaning: Press to reverse the cooling fan direction of rotation from suction to
blowing.
Greasing devices: Press to switch on the greasing device and one indicator light is
turned on . In a malfunction, all indicator lights are flashing and an
error message is displayed on the screen. The greasing device buttons control the
greasing devices of the uppercarriage, swing and undercarriage.
Undercarriage safety gate opening button: Press this to unlock the undercarriage safety
gate. The indicator light flashes when the gate needs to be opened.
Auxiliary hydraulics of undercarriage: Press this to switch on the auxiliary hydraulics of

the undercarriage.
Heating boiler control: (Only electric machine) Press this to switch on the heating boiler.
HybriLift charging button: Press this to charge preset energy in the pressure accumula-
tors of the HybriLift system to lighten the lifting.

No function:
Machine start: Press sufficiently long to start the machine.
Machine switch off: Press to switch of the machine.
3.10 Rocker switch panel

The rocker switch panel is located on the right side
of the operator in the control panel of the machine
(Figure 2665).
Front window heating.
Cab interior light.
Emergency cab lowering.

3.11 Machine control system user interface
Warning!
The settings can only be modified by a qualified person!
Note!
All the icons and corresponding functions cannot be found in an individual machine!
The purpose of the control system is to enable ver-
satile and efficient use of the machine, which makes
the work cost-efficient. The multi-function control
(C Figure 2490) or buttons (A Figure 2490) on the
side of the display are used to move in the user in-
terface (Figure 2490). A button or control field tar-
geted in the user interface is shown in reverse
colours on the display (B Figure 2490).
There are four different security levels in the user
interface. The different levels have different rights
to use the selection and control functions of the user
interface. Users cannot use such user interface func-
tions for which they do not have sufficient rights.
• Basic: A basic user can operate the machine and browse the user interface. A basic user cannot
modify the parameters.
• Operator : An operator has the right to drive the machine and browse the user interface. An
operator can also access the operator's settings window and by-pass the load control. Only the per-
son(s) in charge at the end user company knows the operator's password.
• Service : At service level, you can browse and modify the parameters required in servicing.
Only service tecnicians trained by Mantsinen Group Ltd have the service level rights.
• Factory : The factory level user rights include all the user rights of the user interface.
3.11.1 Machine control system starting display

When the display is turned on, the first display is
the starting display (Figure 2487) which shows the
machine's operating hours and the operating
hours remaining until the next service procedures
. The view is displayed on the screen for 3 sec-
onds before the main display appears.

3.11.2 Main display of control system
Electric motor temperature, status and operating
hours as well as date and time are displayed in the
middle of the main display (Figure 2735).
The table below shows the symbols of the main display and their meaning in the user interface.
Navigation key:
Go to menu which displays the status of the machine.
Red level error message:

A red level error message stops the machine and you cannot continue operating it. Press-
ing the menu button of red level error message shows the list of all error messages.
Orange level error message:

An orange level error message restricts the operation involved. Pressing the menu button
of orange level error message shows the list of all error messages.
Yellow level error message:

A yellow level error message indicates that a defect has been detected in the function.
Operating the machine continues to be possible despite the error message. Pressing the
menu button of yellow level error message shows the list of all error messages.
Info notice:
An info notice gives informative notifications. Pressing the menu button of info notice shows
the list of all error messages.
Front attachment pressure:

Front attachment pressure is 250 bar. Pressing the menu button of front attachment pres-
sure allows you to select an attachment pressure of 250 bar or 330 bar.
Precision running:
Seleting this activates the precision running function. Precision running is switched on
using the lowest button of the left-hand joystick.
Cab elevator drive:

When this function is selected, you can drive the cab elevator. You can select this function
using the yellow button of the miniature joystick.
Slow drive:
Selecting this activates the "slow drive" function. Select this function using the green button
of the miniature joystick. Slow drive is active for 2 seconds if the machine is not driven. Haz-
ard lights are activated automatically when the function is started.

Fast drive:
Selecting this activates the "fast drive" function. Select this function by pressing twice the
green button of the miniature joystick. Fast drive is active for 2 seconds if the machine is not
driven. Hazard lights are activated automatically when the function is started.
Outrigger control:
Activate manual control of outriggers, outrigger control is activated using the outrigger oper-
ating panel or miniature joystick.
Heavy lift:
Select this to activate the Heavy lift function. You can also select the Extra Heavy lift func-
tion if the machine has it. Activate Heavy lift using the left-hand joystick. Selecting this func-
tion also activates precision drive.
Extra heavy lift:

Select this to activate the Extra heavy lift function. Selecting this function also activates pre-
cision drive.
Control mode menu:

In a machine with wheels, the control mode is selected in the control mode menu.
Cab safety gate:

Unlocked - movement allowed.
Locked - movement prevented.
Fuel level:
Fuel level of each tank in percentages [%] is shown next to the symbol.
White - fuel level ok.
Yellow - fuel level low.
Red - no fuel.
Diesel engine temperature:

The thermometer on the left of the symbol indicates the temperature of the engine coolant
[°C].
Engine speed in rpms:

The metre on the left of the symbol indicates the engine rpms [r/min].
HybriLift:
Yellow - Low HybriLift pressure.
Red - Too high HybriLift pressure.
Charge HybriLift using the HybriLift system charge button on the one-touch switch panel of
the control system.
Diesel engine check engine light:

Yellow - Malfunction limiting operation is detected in the engine.
Red - Critical malfunction requiring immediate action is detected in the engine
Operating hours:
Operating hours [h] next to the symbol.

Urea quantity:
Urea level of the tank in percentages [%] is shown next to the symbol.
Parking station:
When the machine is in an area, where cab lowering is allowed, or when the machine is at
the intermediary level docking point.
Electric motor
The symbol on the display indicates that the machine is using an electric motor.
Generator:
An electric machines may have an optional diesel generator, which can be used to power
the machine instead of the electric motor, if necessary.
Electric motor start:

The symbol indicates that the electric motor is being started.
Electric motor running:

The symbol indicates that the electric motor is running and the machine is being operated.
Electric motor stopped:

The symbol indicates that the electric motor has stopped.
Electric motor temperature normal:

The symbol indicates that the electric motor temperature is within allowed limits.
Electric motor temperature too high:

The symbol indicates that the electric motor temperature is too high.
3.11.3 Main menu of control system

The main menu of the control system has 10 but-
tons, each with a symbol indicating its content.
Some of the manus are protected so that they can
only beaccessed with specific user rights. Use the
scroll wheel of the multi-function control to move
in the main menu. Select the desired menu by press-
ing the scroll wheel at the desired menu.

The table below shows the symbols of the menu display and their meaning in the user interface.
Home menu:
Go to main display.
Driver settings:
Go to driver settings menu to change drive settings. Driver level or greater user rights give
access to change these settings.
Diagnostics:
Go to diagnostics menu to test hydraulic pumps and monitor the output and input ports of
modules. Diagnostics menu is accessed with service level user rights.
Transaction log:
Go to transaction log to browse recorded transactions. Only factory level user rights give
access to transaction log.
Factory Settings:
Go to factory settings menu to change factory settings. Only factory level user rights give
access to change factory settings.
Service settings:
Go to service settings menu to change service settings. Service or factory level user rights
give access to change the settings.
Electric motor info:

Go to electric motor menu to view electric motor values.
Alarm list:
Go to alarm list to see error messages.
Operating times:
Go to operating times menu to see e.g. operating hours, utilisation level and fuel consump-
tion of the machine.
Hydraulics info:
Go to hydraulics info menu to see e.g. hydraulic oil temperature and hydraulic pressure val-
ues.

3.11.4 Enter PIN code display
Enter PIN code display (Figure 2541) is for enter-
ing a four-digit password to move in the menus re-
quiring different user right levels.
Enter PIN code using the scroll wheel of the multi-
function control. Scroll the menu and change the
number values by rolling the scroll wheel. The num-
ber is selected and approved by pressing the scroll
wheel at the desired number.
3.11.5 Driver settings menu

Select the driver settings menu by pressing the scroll
wheel of the multi-function control in the menu dis-
play at the driver setting menu (Figure 2491). Use
the scroll wheel to move within the menu. Press the
scroll wheel to make selections within the menu.
The driver settings menu is only accessed by driver
level user rights or higher. When you select the driv-
er settings menu, the operating system will ask for
the four-digit access password. Only the person(s) in
charge at the end user company knows the operator's
password.
The following information is on the first page of the menu (Figure 2545):
• Attachment valve count: Number of tool
valves [pcs].
• Attachment mirrored: Tool mirroring
function allows you to reverse the tool
movement. (white square in square brackets
indicates that the function is in use).
• Attachment control gain positive: Adjust-
ing tool movement speed +[%].
• Attachment control gain negative: Adjust-
ing tool movement speed -[%].
• Boom power down: The main boom can be driven down with hydraulics. Pressing with the main
boom may be necessary when, for example, a grab is used as a front attachment in challenging
conditions. In normal conditions, however, the weight of the boom is sufficient for working.
Pressing must be avoided, because it puts strain on the front equipment and consumes energy (a
white square in the square brackets indicates that the function is in use).
• Boom power down pressure: Main boom pressing pressure [bar].
• Tool pressure selection: Front attachment pressure [bar].
• External hydraulics control gain: Adjusting external hydraulics movement speed [%].

The second page of the menu (Figure 2546) has the following information:
• Auxiliary valve count: Number of valves
of auxiliary hydraulics [pieces]
• Auxiliary hydraulics 1 mirrored: Mirror-
ing of auxiliary hydraulics 1. This function
enables reversing the movement of auxilia-
ry hydraulics 1. (white square in square
brackets indicates that the function is in
use).
• Auxiliary hydraulics 1 control gain pos:
Adjusting the movement speed +[%] of
auxiliary hydraulics 1.
• Auxiliary hydraulics 1 control gain neg: Adjusting the movement speed -[%] of auxiliary hy-
draulics 1.
• Auxiliary hydraulics 2 mirrored: Mirroring of the second auxiliary hydraulics. This function en-
ables reversing the movement of auxiliary hydraulics 2. (white square in square brackets indicates
that the function is in use).
• Auxiliary hydraulics 2 control gain pos: Adjusting the movement speed +[%] of auxiliary hy-
draulics 2.
• Auxiliary hydraulics 2 control gain neg: Adjusting the movement speed -[%] of auxiliary hy-
draulics 2.
The third page of the menu (Figure 2547) has the following information:
• Load control override: Select this func-
tion to by-pass load control. The machine
must not be operated under any circum-
stances when load control is not in use.
Load control is by-passed when the square
brackets have a white square.
• Manlift: If a manlift is used instead of a
front attachment, the settings of the ma-
chine are changed to apply to a manlift (a
white square in square brackets indicates
the function is in use).
• Manlift (redundant): If a redundant man-
lift is used, the settings of the machine are changed to apply to a redundant manlift (a white square
in square brackets indicates the function is in use).
• Spreader: (white square in square brackets indicates that the function is in use).
• Language: Select the language of the operating system in this menu. Browse the languages in the
menu using the scroll wheel of the multi-function control. Select the language by pressing the
scroll wheel.
• Imperial units: Select to adopt imperial units and quantities (white square in square brackets in-
dicates that the function is in use).

3.11.6 Diagnostics menu
Only service and factory level users can access and change the diagnostics menu information. When you
select the diagnostics settings menu, the operating system will ask for the four-digit access password.
3.11.7 Transaction log

Only factory level user rights give access to transaction log. When you select the transaction log menu, the
operating system will ask for the four-digit access password.
3.11.8 Factory settings menu

Only factory level user rights give access to browse and change the settings of the factory settings menu.
When you select the factory settings menu, the operating system will ask for the four-digit access pass-
word.
3.11.9 Service settings menu

Only service and factory level user rights give access to browse and change the settings of the service set-
tings menu. When you select the service settings menu, the operating system will ask for the four-digit ac-
cess password.
3.11.10Hydraulics info menu

Go to hydraulics info menu in the main menu with the scroll wheel of the multi-function control and press-
ing the scroll wheel at the hydraulics info symbol .
The following information is on the first page of the menu (Figure 2542):
• Pump 1 pressure: The pressure of the first
main pump [bar].
• Pump 2 pressure: The pressure of the sec-
ond main pump [bar].
• Pump 3 pressure: The pressure of the third
main pump [bar].
• Pump 4 pressure: The pressure of the
fourth main pump [bar].
• Pump 1 angle: The operating plate angle of
the first main pump [deg] (not in all ma-
chines).
• Pump 2 angle: The operating plate angle of the second main pump [deg] (not in all machines).
• Pump 3 angle: The operating plate angle of the third main pump [deg] (not in all machines).
• Pump 4 angle: The operating plate angle of the fourth main pump [deg] (not in all machines).
The second page of the menu (Figure 2543) has the following information:

• Swing CW pressure: Swing pressure

clockwise [bar].
• Swing CCW pressure: Swing pressure an-
ticlockwise [bar].
• Pilot pressure: Pilot circuit pressure [bar].
• Boom cylinder pressure: Pressure of both
lifting cylinders of the boom on piston side
[bar].
• Boom cylinder rod pressure: Pressure of
both lifting cylinders of the boom on piston
rod side [bar].
• HybriLift cylinder pressure: In machines with HybriLift system as optional equipment. Pres-
sure in HybriLift cylinder(s) on the piston side [bar].
• HybriLift cylinder rod pressure: In machines with HybriLift system as optional equipment.
Pressure in HybriLift cylinder(s) on the piston rod side.
• HybriLift accumulator pressure: In machines with HybriLift system as optional equipment. Gas
pressure in the hydraulic circuit of the energy storage system [bar].
The third page of the menu (Figure 2544) has the following information:
• Hydraulic oil level: Hydraulic oil level
[%].
• Hydraulic oil temperature: Hydraulic oil
temperature [°C].
• Pump gear temperature: Pump gear tem-
perature [°C].
• Outrigger 1 pressure: Cylinder pressure of
the first outrigger [bar].
• Outrigger 2 pressure: Cylinder pressure of
the second outrigger [bar].
• Outrigger 3 pressure: Cylinder pressure of the third outrigger [bar].
• Outrigger 4 pressure: Cylinder pressure of the fourth outrigger [bar].

3.11.11Engine info menu (electric motor)
Select the engine info menu by pressing the scroll
wheel in menu display at engine info (Figure 2494).
Use the scroll wheel to move within the menu. Press
the scroll wheel to make selections within the menu.
Engine info menu shows real-time values of the
electric motor. The menu has four pages, each with
the specific values of a motor function.
The following information is on the first page of the
menu (Figure 2548):
• Engine hours: Electric motor operating
hours in total [hours].
• Engine actual rpm: Electric motor rpms
[rpm]
• Engine set rpm: The set rpm of the elec-
tric motor [rpm].
• Engine load: Electric motor load [%].
• Coolant temperature: N/A.
• Oil temperature: N/A.
• Oil pressure: N/A.
The second page of the menu (Figure 2549) has the
following information:
• Intake manifold pressure: N/A.
• Intake manifold temperature: N/A.
• Fuel rate: N/A.
• Total fuel used: N/A.
• battery potential: N/A.
• Fuel pressure: N/A.
The third page of the menu (Figure 2550) has the
following information:
• Scr tank level: N/A.
• Scr tank temperature: N/A.
The active fault codes of electric motor are on the
fourth page of the menu.

3.11.12Operating times menu
Operating times menu (Figure 2551) shows information and consumption related to the machine. Select
the operating times menu by pressing the scroll wheel in main menu display at operating times sym-
bol . Use the scroll wheel to move within the menu.
The operating times menu (Figure 2551) comprises the following information:
• Drive time: Working time means the time
when the drive, boom, front attachment or
uppercarriage swing is active. Reset can on-
ly be done by a factory level user [h].
• Engine run time: The total running time of
the machine engine. Reset can only be done
by a factory level user [h].
• Usage percentage: Ratio between working
time and hours of use [%].
• Trip Drive Hours: Working time elapsed
from the previous reset of the trip metre [h].
• Usage percentage: Utilisation level measured from the previous reset of the trip metre [%].
• Total fuel used: Total consumption from previous reset of trip metre [l].
• Fuel / hour: Average consumption per hour from previous reset of the trip metre [l/h].
3.11.13Control system warning pop up windows

Control system warning pop up windows appear in the control system display (Figure 2638) of the ma-
chine. The warning pop up windows provide the following information:
A. Gives the error quality and error code.

Gives a code for the component causing the
B.
error and an ordinal number for the error.
Gives the location of the component caus-
C.
ing the error.
D. Gives the cause of the error.
Each warning pop up window generates a new row

in the error notice list, which also gives the time the
error occurred. Error quality indicates the serious-
ness of the error. The component code given in the
warning pop up window helps you find the corresponding component in the hydraulics and electrical dia-
gram of the machine. Based on the location of the component causing the error, you can trace the error to a
particular part of the machine. The row indicating the cause of the error helps you find out the change in
the component data that caused the error.

3.11.14List of control system error messages
Go to the alarm list using the alert panel buttons (A
Figure 2492) on the edge of the main display or
alert list button of the menu display . Each but-
ton leads to the same list.
First on the alarm list are the red level error
messages which require immediate action.
Next on the list are the orange level error mes-
sages which notify the operator that some fault in
the machine requires attention.
After this, the list has the yellow error messag-
es. Yellow level error messages mean that there is a
malfunction in the machine but the malfunction
does not influence the operation of the machine.
Last on the list are info notices which notify
about general matters concerning the operation of
the machine.
To move in the alarm list from one page to another,
use the scroll wheel of the multi-function control or
the buttons on the edges of the display.
When you move over a certain error message group
in the alert panel, the number of error messages in
the said group is displayed.
3.11.15Emergency stop view

When one of the machine's EmergencyStop buttons
has been pressed, the machine switches off and the
EmergencyStop window (Figure 2536) appears on
the control system display. Remove the Emergen-
cyStop view by acknowledgeing the Emergen-
cyStop buttons that were pressed.

3.11.16Menu to adjust windscreen wiper wiping interval
The wiping interval of the windscreen wiper is ad-
justed in the adjust menu. Access the adjust menu
by using the wiper button of the multi-function
control and adjust the wiping interval by scrolling
the scroll wheel of the multi-function control. The
wiping interval can be adjusted between 1000 to
5000ms.
Exit from adjust menu using the wiper button or
scroll wheel button.
3.12 Load control user interface
Warning!
The settings can only be modified by a qualified person!
Note!
All the icons and corresponding functions cannot be found in an individual machine!
The purpose of the system is to enable safe, versa-
tile and efficient use of the machine, which makes
the work cost-efficient. The interface is navigated
with a screen wheel, which serves as a selection
button at the same time (Figure 137). A button or
control field targeted in the user interface is shown
in reverse colour.
3.12.1 Main load control window

The machine icon on the display is animated, so it moves in real time with the movements of the machine
(Figure 143). In the icon, the front attachment and its reach are shown with a grey box. The safety areas of
the cab are marked in the graphic with a green alarm limit and with a red stop limit. If the attachment is se-
lected correctly, the system prevents the front attachment from colliding with the cab. It must be noted,
however, that the system does not take into account the reach of logs hoisted with a log grab, for example,
and thus it is possible that the load hits the cab. When the load comes to the stop limit, the motions of the
machine boom to dangerous directions are prevented and red and green arrows appear on the display. The
green arrows show the allowed directions of motion and the red arrows the forbidden directions.

Function symbols:
A. Icons related to the functions of the
machine.
Bottom bar:
B. Icons for moving between different win-
dows.
Top bar:
C.
Contains time and date.
SWL bar:
D. Shows the percentage of the maximum
capacity the machine is using.
Function symbols (values are shown on the screen next to the icon):
Horizontal distance of the load:

Provides the distance from the machine's swing center to the end of the boom.
Vertical distance of the load:

Provides the distance from the ground level to the end of the boom.
Load weight:
Provides the weight of the load.
Maximum load weight:

Provides the maximum weight of the load with the current reach of the stick.
Forward or backward inclination of the base machine:

Provides the angle of inclination of the base machine in the direction of the boom.
Lateral inclination of the base machine:

Provides the lateral inclination of the base machine in degrees, perpendicularly to the
boom.
Front attachment selection:

The number of the selected front attachment is shown inside the front attachment icon.
The name of the front attachment is shown next to the icon.

Symbols occurring in the bottom bar:
Selection of front attachment:

Move to front attachment selection window.
Settings:
Move to settings window.
Diagnostics:
Move to diagnostics window.
Alarm:
Move to alarm window.
Date and time:

Move to the date and time window.
Step backward:
Returning to the higher level.
Main window:
Move to main window.
Distance diagnostics:
Move to distance diagnostics window.
Pressure diagnostics:
Move to pressure diagnostics window.
OK:
Password approval in the password window.

3.12.2 Front attachment selection window
Warning!
Due to the danger of collision of the front attachment with the cab, it is extremely important
that the correct front attachment data be entered in load control!
In the attachment selection window, the attachment
used with the material handling machine is selected
to enable the load control to function as intended
(Figure 144).
3.12.3 Diagnostics window

The diagnostics window shows the inclination val-
ues of the inclination sensors, and the bus functions
of the system's modules (Figure 422). The X and Y
readings of the sensors indicate the readings of indi-
vidual inclination axes and the YHT reading is the
actual inclination angle of the boom, calculated
from the other two readings.
3.12.4 Distance diagnostics window

The distance diagnostics window shows the differ-
ent distances from the machine's swing centre at
ground level (Figure 423). The machine icon is not
animated.

3.12.5 Hydraulics diagnostics window
The hydraulic diagnostics window shows the pres-
sures of the main boom piston and piston rod side of
the machine (Figure 424). If the machine has an en-
ergy storage system, the window will also show
pressure values of the HybriLift system.
3.12.6 Load control alarm window

If there is a fault in the load control system, a buzzer will sound and the alarm icon in the bottom bar of the
screen will start blinking. The system alarms can be read in the alarm window (Figure 146). Alarm infor-
mation can only be reset by a factory level user.
Scroll up
The alert list can be scrolled up.
Scroll down
The alert list can be scrolled down.
Each alarm is shown on its own line in the window,

with a name and number. Four alarms are shown at
the same time on the display. An active alarm is
marked with an asterisk. In addition, each alarm row
shows the number of occurrences of the alarm and
the date of the first and last alarm. There are 17 reg-
istered alarms.

Overloading
HCM4000A Missing
1. 10. Load control has prevented the lifting of
HCM4000-A sensor is not in the CAN bus.
an oversized load.
Maximum SWL of the attachment is

HCM4000B Missing exceeded.
2. 11.
HCM4000-B sensor is not in the CAN bus. The safe working load of the front attach-
ment is exceeded.
Pressure fault of the main boom cylinder

HCM4000C Missing arm's side.
3. 12.
HCM4000-C sensor is not in the CAN bus. An error in pressure measurement, a sig-
nal is faulty.
Pressure fault of the main boom cylinder

HCM4000D Missing on the piston side.
4. 13.
HCM4000-D sensor is not in the CAN bus. An error occurred in pressure measure-
ment or the signal was faulty.
Pressure fault of the HybriLift cylinder

HCM4000E Missing arm's side
5. 14.
HCM4000-E sensor is not in the CAN bus. An error occurred in pressure measure-
Pressure fault of the HybriLift cylinder on

MCL5000 Missing the piston side.
6. 15.
MCL5000 module is not in the CAN bus. An error occurred in pressure measure-
Forward inclination alarm Danger of collision alarm

7. The forward inclination of the base 16. The front attachment is in the collision
machine is too high. hazard area.
Backward inclination alarm

Swing suppression
8. The backward inclination of the base 17.
Swing suppression is on.
machine is too high.
Lateral inclination alarm.

9. The lateral inclination of the base machine
is too high.

3.13 Seat adjustments
Armrest side- Armrest hori-

Armrest angle
A. B. ways adjust- C. zontal adjst-
adjustment.
ment. ment.
Height adjust- Angle adjust-

ment of joy- ment of joy- Seat belt
D. E. F.
stick in relation stick in relation buckle.
to arm rest. to arm rest.
Backrest Horizontal Seat heating

G. angle adjust- H. adjustment I. operating
ment. of seat. switch.
Horizontal
Neck support. Angle and Armrest height
J. K. adjustment of L.
height control. adjustment.
side console.
Seat cushion- Seat front part

M. Seat belt. N. ing rigidity O. height adjust-
adjustment. ment.
Seat rear part

Seat horizontal Turning of the
P. height adjust- Q. R.
adjustment. seat
ment.

4 Operating the machine
Warning!
Never operate the machine when load control is switched off!
Note!
The machine's lowest operating temperature is -35 °C and highest operating temperature is
+50 °C!
Safe and efficient use of the machine requires good knowledge of the control devices of the machine. In
this section it is expected that the reader has carefully studied the previous sections.
4.1 Daily Inspections
Note!
If you suspect that there is something wrong with the machine or that operating it is not safe
for some reason, please contact maintenance!
Daily checks ensure that there are no deficiencies in the machine, incipient damage or defects which may
lead to fast wear of components, or in the worst case, breaking of the machine.
4.1.1 Checking the general condition

A visual inspection of the general condition of the machine focuses on the following:
• Condition and fixture or electric conductors and loosened connectors. The conductors may not rub
against any parts of the machine or each other, either.
• Steel structures are checked for possible damage. Cracked paint may be a sign of damage.
• There must be no leaks in the hydraulic system. All hoses and pipes must be undamaged. The hos-
es must not rub against each other or against any part of the machine.
• There must be nothing extra on top of the machine or in the pump room. All loose objects must be
removed.
64 4 Operating the machine S/N: 160ES268113 Ver: 170203

4.1.2 Inspection of the level of hydraulic oil and adding of oil
Note!
Prevent the entry of dirt particles into the hydraulic system!
1.If the machine is equipped with the HybriLift
system, the system is loaded by elevating the
main boom to the up position and keeping the
joystick in the lift position long enough for the
HybriLift indicator light on the display of the
machine's control system to turns off (see sec-
tion: “Machine control system”).
2.The main boom is raised to its top position and
the stick is turned to point perpendicularly
down.
3.The level of hydraulic oil can be checked in the
measuring glass on the side of the oil tank (A
Figure 2620). The oil level must be between the
center point of the measuring glass and the top edge.
4.If there is less oil than required, the reason for the lack of oil must be examined. Hydraulic oil is added
through the quick filling adaptor (B Figure 2620) on the lid of the return filter. The adaptor end must be
cleaned carefully before connecting the filling hose in the quick filling adaptor.
4.2 Greasing equipment and filling them
Note!
When using different grades of grease, make sure that the old grease in the system and the
new do not react with each other!
Info!
See Appendix 2 for grease grades recommended by the manufacturer.
The greasing of the boom and slewing bearing is automated in all machines. Several greasing points, such
as the link and attachment, may be included in the automated greasing depending on what kind of equip-
ment has been chosen. Machinery of series 70, 90, 95 and 120 always have at least one common greasing
device for the boom and slewing bearing. In the larger models of machinery, series 160 and 200, the slew-
ing bearing and boom have their dedicated greasing devices. In some machine types, such as machines
with wheels, the greasing points in the undercarriage may have their dedicated greasing device.
The grease containers of greasing devices are filled through the filling adaptor (A Figure 2656) with a fill-
ing device provided with the machine. Do not fill the greasing device from above through the cover, be-
cause this allows air and impurities to enter the system causing a possible malfunction. The condition of
the lubrication lines must be observed in connection with each filling. Check in particular the overpres-
sure valve of the greasing device (C Figure 2656). If grease is leaking from the overpressure valve, the line
has excessive resistance for some reason, and the grease cannot move.
All greasing devices use grease of similar grade, mainly NLGI-2 or NLGI-1, depending on the operating
temperature of the machine. If the machine is operated in very cold conditions, consider using grease
grade NLGI-0. The viscosity of the basic oil of the grease must be in the range of ISO VG 100 - 220 cST
@ 40°C. Due to low RPMs, the grease must contain an EP (Extreme Pressure) additive.
S/N: 160ES268113 Ver: 170203 4 Operating the machine 65

The grease used by the factory in the greasing devices is Kendall SHP Grease, a mineral oil based grease
with a calcium sulfonate thickener, compatible with commonly used mineral oil based lithium and lithium
complex greases. When using different grades of grease, make sure that the old grease in the system and
the new do not react with each other. Some greases lose their lubricant quality if they are mixed with an-
other type of grease. Furthermore, note that greases by different manufacturers but of the same consisten-
cy may differ, and the suitability for pumping of all greases at temperatures below 0 °C cannot be
guaranteed. The suitability for pumping must always be ensured separately for each grade of grease.
All greasing devices are connected to the machine's
control system, but the greasing devices can also be
operated manually using the one-touch switch pan-
el (see “One-touch switch panel of the control sys-
tem”). This may be useful to remove air from the
system, for example.
In case of malfunctions, the greasing devices have a
by-pass nipple (B Figure 2656), which can be used
to add grease to the line manually using a grease
gun.
4.3 Adding washer fluid
Note!
Use only windshield washer fluids!
Windscreen wiper fluid tank is in the cab and it is
filled through the filling hole (Figure 2582).behind
the cab.

4.4 Starting up the machine
Note!
Ensure that the surface under the machine is firm, and can take the weight of the machine!
Note!
Before starting the machine, make sure there are no unauthorised people or property which
may be damaged near the machine!
Start the machine in two stages. First, turn the ignition key to position I. Let the ignition key be in posi-
tion I for about 10 seconds to let the control system to start up. After this, start the machine by pressing the
START button in the one-touch switch panel of the machine's control system (see “One-touch switch pan-
el of the control system”).
4.5 Operating the machine at low temperatures
Warning!
In low temperatures the movements of the machine slow down. The machine may operate in
an unusual manner!
Note!
The lubricants must be designed for the working conditions!
Note!
The heating run of the machine must be always performed before working with a cold
machine!
Below a list of possible other optional equipment for low operating temperatures.
• Thermostat-controlled heating of the hydraulic oil tank.
• Thermostat controlled heating resistors of electric boxes.
• Interior heater.
The heaters are always on when the machine is connected to the mains and the main power switch is in the
ON position. Note that operating the machine is possible even when the heating plug is in place. Absolute-
ly never use the machine until the heating is unplugged! The heating time of the machine depends on the
outdoor temperature. The recommended heating times are shown in the table below:
Outside temperature t [°C] Heating time [h]

t>0°C No heating
0 °C > t > -10 °C 2
-10°C < t < -20°C 4
-20°C < t < -30°C 8
t<-30°C Steady

The heating run is started by running the electric motor as shown in the table below. The electric motor is
run to allow the hydraulic oil and, in particular, the power cable to warm up a bit.
Outside temperature t [°C] Operating time [min]

t > 0 °C 5
0 °C > t > -20 °C 15
t < -20 °C 30
The heating run of the machine is continued by driving the machine a short distance several times to and
fro. The front equipment is moved to and fro without load, avoiding extreme movements. The uppercar-
riage is turned to and fro until the movements of the machine are accurate and fast. After this, work can be
carefully started. It must be noted that reaching the normal operating temperature of the machine hydrau-
lics may last a long time, depending on the circumstances.
4.6 Driving the machine
Warning!
Never leave the cab safety gate closed when you leave the operator's seat!
Note!
When driving the machine, the boom must always be longitudinal to the undercarriage and
the boom as close to the base machine as possible!
Note!
Ensure that the surface under the machine is firm, and can take the weight of the machine!
The cab safety gate is closed. The machine is driven forward and backward using the miniature joystick
(see "Miniature joystick"). The machine moves in the direction the joystick is deflected even if the upper-
carriage was turned 180 degrees in relation to the undercarriage. When driving the machine the uppercar-
riage and undercarriage must always be kept parallel, and the stick as close to the base machine as
possible. Only a front attachment without a load is allowed at the end of the boom. Under no circumstanc-
es can loads be moved by driving. When going under low obstacles it must be ensured that the cab eleva-
tor arms do not touch anything, because the arms are considerably higher than the cab when the cab is in
its basic position.

4.7 Using the boom
Warning!
The maximum allowed inclination of the operating surface during work is 2°!
Warning!
Never leave the cab safety gate closed when you leave the operator's seat!
Warning!
The control system of load control must have correct data on the attachment and the load,
so that the load control can prevent the load from hitting the cab!
Note!
The boom may only be used for lifting. It must not be used for pressing the load or pushing it
in any direction!
The cab safety gate must be down so that the stick can be moved. The maximum allowed inclination of the
operating surface during work is 2°. We recommend that the tolerance of the operating surface is ensured
with calculations by experts. The surface pressures caused by the machine on the operating surface are
given in the specifications provided with the machine.
4.7.1 Load control

A load as high as the load control allows can be lifted with the machine. When the load and its distance
from the base machine is too high, the load control prevents the lift and emits an alarm. Appendix 6 shows
a lifting capacity table, where the lifting capacity of the machine can be checked with all beam outreach-
es. The lifting capacity table can also be found on the right hand side cab window.
Another task of the load control is to prevent the front attachment from colliding with the cab of the ma-
chine. Therefore it is extremely important that when a front attachment is changed, the data about the at-
tachment is entered in the control system. When operating normally, the control system stops the boom
when the cab is in the hazardous area of the attachment.
4.7.2 HybriLift® system

The HybriLift system must be in use to increase energy efficiency. The system is loaded by elevating the
main boom to the up position and keeping the joystick in the lift position long enough for the HybriLift in-
dicator light on the display of the machine's control system to turn off.

4.7.3 Pressing with the boom
Note!
Pressing with the boom must be avoided, because it shortens the service life of the boom!
The main boom can be driven down with hydraulics. Pressing with the main boom may be necessary
when, for example, a grab is used as a front attachment in challenging conditions. In normal conditions,
however, the weight of the boom is sufficient for working. Pressing must be avoided, because it puts strain
on the front equipment and consumes energy. Pressing with the boom is selected in the driver settings
menu of the machine's control system user interface.
4.7.4 Heavy lift function

For extremely heavy lifting, the machine has the optional Heavy lift function. When the function is on, the
machine can momentarily lift heavier than normal loads. When the Heavy lift function is activated, the
motions of the machine are constrained.
4.7.5 Precision running

The selection button or precision running is located in the left joystick. When precision running is activat-
ed, the motions of the machine are constrained, which makes it easier to operate the machine in situations
requiring precision.
4.7.6 Swing brake
Note!
The swing brake is only meant as a parking brake to keep the upperstructure in place, for
example, when a load is positioned in windy conditions. The brake must not be used to slow
down motions!
Apart from the 70 series machines, all machines are equipped with the swing brake function. The swing
brake is only intended as a parking brake to keep the uppercarriage in place, for example, when a load is
positioned in windy conditions or on an inclined surface. The brake can only be activated when precision
running is in use, and switching it on will not succeed if the swing joystick has been deflected over 50 per
cent from its middle position. The brake is on for as long as the button is kept down.
However, all machines have a swing parking brake that switches on automatically. The parking brake
switches on automatically when the uppercarriage has been still for approximately 20 seconds. This pre-
vents the uppercarriage from turning unintentionally when the machine is standing in strong wind, for
example.

4.8 Use of cab elevator
Note!
Ensure that the cab does not collide with the undercarriage or any other obstacle when
using the elevator!
The machine has a hydraulically operating cab elevator, which helps the operator see the materials han-
dling place better, for example, when unloading a cargo compartment of a ship. Use the cab elevator with
the miniature joystick (see “Miniature joysticsk”).
4.9 Ending the use
Warning!
Never leave the cab safety gate down when you leave the operator's seat!
Turn off the engine by pressing the Stop button in the one-touch switch panel of the control system (see
“One-touch switch panel of the control system”). Then, turn the ignition key to position 0. When you
leave, lock the cab door to prevent unauthorised access.

5 Maintenance
Warning!
Before every service task, ensure that no one can even accidentally use the machine during
service!
To maximize the service life of the machine and to maintain safety and a reliable operation, periodic main-
tenance tasks must be performed. This section covers the different basic maintenance objects and the tasks
are illustrated, when necessary. It is recommended to contact the manufacturer or an authorised service
shop for the most demanding maintenance and repairs.
If the machine is equipped with extinguishing equipment, it is mandatory to switch off the system for the
following service tasks
• Electric welding.
• Steam wash.
• Washing with a pressure washer.
In connection with all servicing, it is recommended
that the main power switch be turned to OFF posi-
tion and locked with a padlock (Figure 625). Turn-
ing the switch to OFF position prevents the machine
from being used. Note that some of the high volt-
age cables still have voltage, which is why the pow-
er must also be turned off at the main power supply
of the machine when electric work is done. In addi-
tion, a sign informing of the ongoing maintenance
work must be placed in a visible place in the cab of
the machine.
72 5 Maintenance S/N: 160ES268113 Ver: 170203

5.1 Electric system
Warning!
The electrical cabinets of the machine has life-threateningly high voltage and electric
currents!
Note!
The machine has a power current and low current system. Power current work can only be
carried out by a qualified and authorized electrician!
Info!
See Appendix 3 for the maintenance intervals of different service objects.
The conditions of electric conductors, terminals and conductor connections must be checked carefully dur-
ing service. All defective conductors and connections are to be repaired or replaced. Loose electric con-
ductors are attached firmly in place and it must be checked that the insulation material of the conductors
does not rub and break due to the vibration of the machine.
Electric cabinets must be checked for moisture. If the electric cabinets are equipped with heaters, their op-
eration must be checked. The task of the heaters is to keep the indoor temperature of the boxes even,
which prevents moisture from condensing in the boxes due to the variation in the temperature of electric
equipment.
5.1.1 Checking the emergencyStop circuits

Every EmergencyStop button is pressed down in
turn while the machine is running. The machine
must switch off immediately when an Emergency-
Stop button is pressed. An EmergencyStop window
is shown on the display of the machine's control
system interface (Figure 2536) and the acoustic
alarm of the cab goes off. It is not possible to exit
the window until all EmergencyStop buttons have
been released.
5.1.2 Fuses and relays 24 VDC
Note!
Make sure that the interchangeable fuses
have matching amperages. Never replace
a smaller fuse with a larger one!
The machine has low current fuse boxes. The fuse
box of the base machine is located in the electric
cabinet of the uppercarriage (Figure 2731), the cab
fuse box is next to the side window (Figure 2781)
and the undercarriage fuse box is in the undercar-
riage electric cabinet (Figure 2780). The fuses and
relays are itemised in Appendices 7, 8 and 11.
S/N: 160ES268113 Ver: 170203 5 Maintenance 73

5.1.3 Power current conductor connectors requiring retightening
Warning!
Switch off the power supply to the machine from the feed point before a service measure!
Note!
Electric work can only be performed by qualified electricians!
The loosening of connectors causes resistance in the connection, and the conductors may heat up. At
worst, the situation may lead to a fire in the electric box. The power current screw joints in the electric
boxes of the machine require retightening after the first 150 hours of operation. The next tightening will
take place at 500 hours of operation. The recommended torques are shown in the table below.
Screw, strength 8.8 Tightening torque [Nm]

M6 10
M8 24
M10 47
M12 81
After that, it is recommended to check the conductor connections every 1000 hours of operation. The in-
spections - every 1000 hours of operation - are recommended to be done with an infrared camera while the
machine is running. Then a loosened connector can be seen in the image as a hotter than normal area. At
inspection it must be remembered that the box contains hazardous electric currents and live components.
The machine becomes totally dead only when disconnected from the mains.
5.1.4 Checking the load control function
Note!
The machine must not be operated when the load control is turned off. If operation is contin-
ued regardless of this, the operator is solely responsible for any damage caused!
The operation of the load control must be inspected annually through the following procedures (see sec-
tions “Load control user interface” and “Machine control system user interface”).

1.Previously known weight is attached to the boom. The boom is lifted off the ground and the weight of
the load is compared with the load control reading. The values must be roughly the same.
2.The boom is moved away from the machine and the distance between the boom tip and the centre of the
uppercarriage swing is measured. The result is compared to the load control reading. The values must
be roughly the same.
3.The front attachment is chosen in the base machine interface after which the safety limits appear on the
load control interface display. The boom is driven toward the cab until the load control sets off the
alarm and stops the machine.
4.The boom is driven to its outermost position and a weight exceeding the lifting capacity table value for
the same boom reach is attached to the end of it. An attempt to lift the load is made with the load control
switched on. The load control must prevent the lifting.
If any of the above procedures is not successful or the system fails to function in any way, contact the
manufacturer or an authorized service shop to examine the failure. The load control system has a self-diag-
nostics feature. The system inspects itself in the beginning of each time it is used. For this reason, it is rare
for the problems to appear only in the operation testing.
5.1.5 Cleaning the air filters of electrical cabinet +LCC1
Info!
See Appendix 3 for the maintenance intervals of different maintenance objects.
Electrical cabinet +LCC1 has four filters (Figure
2771). The air inside the electrical cabinet must be
ventilated to prevent humidity from condensating in
the electrical equipment inside the cabinet due to
temperature variations.
The filter mats are located in each filter behind a
hatch that opens (Figures 2772 and 2773). In nor-
mal circumstances the mats must be cleaned at least
once a year. In demanding circumstances, such as
carbon dust, the filter mats must be cleaned more
often.

5.1.6 Cleaning the air filter of the cooling unit of electrical cabinet +MCC2
Warning!
Switch off the cooling unit before removing the front panel!
Info!
Electrical cabinet +MCC2 has a cooling unit, which
contains an air filter (Figure 2774). The cooling unit
is for maintaining a steady temperature in the elec-
trical cabinet and for preventing the electrical equip-
ment in the cabinet from overheating.
In normal circumstances the cooling unit air filter
must be cleaned at least once a year. In demanding
circumstances, such as carbon dust, the filter must
be cleaned more often.
The air filter is located behind the front panel of the
cooling unit. Clean the air filter as follows:
1.Turn off the air conditioner, if it is running.
2.Remove the front panel of the cooling unit (Figure 2775). The front panel is fastened with four screws.
3.Lift off the air filter (Figure 2776). Wash the filter with warm water and dry it using light air flow.
Never use solvents to clean the filter.
4.Reinstall the filter and reattach the front panel of the cooling unit.

5.2 Hydraulic system
Warning!
Release the pressure in the hydraulic system before any service measures!
Info!
See Appendix 2 for the maintenance intervals of different service objects, Appendix 3 for the
oil grades recommended by manufacturers, and Appendix 9 for the fastening instructions of
hydraulic hoses and pipes.
Cleanliness is particularly important when servicing the hydraulic system. Dirty hydraulic oil damages the
hydraulic system in two ways. Firstly, it reduces the efficiency of the system. When the hydraulic system
does not function at full capacity, the performance of the machine deteriorates and energy consumption in-
creases. Performance often deteriorates so slowly that the machine operator only notices the problem when
performance has dropped by up to 20%. Secondly, dirty hydraulic oils causes premature wear. An estimat-
ed 85 % of the failures in hydraulic components are due to impurities in the oil. Dirt particles smaller than
40 µm cannot be seen with naked eye, but particles of this size are the most common reason for the wear
of components manufactured with small tolerances, and other problems in hydraulic systems. For this rea-
son, do not remove the packaging of hydraulic components, hoses, pipes and filters until they are in-
stalled.We also recommend prefiltering the oil when adding or replacing it in the hydraulic system.
Hydraulic system maintenance is primarily preventive by keeping the system clean and serviced.
5.2.1 Pressure release of hydraulic system

Before components are detached from the hydraulic system, the system pressure must be released through
the pressure release tap of the hydraulic oil reservoir (Figure 2621). If the machine is equipped with a
HybriLift system, pressure must also be released from the hydraulic circuit of the energy storage system
by opening the pressure release tap in the valve block of the HybriLift system (Figure 2006). HybriLift
system valve block is located where the pressure accumulators are above the pressure filter.

5.2.2 General inspection of the hydraulic system
Warning!
Release the pressure from the hydraulic system through the pressure release tap of the
hydraulic oil reservoir before removing components from the system! If the machine has
HybriLift system, pressure must also be released from the hydraulic circuit of the energy
storage system by opening the pressure release tap in the valve block of the HybriLift sys-
tem!
No visible damages are allowed in the hydraulic pipes and hoses and they must not rub against each other
or parts of the machine. Be extra careful when looking for leaks in the hydraulic pipes and hoses, because
a sharp spray of hydraulic oil may be difficult to detect with naked eye. Pressurized hydraulic oil may pen-
etrate the skin and create a serious health hazard.
Other hydraulic system components are inspected outwardly for leaks. Pay attention to the running sound
of hydraulic pumps and motors. Check the hydraulic cylinder rods for wear and damages. The primary ser-
vice procedure of these components is to change the filters on time and keep the hydraulic system clean.
All broken or worn hydraulic components and their parts must be replaced with new ones. In case of fail-
ure in the hydraulic system components, we recommend that diagnostics and repair is carried out by the
manufacturer or an authorized service shop. All replacing parts must correspond to the original parts as to
their design pressure.
5.2.3 Draining water from hydraulic oil reservoir
Warning!
Make sure that no one uses the machine during maintenance!
Safety!
Dispose of oil waste in an appropriate manner!
Over time, water will condense in the hydraulic oil reservoir due to variation in temperature. The water
should be emptied only after the machine has stood about 24 hours without being used.
1.The hydraulic system pressure is released through the pressure release tap of the hydraulic oil tank.
2.The service hatch at the bottom of the machine is removed (Figure 2304).
3.The plugs at the end of the drain taps are removed (Figure 2305).
4.A hose is inserted in turn in the drain taps.The other end is placed in a receiver.
5.The drain tap is opened and the water at the bottom is drained to the receiver.
6.The service hatch is closed.

5.2.4 Changing the drain filter
Warning!
tem!
Warning!
Note!
Note!
During the measure, the hydraulics must be at operating temperature!
Safety!
The drain filter is located on top of the hydraulic oil tank (Figure 2622).
1.The machine is driven onto a flat surface and
switched off.
2.The hydraulic system pressure is released
through the pressure release tap of the hydraulic
oil tank. If the machine has HybriLift system,
pressure must also be released from the hydrau-
lic circuit of the energy storage system by open-
ing the pressure release tap in the valve block of
the HybriLift system (see section Hydraulic sys-
tem pressure release).
3.The surroundings of the drain filter are carefully
cleaned of impurities.
4.The fastening screws of the filter cover are
removed and the cover is wrenched loose (Figure 924).
5.The filter is lifted out and placed in the receiver to drain (Figure 925).
6.The dirt collector is removed from the bottom of the filter and placed in a new filter (Figure 926).
7.The new filter is set in place.
8.The O-ring of the cover is checked and replaced with a new one, when necessary. The O-ring is lubri-
cated lightly with hydraulic oil, and the cover is attached back in place.
9.The machine is started and the hydraulics is run warm.
10.The filter and its surroundings are checked for leaks.

5.2.5 Replacement of return filters
Warning!
tem!
Warning!
Note!
Note!
Safety!
The hydraulics return filters are located on top of the hydraulic oil reservoir (Figure 2623).
switched off.
oil tank. If the machine has HybriLift system,
pressure must also be released from the hydrau-
lic circuit of the energy storage system by open-
ing the pressure release tap in the valve block of
the HybriLift system (see section Hydraulic sys-
tem pressure release).
3.The surroundings of the return filters are care-
fully cleaned from impurities.

4.The fastening screws of the filter covers are removed and the covers are wrenched loose (Figure 928).
5.The filters are lifted out and placed in the receiver to drain (Figure 929).
6.The dirt collectors are removed from the bottom of the filters and placed in new filters (Figure 926).
7.The new filters are set in place.
8.The O-rings of the covers are checked and replaced with new ones, when necessary. The O-rings are
lubricated lightly with hydraulic oil and the covers are fastened back in place.
9.The engine is started and the hydraulics is run warm.
10.Filters and their surroundings are checked for leaks.
5.2.6 Changing the swing circuit filter
Warning!
tem!
Warning!
Note!
Note!
Safety!
The swing circuit filter is located in the pump room (Figures 2726 and 1634).

1.The machine is driven onto a flat surface and switched off.

2.The hydraulic system pressure is released through the pressure release tap of the hydraulic oil tank. If
the machine has HybriLift system, pressure must also be released from the hydraulic circuit of the
energy storage system by opening the pressure release tap in the valve block of the HybriLift system
(see section Hydraulic system pressure release).
3.The surroundings of the swing circuit filter are carefully cleaned from impurities.
4.The casing of the filter is removed and the oil contained in it is poured in the receiver.
5.The filter is pulled from the filter mounting base.
6.The O-ring of the new filter is lubricated lightly with hydraulic oil and the filter is pressed in the mount-
ing base.
7.The O-ring of the filter casing is checked and replaced with a new one, when necessary. The O-ring is
lubricated lightly with hydraulic oil, and the cover is attached back in place.
5.2.7 Changing the pilot circuit filter
Warning!
tem!
Warning!
Note!
Note!

Safety!
The pilot circuit filter is located in the pump room (Figures 2726 and 1633).

3.The surroundings of the pilot circuit filter are carefully cleaned of impurities.
5.The filter is pulled from the filter casing.
6.The filter casing is cleaned and a new filter is placed in the casing.
lubricated lightly with hydraulic oil and the cover is attached back in place.
5.2.8 Changing the auxiliary hydraulic filter
Warning!
tem!
Warning!
Note!

Note!
Safety!
The auxiliary hydraulic filter is located in the pump room (Figures 2726 and 1635).

3.The surroundings of the auxiliary hydraulic filter are carefully cleaned of impurities.
6.The O-ring of the new filter is lubricated lightly with hydraulic oil and the filter is pressed in the sup-
port.
lubricated lightly with hydraulic oil and the cover is attached back in place.
5.2.9 Replacing the CJCTM by-pass filter
Warning!
Disconnect the filter system from the hydraulic and electric system of the machine before
servicing the filter!
Warning!
Note!

Safety!
Info!
The CJCTM filter system manual, delivered with the machine, provides more detailed infor-
mation on the by-pass filter.
Hydraulic oil is being filtered even when the machine is standing still. In addition to solid particles of im-
purities, the CJCTM by-pass filter also filters hydraulic oil breakdown products and oil oxidation by-prod-
ucts. The condition of the filter cannot be assessed based only on flow resistance, because oil breakdown
products and oil oxidation by-products do not really increase flow resistance even if the filter was full.
This is why the filter must be replaced at least once a year even if the flow resistance metre reading [A
Figure 2403) was within acceptable limits below 1.8 bar. In normal situations, the flow resistance of the
filter varies based on the viscosity of the oil, but it is usually below 0.3 bar.
1.Stop the oil pump (H Figure 2403) at the switch (G Figure 2403). The oil pump switch is usually near
the filter. The switch may not look like the one in the picture. For safety reasons we recommend that
you also cut the power to the switch.
2.Shut the inlet connection stopcock (I Figure 2403) and the outlet connection stopcock (F Figure 2403).
3.Open the drain valve of the filter (E Figure 2403) and drain the filter casing (D Figure 2403) into a
receiver. Open slightly the bleed screw (B Figure 2403) to drain the oil easier. When the filter casing is
empty, shut the filter drain valve. You can leave the bleed screw as is for bleeding the filter casing later.
4.Open the fastening screw (C Figure 2403) of the filter casing cover (J Figure 2403) and lift off the
cover.
5.Open the spring nut (L Figure 2403) and remove the spring and the spring guide (M Figure 2403).
6.Lift the filter element (O Figure 2403) out of the filter casing. You may use a special tool made for
removing the filter element, but it is not necessary in removing the filter element.
7.Clean the removed components and the inside of the filter casing with a lint-free cloth.
8.Place the new filter element in the
filter casing. Replace the O-ring
(K Figure 2403) inside the spring
guide. Place the spring guide and
spring on top of the filter element.
Turn the spring nut in place so that
it barely touches the spring guide.
Then tighten the spring nut four
full turns to settle the filter ele-
ment properly in place.
9.Replace the O-ring (N Figure
2403) of the filter casing cover,
and reattach the filter casing
cover. Tighten the fastening nut of
the filter casing cover to torque
70 Nm.
10.Open the stopcocks of the inlet
and outlet connections.
11.Start the oil pump and shut the bleed screw as soon as the filter casing is full of oil.
12.Bleed the filter again after an hour of operation by slightly opening the bleed screw until all the air has
left the filter casing. Also, check the filter casing and its surroundings for leaks.

5.2.10 Changing filters in front attachment line
Warning!
Note!
Note!
Safety!
The filters of the front attachment line filter the oil returning from the front attachment. The filters are lo-
cated behind the main valve table in the middle part of the machine (A and B figure 2330).
switched off. Release the pressure of the front
attachment line (see “One-touch switch panel of
the machine control system”).
oil tank (see Section “Pressure release in hydrau-
lic system”).
3.The filter casings of the front attachment rota-
tor's hydraulics circuit (A Figure 2330) is
opened cautiously, and the oil in them is drained
into a receiver.
4.The front attachment rotator's hydraulic circuit
filters are pulled off the filter brackets.
5.The O-rings of the front attachment rotator's hydraulic circuit filters are lightly lubricated with hydrau-
lic oil and the filters are pressed into the filter brackets.
6.The O-rings of the front attachment rotator's hydraulic circuit filter casings are checked and replaced if
needed. The O-rings are lightly lubricated with hydraulic oil and the casings are fastened back in place.
7.The drain plugs are opened in the bottom of the filter casings of the grab’s open-shut hydraulic circuit
(B figure 2330), and the oil is drained into a receiver.
8.The drain plugs are fastened to the bottoms of the filter casings of the grab’s open-shut hydraulic cir-
cuit, and the filter casings are removed.
9.The grab’s open-shut hydraulic circuit filters are pulled off the filter brackets.
10.The new O-rings of the grab’s open-shut hydraulic circuit filters are lightly lubricated with hydraulic
oil and the filters are pressed into the filter brackets.
11.The O-rings of the grab’s open-shut hydraulic circuit filter casings are checked and replaced if needed.
The O-rings are lightly lubricated with hydraulic oil and the casings are fastened back in place.
12.The engine is started and the hydraulics is run warm.
13.The filter's surroundings are checked for leaks.

5.2.11 Changing the oil reservoir breather filter
Warning!
Note!
Note!
In dusty and other demanding conditions, the filter must be changed more often!
Safety!
The oil reservoir breather filter is located in the replacement hatch for suction filters on top of the hydrau-
lic oil reservoir (Figure 2624).
2.The surroundings of the breather filter are carefully cleaned of impurities.
3.The lid of the filter is removed and the filter element is replaced with a new one (Figure 754).
4.The lid is attached back in place.
5.2.12 Changing the suction filters
Warning!
Note!
Safety!
The suction filters of the hydraulic circuits are located inside the hydraulic oil reservoir. The filters can be
accessed by removing the service hatch on top of the hydraulic oil reservoir (Figure 2625).

2.The hydraulic system pressure is released through the pressure release tap of the hydraulic oil tank (see
Section “Pressure release in hydraulic system”).
3.The service hatch of the hydraulic oil reservoir's suction filters and its surroundings are carefully
cleaned from impurities.
4.The service hatch is removed.
5.The filter bracket is disconnected so that the filters remain inside the reservoir at the ends of threaded
rods (Figure 936).
6.The filters are lifted one by one from the tank and replaced with a new filter (Figure 937). The filters
are secured with a locking nut.
7.The O-rings at the bottom of the filters are lubricated lightly with hydraulic oil and the filters are
pressed back in place (Figure 938).
8.When all the filters have been replaced, the filter bracket is set back in place. The threaded rods are
tightened in the support so that the rods are slightly tense.
9.The condition of the service hatch's gasket is checked, and the gasket is replaced if necessary. The ser-
vice hatch is set in place.

5.2.13 Changing the hydraulic oil and cleaning the oil reservoir
Warning!
tem!
Warning!
Note!
Note!
Remove air from the pumps before starting!
Safety!
Info!
See Appendix 9 for the instructions on fastening hydraulic hoses and pipes!
A. The oil reservoir breather filter.

B. Replacement hatch of suction filters.
C. Filter bracket.
D. Suction filter.
E. Service hatch.
F. Surface probe.
G. Drain filter.
H. Return filter.
I. Service hatch.
1.The machine is driven onto a flat surface.

2.Drive the cylinders of the front equipment to
their minimum length.
3.The hydraulic oil reservoir is washed carefully
from the outside.
through the pressure release tap of the hydrau-
lic oil tank. If the machine has HybriLift sys-
tem, pressure must also be released from the
hydraulic circuit of the energy storage system
by opening the pressure release tap in the valve
block of the HybriLift system (see section
Hydraulic system pressure release).

5.The leakage line filter, return filters and oil reservoir's breather filter are removed from top of the
hydraulic oil reservoir.
6.The service hatch at the bottom of the machine is removed (Figure 2304).
7.The plugs at the end of the drain taps are removed (Figure 2305).
8.A hose is inserted in turn in each the drain tap.The other end is placed in a receiver. The reservoir is
emptied.
9.The drain taps are closed and the plugs are fastened to the taps.
10.The hydraulic oil reservoir service hatches at the side and bottom of the hydraulic oil reservoir are dis-
connected.
11.Suction filters are removed (see section “Changing the suction filters”).
12.The inlet pipes of pumps are disconnected from the oil reservoir. The inlet connections are protected
so that no impurities can enter them.
13.The hydraulic oil reservoir is cleaned carefully from the inside.
14.New suction filters, drain filter, return filters and the oil reservoir breather filter are installed. (See sec-
tions “Replacement of suction filters”, “Replacement of the return filters”, “Replacement of the drain
filter” and “Replacement of the oil reservoir breather filter”).
15.Inlet pipes / hoses are connected to the reservoir.
16.The filling adaptor of the hydraulic oil reservoir is cleaned and the reservoir is filled with new hydrau-
lic oil (see section on checking hydraulic oil level and adding hydraulic oil).
17.The inlet pipes of all the pumps are bled by loosening the inlet connection of each hydraulic pump
until the inlet pipes are full of oil. The inlet connections are given in the following table. After bleeding,
the inlet pipes are tightened back to the instructed tightness. In some machines there may be a gauge
flange between the inlet pipe and the pump. In such case, the inlet pipe can be bled at the gauge of the
flange.
18.The volume control pump casings are bled either at the drain connection of the casing or other suitable
point. The bleeding connections are presented in the table on the next page. The connectors are tight-
ened to the instructed tightness when the pump casings have been filled with oil.
19.The service hatches are cleaned and installed in place.
20.The machine is started and the oil reservoir and hydraulics inlet pipes are checked for leaks. The
hydraulic oil level is checked and oil is added as needed.

Pumps
A. Oil circulation pump of the pump gear. B. Hydraulic oil cooling fan.
C. Uppercarriage slewing. D. Main boom.
E. Stick boom. F. Pilot line and auxiliary hydraulics.
G. Wheel turn (in machines on wheels). H. Pump gear.
Casing bleeding con-

Pump Inlet connection
nection
A. Pump gear oil circulation. -
B. Hydraulic oil cooling fan.
C. Uppercarriage slewing.
D. Main boom.

E. Stick boom.
F. Pilot line and auxiliary hydraulics. -
Wheel turn
G.
(in machines on wheels).
5.2.14 Cleaning the radiator element of hydraulic oil
Warning!
Note!
The return blowing system only removes loose debris from the elements!
Hydraulic oil radiator element and prefilter net must be cleaned at regular intervals according to the ser-
vice diagram to avoid heat problems in the hydraulics. Shorten the service interval if the service interval in
the service diagram proves to be too long for the operating conditions of the machine. In demanding con-
ditions, the radiator elements may become so dirty that they cannot be cleaned with a normal external
wash. In such a case, the elements must be disconnected from the machine and taken apart for washing.
Use compressed air and / or pressure washer to clean the radiator element and its prefilter net. During the
cleaning procedure, be careful not to damage the lamellas between the oil pipes. Blow lose debris outward
from the radiator blower side. The air current must be kept perpendicular to the element, and the cleaning
must proceed in the direction of the oil pipes. If the element cannot be cleaned with compressed air, the
cleaning can continue with a pressure washer. The elements are washed in the direction of the oil pipes on
both sides. When washing the element, the direction of the water jet must be kept perpendicular to the ele-
ment. Solvent can be used for any oil or grease residue in the element.

5.3 Mechanics
Note!
Prevent the spreading of corrosion and immediately fix all paint damage occurring in use!
Info!
During use, the machine's support structures are exposed to strain caused by the load, the machine's own
weight and external forces. Wear, corrosion and variation at operating temperature also reduce the durabil-
ity of structures. The machine structures must be monitored daily.
5.3.1 Checking the joints

There must be no visible damage in the locking of joint pins or trim plates of the axial clearance. In the in-
spection, it must be ensured that grease can freely enter the joint. The axial clearance of a joint must not
exceed 0.015 times the diameter of the joint pin. The maximum radial clearance is 0.05 x the diameter of
the joint pin.
The joint pins of the machine are often automatically greased. The joints must look like the grease has
reached the joint. If any joint is dryer than the others, it is likely that the grease has not reached its target.
5.3.2 Inspecting plate fields and weldings
Note!
Do not repair or modify the steel structures without the approval of an authorized service
shop!
One of the most important types of structural damage is fatigue. Occasional structural inspections help
prevent major damage. Fatigue is a process where repeated stress causes fractures in the material. A small
crack in a structure may not look dangerous, but an increasing rate of growth of the crack weakens the re-
sistance of the structure very rapidly as the crack progresses.
There must not be any visible damage in the plate structures or welded joints upon a visual inspection. Paint
peeling on a steel surface may indicate deformation of the steel sheet.Therefore, such places must be inspect-
ed extra carefully. In order to ensure the safety of the machine, any cracks and fractures in the plate struc-
tures and welded joints must be analysed with an inspection method that does not break the material.
Magnetic-particle, liquid penetrant and ultrasound testing are examples of non-destructive testing methods.
Repair welds must be carried out by a professional who can meet the relevant quality requirements. Re-
pair-welded joints must be tidied up and checked to make sure that they are faultless. Structural damage is
often case-specific, as are repair recommendations.Therefore, in all demanding repairs, it is recommended
that the manufacturer or an authorised service shop be contacted.

5.3.3 Measuring the axial clearance of the slewing bearing
Warning!
Ensure that no one uses the machine during maintenance!
The measurement is based on the change in the bearing clearance caused by the tilting moment dependent
on the weight of the front equipment. A dial indicator or some other measurement device with the accura-
cy of 0.1 mm can be used for measuring the clearance.
Below are instructions on how to measure the clearance using a dial indicator. The clearance must be
measured from four different points at 90 degree intervals. The axial clearance of the slewing bearing is
the average of these four measurement results. Between every measurement, the uppercarriage must be
turned three rounds per direction.
2.The boom is driven straight and lifted from the ground.
3.The dial indicator is placed between the slewing bearing and the frame, in the same location where the
stick is pointing to. The dial is set to zero.
4.The stick boom is pressed against the ground
and the clearance is read from the dial indicator.
5.The uppercarriage of the machine is turned three
rounds clockwise and three rounds anticlock-
wise. The measurement activity is continued
until the clearance has been measured at even
intervals in four different places.
6.The result is compared to the service limit given
by the manufacturer. When the axial clearance
of the bearing is at the service limit, the bearing
must be replaced in connection with the next ser-
vice. If the axial clearance is over 0.5 mm larger
than the service limit given by the manufacturer,
you must not continue operating the machine.

5.3.4 Checking the fastening of components
Note!
Do not use a thread-locking compound, unless instructed otherwise!
When fixings are changed, the replacements must correspond to the old ones in strength. If a screw is
loose in a screw assembly, replace the loose screw and, in addition, two screws on both sides of the loose
screw (not applicable to wheel attachment). The threads must be clean and lightly oiled. Correct torques
for screws of different strength classes can be found in the table below. It must be noted that the reference
torques for screws of the same strength class vary when different washers are used. The fastening of dif-
ferent components must be checked at intervals indicated in the maintenance chart. The torques of fasten-
ing screws are checked with a torque wrench or other tool that is accurate enough.
Values for untreated oiled carbon steel screws when using a torque wrench or a machine (torque
divergence max + / - 5%, strength class SS-ISO 898-1).
Width across Width across Nordlock washer. [Nm] Normal washer. [Nm]
flats, hexagon flats, hexagon
M thread.
socket head. head. 8.8 10.9 12.9 8.8 10.9 12.9
[mm] [mm]
8 6 13 25 34 38 24 33 40
10 8 17 49 67 75 47 65 79
12 10 19 85 115 128 81 114 136
14 12 22 135 183 204 128 181 217
16 14 24 205 279 311 197 277 333
18 14 27 288 391 437 275 386 463
20 17 30 402 547 610 385 541 649
22 17 32 548 745 831 518 728 874
24 19 36 693 942 1052 665 935 1120
27 19 41 1010 1375 1533 961 1350 1620
30 22 46 1379 1875 2091 1310 1840 2210
33 24 50 1855 2526 2815 1770 2480 2980
36 27 55 2394 3259 3633 2280 3210 3850
39 27 60 3087 4203 4683 2930 4120 4940
42 32 65 3820 5202 5799 3640 5110 6140
1. The cab fastening (Figure 2769).

• Tightening torque from the table.
• Threads must be lubricated.

2. Connecting the cab to the uppercarriage (Figure 1641).
3. Counterweight fastening (Figure 2730).

• Torque 5100 ± 200 Nm.
4. Fastening of the swing gearbox and the swing motors (Figure 1639).
5. Mounting of the cooling unit (Figure 2627).


6. Fastening of the pump gear (Figure 1643).
7. Mounting the pumps (Figure 1069)

8. Fixing of the swing bearing (Figure 1124).

• Torque 1250 ± 200 Nm.
9. Fixing of the swing bearing (Figure 1644).

• Torque 1250 ± 200 Nm.

10. Electric motor fastening (Figure 2768).
11. Mounting the bogey frame (Figure 2766)

12. Fastening of the drive planetary gears and the motors (Figure 2765).
13. Mounting the cable reel and torque unit (Figure 1768).
•Tightening torque from the table.
•Threads must be lubricated.

5.3.5 Checking the cab elevator
There must not be any visible damage in the plate fields or welded joints of the cab elevator upon visual
inspection. In order to ensure the safety of the elevator, suspicious cracks and fractures must be analysed
using a non-destructive testing method. Magnetic-particle, liquid penetrant and ultrasound testing are ex-
amples of non-destructive testing methods. Some fatigue-critical points in the cab elevator are shown in
Figures 1087 and 1088.
Repair welds must be carried out by a professional who can meet the relevant quality requirements. Re-
pair-welded joints must be tidied up and checked to make sure that they are faultless. Failures in struc-
tures and their repair recommendations vary case by case. We recommend that you turn to the
manufacturer or an authorized repair shop in all cases of demanding repair.
Check the operation of the cab elevator as follows.
• Steering: All steering movements must function flawlessly without hesitation. If the cab elevator
is equipped with a ladder, which must also be checked.
• Emergency lowering: Cab emergency lowering must function in all ordinary circumstances.
Check also the operation of the reserve current system, because the emergency lowering of the
cab elevator is connected to it.
• EmergencyStop: The cab elevator must stop and the engine turn off immediately when any of the
machine's EmergencyStop buttons is pushed.
If any defects are detected in the functioning of the cab elevator, the elevator must not be used until the
reason for the malfunction is discovered and the required components are replaced. Note that according to
the definition provided in the Machinery Directive, the cab elevator is a passenger hoist, which requires
official inspections at regular intervals. The inspection may only be performed by a party authorized to in-
spect passenger hoists.

5.4 Lubrication points
Note!
Avoid mixing different oil and grease types together!
Info!
See Appendix 2 for the oil and grease grades recommended by the manufacturer and Ap-
pendix 3 for the maintenance intervals of different objects of service.
Lubrication oil must be changed at regular intervals. The machine has several parts requiring lubrication,
such as transmissions, joints and bearings. To avoid over- or underfilling, the transmissions are always
filled in as instructed. The filling volumes given in Appendix 2 should only be used to help with the ser-
vice plan.
5.4.1 Changing the pump gear oil and filter
Warning!
Note!
The pump gear must be at operating temperature!
Note!
Prevent the entry of dirt particles into the pump gear!
In the machines of 160 and 200 series, the pump gear has its own oil filter, which must be changed when
the pump gear oil is changed. The pump gear is located in the pump room, as an extension to the machine
(Figure 1654).
2.The service hatches at the bottom of the uppercarriage and pump room are removed (A and B Figure
1654).
3.To facilitate oil draining, the pump gear has an oil drain hose mounted to the bottom of the pump room
near the service hatch (Figure 1654). Remove the plug at the end of the drain hose and let the oil run
into a receiver by opening the oil drain tap at the foot of the pump gear (D Figure 1654). If metal or
other debris is found in oil, the manufacturer or an authorized service shop must be contacted.
4.The oil drain tap is closed and the plug is reattached to the end of the hose.
5.The surroundings of the oil dipstick (E Figure 1655) and the pump gear breather (F Figure 1655) are
cleaned thoroughly.
6.The breather and its connector are unfastened. The parts are washed carefully and reinstalled.
7.The dipstick is removed and the pump gear is filled with new transmission oil through the dipstick
opening until the dipstick shows the right amount of oil. The oil level must be between the grooves in
the dipstick.
8.The dipstick is attached back to its place.

9.The pump gear filter is located behind the door to the pump room (Figure 2726). The surroundings of
the pump gear's oil filter is cleaned from impurities (Figure 1636).
10.The oil filter of the pump gear is removed and the oil contained in it is poured in the receiver. The filter
cartridge is opened and inspected to determine the condition of the pump gear. If there are unusually
large metal particles or a lot of metal, the manufacturer or an authorised service shop must be contacted.
11.The sealing face of the filter support is cleaned carefully.
12.The gasket of a new filter is lubricated lightly with transmission oil.
13.The filter is resinserted and tightened fully by hand.
14.The engine is started and the pump gear is run warm.
15.The dipstick is removed and the oil level checked. Oil is added if needed.
5.4.2 Servicing the swing planetary gears
Warning!
Note!
The swing planetary gears must be at operating temperature!
Note!
Prevent the entry of dirt particles into the swing planetary gear!
Safety!
Dispose of oil and grease waste appropriately!

The swing planetary gears are located in the middle of the uppercarriage of the machine. To make drain-
ing the oil easier, the drain plugs are equipped with draining hoses that are accessed through the service
hatch on the bottom of the machine (Figure 2667).
A. Swing brake drain plug. B. Swing brake breather.

Swing planetary gear expansion tank
C. D. Swing planetary gear expansion tank.
breather.
Swing planetary gear drain plug / drain Grease nipple of the swing planetary gear
E. F.
tap. main axle bearing
Swing planetary gear main axle bearing
G. H. Swing planetary gear filling plug.
grease overflow pipe.
I. Swing planetary gear dipstick.

2.The service hatch on the bottom of the machine is opened.
3.Swing planetary gear expansion tank breather is removed and replaced.
4.The drain plug at the end of the swing planetary gear draining hose is removed, the drain tap at the end
of the hose is opened, and the oil is drained into the receiver. If metal or other debris is found in oil, the
manufacturer or an authorized service shop must be contacted.
5.The filling device oil hose is connected to the drain hose of the swing gearbox, and the swing planetary
gear is filled with new transmission oil. Monitor the swing planetary gear during filling to make sure
that the same amount of oil goes into the gear as came out. This is to make sure that the gear will have
the right amount of oil. Finally, check the oil level in the swing planetary gear expansion tank inspec-
tion window. The expansion tank must be half full. If you do not have access to a filling device, the
swing planetary gear can also be filled through the filling hole next to the dipstick.
6.Swing brake breather is removed completely from the side of the brake.
7.Shut the drain cock of the swing planetary gear and remove the filling device oil hose from the swing
gearbox drain hose. Reattach the drain plug of the drain hose of the swing gearbox.

8.Remove the swing brake drain plug and drain the oil into a receiver. If metal or other debris is found in
oil, the manufacturer or an authorized service shop must be contacted.
9.Swing brake drain plug and its sealing surface are cleaned and the plug is reattached.
10.The swing brake is filled with new hydraulic oil through the breather attachment hole up to the lower
edge of the hole.
11.The swing brake breather is replaced and reattached.
12.Swing planetary gear main axle bearing is greased using the grease nipple near the greasing devices.
When new grease is pressed into the bearing, old grease is pushed out through the overflow pipe. Col-
lect the old grease and dispose of it appropriately.
13.The above maintenance measures are repeated with the other swing planetary gear.
14.The service hatch in the bottom of the machine is closed.
15.Start the engine and run the swing planetary gears warm. Check the oil levels of swing planetary gears.
Oil is added if needed. The surroundings of the swing brakes are checked for leaks.
5.4.3 Inspecting and changing the slewing ring grease
Warning!
Safety!
Dispose of grease waste in an appropriate manner!
The inspection hatches of the slewing ring grease are located in the front part of the uppercarriage (Figure
2732). In the slewing ring, the grease layer thickness must be no less than one third of the height of the
cog. The grease must be clean and there must be no water mixed in it.
Change the grease as follows:
2.Open the grease drain hatches in the centre and turn the uppercarriage back and forth until all grease is
removed from the grease space (Figure 2733).
3.Check the seals of the grease drain hatches and replace them if needed. Reattach the grease drain
hatches.
4.Fill the grease space through the inspection hatches. Add grease gradually while turning the uppercar-
riage from time to time. If the grease is difficult to pump, it can be heated to about 60 °C. The grease
space must not be filled above half of the cog height, because excess grease in the slewing ring causes
faster working of grease leading to a premature deterioration of the lubrication qualities.
5.Check the seals of the inspection hatches and replace them if needed. Reattach the inspection hatches.

5.4.4 Greasing the joints of the cab elevator
Warning!
Safety!
Info!
See Appendix 2 for the oil and grease grades recommended by the manufacturer and
Appendix 3 for the maintenance intervals of different objects.
If the operating conditions are demanding or the cab elevator is used a lot, the greasing interval indicated
in the service diagram must be shortened. Grease the joints manually with a grease gun though the three
grease nipples (Figure 2604) at the base of the cab elevator. The grease nipples and hoses are grouped so
that one of three joint groups is greased at a time through one grease nipple.
1.The cab elevator is driven into parking position so that the grease nipples of the greasing point are eas-
ily accessible.
2.The machine is switched off.
3.The grease nipples and the tip of the grease gun are cleaned carefully.
4.Grease is applied to the grease nipple until it squeezes out evenly from the joints connected to the
grease nipple (Figure 2605).
5.The cab elevator is driven to its extreme position. This ensures that the grease has even access to each
joint.
6.Excess grease is wiped off.
5.4.5 Greasing the electric motor bearings
Warning!
Safety!
The bearings of the front and rear end of the electric motor are greased with a grease gun while the motor
is running. Different grades of grease should not be mixed. The grease nipples are located above the mo-

tor in the front and rear end (Figures 2409 and 2410).
5.5 Bogies
Info!
See Appendix 2 for the maintenance intervals for different objects of service and Appendix 3
for the oil grades recommended by the manufacturer.
The machine has four bogies, each with four two and two traction motors including final drives.
5.5.1 Greasing the wheel bearings
Warning!
Safety!
The grease nipples of bearings are located on both
sides at the stem of the wheels (Figure 2201). Re-
member to clean carefully the head of the grease
nipple before greasing the bearing. Press grease into
the bearing so that some of the old grease is pushed
out through the bearing gasket. When greasing the
bearing, pay special attention to the condition of the
gasket.
Change bearing grease once a year. The grease is
changed by pressing grease into the bearing until
the grease pushing out between the gasket lips is
clean. Avoid mixing different grease grades. When
using different grease grades, make sure that the old
and new grease do not react with each other.

5.5.2 Changing the drive gear oil
Warning!
Note!
Prevent the entry of dirt particles into the gears!
Safety!
1.Wash the gears externally with solvent detergent.
2.Remove the drain plug (A Figure 2389) and drain the oil in the receiver. If metal or other debris is
found in oil, the manufacturer or an authorized service shop must be contacted. You can speed up the
draining by removing the gear box breather (B Figure 2390).
3.The drain plug and its sealing face are cleaned carefully. The gasket must be replaced with a new one
when necessary. The drain plug is tightened back in place.
4.If the breather is not removed, remove it at this stage and wash carefully.
5.Remove the transmission oil inspection plug (C Figure 2390).
6.Fill the gear box through the breather opening until oil starts to run out of the inspection plug opening.
7.Clean carefully the inspection plug and its sealing face. The gasket must be replaced with a new one
when necessary. The inspection plug is tightened back in place.
8.The breather is checked and attached back in place.
9.The maintenance measure is
repeated for all eight drive gears.
10.A short distance is driven with the machine and the oil levels are rechecked.

5.5.3 Greasing the joint between bogey and bogey frame
Warning!
Safety!
Between the bogey and bogey frame there is a joint
that requires greasing (Figure 2770). Note that in
the horizontal joints, the greasing points are located
at both ends of the pin. Remember to clean careful-
ly the head of the grease nipple before greasing the
joint. Avoid mixing different grease grades. When
using different grease grades, make sure that the old
and new grease do not react with each other.
5.6 Vertical collector
Info!
for the grease grades recommended by the manufacturer.
The vertical collector includes the lead-throughs of both electricity and hydraulics.
5.6.1 Greasing the bearings of circular coupler

The rotating joint of the lead-through has slide bear-
ings. The greasing points are illustrated in Figure
2008. The lead-through greasing points are ac-
cessed through the service space below the lead-
through. The tips of the grease nipples must be
cleaned carefully before greasing.

5.6.2 Checking the slip rings and brushes
Warning!
Note!
The carbon brushes wear in use. The brushes must be replaced when the distance between the brush hold-
er and the slip ring is less than 2 mm. If even one brush holder shows signs of overheating based on discol-
ouring, all the brushes of the same phase ring must be replaced at the same time.
The condition of the slip rings indicates the function of the electric lead-through. Traces of burning on the
slip rings may indicate poor contact. Rusting and traces of burning can be removed with a fine sandpaper.
Never use solvents for cleaning. Badly grooved slip rings must always be replaced.
5.6.3 Checking conductor connections
Warning!
Note!
Check the conductor connections visually for signs of overheating, such as melted isolations or discolouring
of copper conductor components. The conductors must not touch anything in the collector housing, which
may wear a hole in the conductor isolation. All damaged components must be replaced with new ones.
All conductor connections inside the slip ring casing are to be checked for loosening. The torques of the
connections can be found in the table below. Finally, the inside of the casing is vacuumed. Compressed air
must not be used to prevent carbon dust from spreading in the environment.

M6 10
M8 24
M10 47
M12 81
5.7 Cable reel
Info!
for the oil grades recommended by the manufacturer.
The main components of the cable reeling system are collector housing, torque unit, electric motor and ca-
ble reel. The purpose of the cable reeling system is to keep the power cable adequately tight while not
causing excessive tension when the machine is moving.

5.7.1 Checking the electric motor
Warning!
The cable reel may inadvertently turn while the machine is connected to the mains! Switch
off the power supply to the machine before any service procedure!
Check the cooling air input of the electric motor and the condition of the conductor connections. The elec-
tric motor bearings have permanent lubrication so in that regard, the motor is service-free.
5.7.2 Checking the cable guide
Warning!
On visual inspection, the cable guide must be in perfect condition. The rollers of the guide must be intact
and they must roll easily. Replace defective rollers not to cause damage to the isolation of the power cable.
5.7.3 Checking the power cable
Warning!
Note!
The cable can only be handled with muscle power!
On visual inspection, the power cable must not have cracks or other damage, and it must be tightly fas-
tened to the cable reel. The power cable must be able to move without hindrance on the cable reel. This is
ensured by measuring the distance between the girdles of the reel, which must not be less than one milli-
meter smaller than the diameter of the cable. The distance between the girdles of the reel can be adjusted
with the reel mounting screws, if needed.
Due to the manufacturing process, the power cable will have residual tension, which is discharged during
use. The tension is seen in the power cable as curls, which tend to move toward the power supply. If the
tension is not discharged, over time, it may result in damages to the power cable. There are two ways to
discharge the tension.
A. Drive the cable reel empty, and disconnect the power cable from the power supply. Place a bar under
the cable and slide the bar over to the free end (Figure 1889). You may need to repeat the procedure
several times to remove all curls.
B. Drive the cable reel empty, and disconnect the power cable from the power supply. Make a loop in the
power cable and roll it to the free end (Figure 1890). You may need to repeat the procedure several
times to remove all curls.

5.7.4 Checking the collector housing
Warning!
Note!
The wear of the slip rings and carbon brushes is assessed visually. Worn carbon brushes are replaced with
new ones. If the surface of the slip rings has oxidised, they can be sanded with fine sandpaper. All conduc-
tor connections inside the collector casing are to be checked for loosening. The torques of the connections
can be found in the table below. Finally, the inside of the casing is vacuumed. Compressed air must not be
used to prevent carbon dust from spreading in the environment. The surfaces of electrical parts can be
cleaned with alcohol based solvent.

M6 10
M8 24
M10 47
M12 81
5.7.5 Adjusting the reeling torque
Warning!
Note!
Remember to turn the torque adjustment key into its original position after adjusting the reel-
ing torque!

Note!
Do not adjust the torque to be too high in order not to damage the reel gear of the torque
unit!
switched off.
2.Switch off power to the machine at the power
source.
3.The torque adjustment key and its surroundings
are carefully cleaned from impurities (Figure
1891).
4.The torque adjustment key is removed and put in
place upside down. You may need to turn
slightly the cable reel to push the key all the way
in.
5.The reeling torque is increased and decreased by
turning the cable reel while the torque adjustment key is in place. Looking from the side of the cable
reel, the reeling torque increases when you turn the cable reel clockwise and decreases when you turn
the reel counterclockwise. When looking for the suitable torque, the reel must only be turned a quarter
of a cycle at a time. The suitable torque has been found when the power cable is appropriately tense
when the cable reel is full.
6.The O-ring of the torque adjustment key is checked and replaced with a new one, when necessary.
7.Place the torque adjustment key back in its original position.
5.7.6 Changing the torque unit oil
Warning!
Safety!
Dispose of oil and grease waste appropriately!
switched off.
2.The surroundings of the oil drain plug are care-
fully cleaned from impurities.
3.The drain plug of the torque unit is removed and
the oil is drained in the receiver (Figure 1892). If
metal or other debris is found in oil, the manu-
facturer or an authorized service shop must be
contacted.
4.The drain plug gasket is checked and replaced
with a new one, when necessary.
5.The drain plug is attached back to its place.
6.The surroundings of the oil filler cap (A Figure
1893) and torque adjustment key (B Figure 1893) are carefully cleaned from impurities.
7.The oil filler cap is removed and the torque unit is filled with new transmission oil up to the center point
of the measuring glass (Figure 1894).

8.The filler cap is attached back in place.
9.Remove the torque adjustment key and check its breather hole for blockage.
10.The O-ring of the torque adjustment key is checked and replaced with a new one, when necessary.
11.The torque adjustment key is attached in place.
5.8 Maintenance inspections of the HybriLift® system
Warning!
The system contains high pressure gas and oil!
Note!
The registered owner of the pressure equipment is obligated to organise official inspections
of the pressure equipment at a time defined in the previous inspection. The owner is also
obligated to keep track of the inspections of the equipment and other documentation con-
cerning the equipment. The documents must always accompany the pressure equipment!
Note!
The registered owner of the pressure equipment is obligated to appoint a supervisor for the
equipment. The supervisor of the equipment must have sufficient knowledge of and compe-
tence for using the pressure equipment, safety regulations, condition monitoring and mainte-
nance!
Info!
The HybriLift system is an energy storage system which uses the waste energy generated while lowering
the boom. The hydraulic oil flow and the pressure it generates while the boom is being lowered are fed to
the pressure accumulators. When a load is lifted with the boom, the pressure charged in the accumulators
is taken into use to make lifting lighter. The larger machines of series 160 and 200 have a third main boom
cylinder, which works both as a spare cylinder for the HybriLift system and as a relief cylinder of the
boom. The 120 series machines do not have a separate charging / relief cylinder, but the functions have
been integrated in the two main boom cylinders of the machine.

5.8.1 Checking the gas preload pressure of the pressure accumulators
Warning!
The measurement results are recorded in Appendix 4 of the operating manual. 1. Figures 2662, 2308 and
1748 show the order of inspection of the accumulators in the machines of series 120, 160 and 200.
The gas preload pressure of pressure accumulators is 175 bar (+20 °C). When comparing the measure-
ment result of the pressure accumulator's gas preload pressure to the original gas preload pressure, the
measurement temperature must be taken into account. Figure 1425 displays a diagram where pressure
[bar] is presented as the function of the temperature [°C], from which the impact of the measurement tem-
perature on the inflation pressure can be estimated.
If the energy storage system has to be repaired, a reinspection must be carried out prior to taking the ma-
chine into use. The inspection protocol is country-specific and a reinspection can only be carried out by a
party authorized to inspect pressure equipment in the given country. The inflation pressures of pressure ac-
cumulators are measured as follows:
1.The machine is driven onto a flat surface and the main boom is left in the top position.
2.The pressure is released from the hydraulic circuit of the energy storage system by turning the pressure
release tap anticlockwise (Figure 2006). It must be taken into account that when the pressure of the
hydraulic circuit decreases, the gas pressure still remains high in the gas compartment of the pressure
accumulators.
3.The inspection is started by measuring the surface temperatures of the pressure accumulators. The sur-
face temperatures are measured with a thermometer suitable for the purpose (Figure 1902). The meas-

urement results are marked in Appendix 4. If the machine has been operated right before the inspection,
the temperature of the pressure accumulators must be allowed to settle for 15 minutes.
4.The gauge connector of the gas pressure is located at the top end of the pressure accumulator. To access
the gas pressure gauge connector, the protective plates and valve plugs must be removed from the top
end of the pressure accumulators (Figure 1903).
5.Gas pressure is measured separately from each pressure accumulator with an appropriate measuring
device and the results are marked in Appendix 4 (Figure 1904). The measurement range must be 0–500
bar and the measurement accuracy ± 2 bar. If the gas pressure of an individual pressure accumulator dif-
fers from the average pressure level by over 20 bar, the manufacturer or an authorised service shop
must be contacted.
6.The pressure release tap of the hydraulic circuit of the energy storage system is closed by turning it
clockwise.
7.The hydraulic circuit of the energy storage system is pressurized by lifting the boom to the up position.
The joystick is kept in the lifting position until the indicator light informing of the energy storage sys-
tem pressure turns off (see section: ”Machine control system”). This means that the HybriLift system is
in operation.

5.8.2 Inspecting the opening pressure of the pressure relief valve in the energy storage
system’s hydraulic circuit
Warning!
The pressure relief valve of the energy storage system's hydraulic circuit determines the upper limit of the
operating pressure of the whole system, thus protecting the system from overload. The opening pressure of
the pressure relief valve may be a minimum of 365 bar and a maximum of 385 bar. The measurement re-
sults are recorded in Appendix 5 of the operating manual. If the opening pressure of the pressure relief
valve is outside the limits, the manufacturer or an authorised service shop must be contacted.
If the pressure relief valve of the energy storage system has to be adjusted, a reinspection must be carried
out prior to taking the machine into use. The inspection protocol is country-specific and a reinspection can
only be carried out by a party authorized to inspect pressure equipment in the given country.
2.The pressure gauge is connected to the pressure gauge quick coupling adaptor of the energy storage
system switching block (Figures 1905 and 1906). The measurement range of the gauge must be 0–500
bar and the measurement accuracy ± 2 bar.
3.The position of the adjustment screw of the energy storage system’s charging valve is measured in rela-
tion to the frame, for example, with a side gauge and the measurement result is recorded (Figure 1907).
4.The locking nut of the charging valve’s adjustment screw is loosened (Figure 1908).

5.The machine is started and the main boom is raised to the up position. The joystick is kept in the lifting
position and at the same time, the charging pressure is set to 240 bar from the charging valve's adjust-
ment screw, after which the lift is released (Figure 1909).
6.The main boom is carefully lowered and the pressure increase of the energy storage system is simulta-
neously monitored in the pressure gauge. The lowering of the boom is slowed down when the pressure
gauge reading approaches 375 bar (Figure 438). The opening pressure of the pressure relief valve is
read in the gauge and the reading is marked in Attachment 5 at the end of this manual.It must be noted
that the reading of the pressure gauge may still continue to rise after the pressure relief valve has
opened. The measurement result must be verified with different main boom lowering speeds.
7.Lift the main boom to the top position and switch off the machine.
8.The adjustment screw of the energy storage system’s charging valve is set to its original position.
9.The pressure release tap of the energy storage system is opened carefully so that the pressure in the
energy storage system starts to slowly sink. The tap is closed when the pressure has lowered to about
160 bar (Figure 2006).
10.The machine is started and the main boom is raised to the up position. The joystick is kept in the lift
position and the charging pressure of the energy storage system is simultaneously set to 195 bar, after
which the lift is released.
11.The locking nut of the charging valve is tightened.
12.The adjustment of the charging valve is checked. The pressure release tap of the energy storage system
is opened and the pressure is allowed to lower to about 160 bar, after which the tap is closed.
13.The joystick of the machine is kept in the lifting position and the charging pressure is checked in the
meter.
14.When the pressure is okay, the pressure gauge is disconnected.

5.8.3 Replacing the flushing filter
Warning!
tem!
Warning!
Note!
The hydraulics must be at operating temperature!
Safety!
The flushing filter is located in the uppercarriage near the main control valve block (Figures 2311 and
2312).

2.The hydraulic system pressure is released through the pressure release tap of the hydraulic oil tank (Fig-
ure 2621).
3.The pressure of the energy storage system’s hydraulic circuit is released by opening the pressure release
tap (Fig 1665). Leave the tap open.
4.The surroundings of the flushing filter are carefully cleaned from impurities.
5.The casing of the flushing filter is removed and the oil contained in it is poured in the receiver.
7.The O-ring of the new filter is lubricated lightly with hydraulic oil and the filter is pressed in the mount-
ing base.
8.The filter casing is cleaned from inside. The O-ring of the casing is checked and replaced with a new
one, when necessary. The O-ring is lubricated lightly with hydraulic oil and the cover is attached back
in place.
9.The pressure release tap of the hydraulic circuit of the energy storage system is closed.
10.The energy storage system is charged and its operation is checked.

5.8.4 Replacing the pressure filter
Warning!
tem!
Warning!
Note!
The hydraulics must be at operating temperature!
Safety!
The pressure filter is located in the uppercarriage near the pressure accumulators (Figures 2309 and 2310).

2.The pressure of the energy storage system’s hydraulic circuit is released by opening the pressure release
valve. The tap is left open (Figure 1665).
3.The hydraulic system pressure is released through the pressure release tap of the hydraulic oil tank (Fig-
ure 2621).
4.The surroundings of the pressure filter are carefully cleaned from impurities.
5.The filter casing drain plug is in the bottom of the pressure filter. The drain plug is opened and the oil is
drained in the receiver.
6.After the drain plug is attached, the filter casing is removed and the filter is pulled out of the filter sup-
port.
7.The O-ring of the new filter is lubricated lightly with hydraulic oil and the filter is pressed in the sup-
port.
8.The filter casing is cleaned from inside. The O-ring of the casing is checked and replaced with a new
one, when necessary. The O-ring is lubricated lightly with hydraulic oil and the cover is attached back
in place.
9.The Hybrilift system must be bled after chang-

ing the filter. In Figure 1668, one hexagon
socket plug is loosened in valve block A and the
machine is started. The plug is closed once the
air has bled from the system. The boom of the
machine must not be moved during bleeding.
10.The pressure release tap of the hydraulic circuit
of the energy storage system is closed.
11.The energy storage system is charged and its
operation is checked.
5.8.5 Flushing the energy storage system
Warning!
Info!
The energy storage system is flushed so that the hydraulic oil can be changed in the loading circuit of the
system. If the oil cannot be changed, its properties weaken possibly resulting in malfunctions of the Hybri-

Lift system and premature wear of the components. The flushing is carried out simply by releasing the
pressure from the hydraulic circuit of the energy storage system and by reloading the system.
1.The machine boom is lowered onto a firm surface and the engine is switched off.
2.The pressure release tap (Figure 1665) from the
HybriLift valve block is opened, after which the
hydraulic oil loaded into the pressure accumula-
tors is discharged into the hydraulic oil reservoir
and sent back to the circulation. The discharge of
the oil from the accumulators can be heard as a
hiss.
3.When the pressure in the hydraulic circuit of the
energy storage system has decreased, the pres-
sure release tap is closed.
4.The energy storage system is loaded normally, in
which case new hydraulic oil flows into the
loading circuit of the system.
5.9 Inspection and service of air-conditioning system

The machine has an air-conditioning system. The air-conditioning system makes the cab indoor air pleas-
ant by removing heat and humidity. Note that installation, service and repair of the air-conditioning sys-
tem and handling refrigerants requires qualification in cooling technology.
Warning!
Warning!
Do not disconnect the AC hoses!
Note!
The installation, service and repair of the air-conditioning system and handling refrigerants
requires qualification in cooling technology!
Info!
A. Compressor.
B. Condenser core.
C. Dryer.
D. Expansion valve.
E. Evaporator core.
The air conditioning compressor is located in the

pump room of the machine. The condenser core is
located behind the cab. The dryer is in the uppercar-
riage. The expansion valve and evaporator core are
in the cab.
Note the following when using the air conditioning system:

5.Use air conditioning also in the winter at least once a week for five minutes. If you do not, the shaft
seals of the compressor will dry up and the refrigerant will leak out. When you use the air conditioning,
the compressor remains lubricated and moving parts remain clean and avoid oxidation.
6.Note that you must never disconnect the air conditioning hoses during inspections and servicing exter-
nal to the system.
7.Always keep the condenser core clean. Remove dirt between the cores using a soft brush and / or com-
pressed air.
8.Make sure that the refrigerant hoses do not touch sharp edges or hot surfaces.
9.Keep clean the pollen filter and indoor air recycle filters.
10.Note that you must never weld or clean with steam the hoses and components near the air conditioning
equipment.
11.The system uses R134a refrigerant, which may only be handled by a person with qualification in cool-
ing technology.
12.You can check the operation of the air conditioning system as indicated in Section “Checking the oper-
ation of air conditioning system”.
5.9.1 Visual inspection of air conditioning system and fault diagnostics

Check visually the following in the air contitioning system:
• Hoses, shaft seals and service couplings for leaks. Repairing leaks requires qualification in cool-
ing technology. When repairing leaks, always replace the dryer as well. We recommend you disin-
fect the evaporator core and fresh air ducts and replace the pollen filter.
• Air conditioning compressor belt tightness and condition. Tighten the belt and replace if needed.
• Condenser core condition. Clean the dirty condenser cores carefully with a soft brush and / or
compressed air.
• Quantity of refrigerant in the system through the sight glass. Note that adding / draining refriger-
ant requires qualification in cooling technology.
• Pollen filter condition. Clean or replace if needed.
The table below shows usual malfunctions of air conditioning system:
Fault Reason
Main power centre circuit breaker is tripped (only
electric machines).
Blower fails to work. Air conditioner fuse is blown.
Blower switch is broken.
Blower motor is broken or jammed.
electric machines).
Refrigerant pressure in the system has dropped.
Air conditioning fails to work. Air conditioner fuse is blown.
Compressor fails to rotate.
The system is frozen (check the operation of
expansion valve and condition of dryer).
electric machines).
Defroster is on.
Pollen filter is blocked.
Air conditioning is inefficient. Condenser core is blocked.
Evaporator core is dirty.
Too little refrigerant in the system.
Expansion valve is frozen.
Dryer is blocked or frozen.

electric machines).
Heating resistance feed fuse is tripped (only elec-
Heating fails to work.
tric machine).
Air conditioner fuse is blown.
Water valve is broken.
Blower motor in the cab is broken.
Low compressor oil level.
Bearing defect in compressor.
Too little refrigerant in the system (loud evaporator
Loud running.
core).
Too much humidity in the system (loud expansion
valve).
Pollen filter is blocked.
5.9.2 Checking and replacing the air conditioning compressor belt

Check the condition and tightness of air conditioning compressor belt. If the belt is cracked or pieces are
missing in it, replace it immediately. Use SPA 1030 V-belt.
If a loud or strange noise is heard from the compressor system (Figure 2411), the reason may be the inap-
propriate tightness of the belt (F Figure 2412) between the motor (B Figure 2411) and the compressor (A
Figure 2411). The belt may be checked by removing the belt shields (C and D Figure 2411). Both shields
are fastened with two screws (E Figure 2411).
Adjust the tightness of the belt by loosening the screws (H and I Figure 2412), after which you tighten or
loosen the belt by moving the compressor up or down using the adjusting screw (G Figure 2412).
Replace the belt by moving the compressor down with the adjusting screw so that the old belt can be re-
moved. Remove the old belt and put the new belt in its place. Adjust the tightness of the new belt by us-
ing the adjusting screw to move the compressor to the correct height. The belt tightness is correct when the
belt sag, measured in the middle, is 3mm when pressed with a force of 6 Newton. The tightness of a used
belt must be 3mm with a force of 4 Newton. Tighten screws (H and I) once the belt tightness is correct.

5.9.3 Checking the condenser unit
The condenser unit is located behind the cab (Fig-
ure 2727). The condenser core is inside the con-
denser unit behind the blowers. The cleanliness of
the condenser core must be checked when the AC is
serviced. Dirty spaces in the core can be cleaned
with a brush and / or compressed air. While check-
ing the condenser core, check also the condenser
unit hoses and couplings for leaks.
5.9.4 Checking refrigerant level

The amount of refrigerant can be checked from the
sight glass of the system’s dryer (Figure 2589). The
dryer is located near the condenser unit.
Check the amount of refrigerant by observing the
changes in the sight glass for the duration of one
minute after the air conditioner starts. It must be
noted that in a cool temperature of about 10 °C, the
sight gauge shows an acceptable result with a lower
amount of refrigerant. The table below shows how
to check the refrigerant level in the sight glass.
The flow of refrigerant in the sight glass for the

Amount of refrigerant duration of about one minute from the start of air
conditioning.
Correct refrigerant quantity.
Too much refrigerant in the system.
Too little refrigerant in the system.
5.9.5 Checking the operation of air conditioning system

The operation of the AC is checked by measuring the temperature of the air coming from the nozzles in
the cab. The air temperature is measured at the nozzle closest to the blower casing while all the other noz-
zles are closed. Use the AC for about 5 minutes with the temperature set to minimum before starting the
measurement. After this, set the blower to minimum speed and measure the temperature. The temperature
must be between 4 and 8 °C to indicate that the AC is working correctly.

5.9.6 Cleaning and replacing fresh air filter and circulation air filter
Info!
The replacement interval of the fresh air filter in the cab depends on the operating conditions of the ma-
chine. The filter must be changed at least once a year to prevent the formation of mould or other microbial
growth that is detrimental to health. The fresh air filter is in the cab behind the operator's seat (Figures
2583 and 2584). Clean the fresh air filter with compressed air a maximum of four times before replacing
it.
Replace the fresh air filter as follows:
1.Put the driver's seat in forward position.
2.Fold up the cab carpet from the top of the filter.
3.Open the quick fastening screws of the fresh air
filter hood (Figure 2583).
4.Remove the hood.
5.Lift out the fresh air filter by pulling the string
(Figure 2584).
6.Put the new fresh air filter in its place.
7.Reattach the filter hood.
8.Reattach the quick fastening screws of the fresh
air filter hood.
9.Put the cab carpet back in place over the filter.
10.Move the driver's seat back in its normal posi-
tion.
The circulation air filter (A Figure 2585) is located
under the grid (B Figure 2585) behind the driver's
seat. Replace the circulation air filter at least once a
year when the fresh air filter is replaced. Clean the
circulation air filter with compressed air a maxi-
mum of four times before replacing it. The grid cov-
ering the circulation air filter is attached with quick
fasteners.

Torques Appendix 1
Values for untreated oiled carbon steel screws when using a torque wrench or a machine (torque
divergence max ± 5 %, strength class SS-ISO 898-1).
When a normal washer is being used

M thread 8.8 [Nm] 10.9 [Nm] 12.9 [Nm]
8 24 33 40
10 47 65 79
12 81 114 136
14 128 181 217
16 197 277 333
18 275 386 463
20 385 541 649
22 518 728 874
24 665 935 1120
27 961 1350 1620
30 1310 1840 2210
33 1770 2480 2980
36 2280 3210 3850
39 2930 4120 4940
42 3640 5110 6140
When a Nord-Lock washer is being used

M thread 8.8 [Nm] 10.9 [Nm] 12.9 [Nm]
8 25 34 38
10 49 67 75
12 85 115 128
14 135 183 204
16 205 279 311
18 288 391 437
20 402 547 610
22 548 745 831
24 693 942 1052
27 1010 1375 1533
30 1379 1875 2091
33 1855 2526 2815
36 2394 3259 3633
39 3087 4203 4683
42 3820 5202 5799
Exceptions to torques
• Counterweight fastening screws 5100 ± 200 Nm.
• Slewing ring bearing mounting screws 1250 ± 200 Nm.
Fluids and lubricants Appendix 2
Maintenance interval
Application Quality
(volume / quantity)
2000 h / 2 years
DIN 51524-3 HVLP 46.
(Change volume 1500 l).
Hydraulics.
Teboil Hydraulic 46 S Oil condition monitoring is
(The oil grade used by the fac-
Mobil Univis N 46 recommended for determin-
tory is Teboil Hydraulic 46 S.)
Shell Tellus S2 V 46 ing the oil change interval;
Castrol Hyspin AWH-M 46 when it is used, the change
interval can be longer.
DIN 51517-3 CLP HC 220. 1st service after 150 h, 2nd

service after 1000 h, after
Pump gear.
Teboil Sypres 220 which the service interval is
(The oil grade used by the fac- 1000 h / 1 year.
Mobil Mobilgear SHC Gear 220
tory is Teboil Sypres 220)
Shell Omala S4 GX 220
Castrol Alphasyn EP 220 (7 l).
DIN 51517-3 CLP HC 220. 1st service after 150 h, 2nd

Swing planetary gear.
Teboil Sypres 220 which the service interval is
tory is Teboil Sypres 220)
Castrol Alphasyn EP 220 (2 x 18.9 L).
ISO VG 32. 1st service after 150 h, 2nd

Swing brake.
Teboil Hydraulic 32 S which the service interval is
Mobil Univis N 32
tory Teboil Hydraulic Oil 32 S.)
Shell Tellus S2 V 32
Castrol Hyspin AWH-M 32 (2 x 1.7 l).
NLGI 2, basic oil ISO VG 100 - 220

Swing gearbox main axle cST. @ 40°C.
bearing. 2000 h / 1 years.
(The grease grade used by the Kendall SHP Grease 2
factory is Kendall SHP Grease Mobil Mobilgrease XHP 222 (50 g).
2.) Shell Gadus S2 V220 2
Castrol Spheerol EPL 2
NLGI 1 / 2, basic oil ISO VG 100 - 220
cST. @ 40°C, with EP additive.
Slewing bearing.
If there is no automatic
(The grease grade used by the greasing, the maintenance
factory is Kendall SHP Grease interval is 50 h.
2. The grease grade is selected
based on the operating tempera- (400 g).
ture.)
Kendall SHP Grease 1 / 2
Mobil Mobilgrease XHP 221 / 222
Shell Gadus S2 V220 1 / 2
Castrol Spheerol EPL 1 / 2

cST. @ 40°C.
Cab elevator joints.
500 h / 6 months.
(The grease grade used by the
Kendall SHP Grease 2
factory is Kendall SHP Grease (20 g).
Mobil Mobilgrease XHP 222
2.)
Shell Gadus S2 V220 2
Appendix 2 Fluids and lubricants
Application Quality
(volume / quantity)
NLGI 000 - 1, basic oil ISO VG 600 -

1000 cST. @ 40°C, with EP additive.
Swing gear.
6000 h.
Teboil Gear Grease XHP
factory is Teboil Gear Grease (140 l).
Mobil Mobilgear OGL 007
XHP.)
Shell Gadus S2 OG 40
Castrol Molub-Alloy 936 SF Light
Central lubrication sys-

tem.
factory is Kendall SHP Grease When necessary.
2. The grease grade is selected
based on the operating tempera-
ture.)
4000 h.
Electric motor. DIN 51825 KE2R-40.
(The grease grade used by the (Front bearing 78 g).
factory is Klüber Asonic GHY Klüber Asonic GHY 72
72.) Esso Unirex S 2 (Rear bearing 57 g).
DIN 51517-3 CLP HC 220.

Drive planetary gear.
1st service after 150 h, 2nd
(The oil grade used by the fac- service after 2000 h, after
Teboil Sypres 220
tory is Teboil Sypres 220. The oil which the service interval is
grade is selected based on the 2000 h / 1 year.
operating temperature.)
Castrol Alphasyn EP 220

cST. @ 40°C.
Crane wheel bearing.
(The grease grade used by the 2000 h / 1 y.
factory is Kendall SHP Grease
2.)
Bogey joint.
(The grease grade used by the 100 h.
2. The grease grade is selected (20 g).
based on the operating tempera-
ture.)
Fluids and lubricants Appendix 2
Application Quality
(volume / quantity)
SAE 85W-140, API GL5. 1st service after 150 h, 2nd

Cable reel torque unit.
Mobil Mobilube HD 85W-140 which the service interval is
(Oil grade used by the factory 2000 h / 1 year.
Teboil Hypoid 85W-140
Mobil Mobilube HD 85W-140.)
Shell Spirax S2 A 85W-140
Castrol Axle EPX 85W-140 (67 l).

Mounting bearings on
cST. @ 40°C.
lead-through of circular
500 h / 3 months.
coupler.
(The grease grade used by the (20 g).
2.)
Hydraulics 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Service chart
Cooler core - inspect Daily.
Cooler core - clean Service interval 500 h / when necessary.
Hydraulic lines - inspect X X X X X X X 1v
Return filters - change X X X X X X
Drain filter - change X X X X X X
Oil reservoir breather filter - change X X X X X X
Pilot circuit filter - change X X X X X X
Auxiliary hydraulic filter - change X X X X X X
Swing circuit filter - change X X X X X X
CJCTM -by-pass filter element - change Service interval 1 week or when flow resistance exceeds 1.8 bar.
Oil reservoir - drain water X X X X X X 1v
Hydraulic oil - change Service interval 2000 h / 2 year. The service interval may be longer if oil condition monitoring is in use.
Suction filters - change Always when hydraulic oil is changed.
Oil reservoir - clean Always when hydraulic oil is changed.
HybriLift®-system 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Pressure filter - change X X X X X X
Flushing filter - change X X X X X X
Pressure relief valve set pressure - check X X 1v
Gas preload pressure - measure X X 2v
Energy storage system- flush Weekly.
Pressure equipment official inspection Service interval 4 y / in accordance with local regulations.
Lubrication 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Swing planetary gear main axle bearings - grease X X X 1v
Pump gear filter - change X X X X X X 1v
Cab elevator joints - grease X X X X X X X X X X X X 6 months
Electric motor bearings - grease Type plate.
Rail tongs - grease Service interval 50 h.
Swing planetary gears - change oil X X X X 1v
Swing planetary gears - check oil level Weekly.
Swing planetary gear expansion tank breathers - replace X X X 1v
Swing brake - change oil X X X X 1v
Swing brake breather - replace X X X 1v
Swing gear - check grease X X X 1v
Swing gear - change grease X
Pump gear - change oil X X X X X X X 1v
Pump gear - check oil level Weekly.
Pump gear breather - replace X X X X X X 1v
Appendix 3
Slewing bearing - grease If there is no automatic greasing, the service interval is 50 h / 400 g.
Hinges - grease X X X X X X X X X X X X 6 months
Boom joints - grease In the central lubrication system.
Front attachment and link - grease Service interval 8 h / as per separate instructions.
Electric system 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Appendix 3
High voltage connections - retighten X X X X X X X X 1v
Electric cabinets - change air filters When necessary.
Electric cabinets - clean air filters When necessary. 1v
Electric cabinets - inspect visually X X X X X X X X X X X X 1v
EmergencyStop circuits - test X X X X X X X X X X X X 1v
Wires and harnesses - inspect X X X X 1v
Mechanics 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Cable reel torque unit - check fastening X X X X X 1v
Cab - check mounting X X X X X 1v
Cab elevator - check mounting X X X X X 1v
Oil cooler - check fastening X X X X X 1v
Electric motor - check fastening X X X X X 1v
Counterweight - check fastening X X X X X 1v
Swing planetary gears and motors - check fastening X X X X X 1v
Pump gear - check fastening X X X X X 1v
Pumps - check fastening X X X X X 1v
Slewing bearing - check fastening X X X X X 1v
1st service 50 h, 2nd service 100 h, after which the service interval is 500 h.
Wheels - check fastening 1v
(After tyre change, inspections after 50 and 200 operating hours.)
Slewing bearing axial clearance - measure Service interval 6000 h / when necessary.
Boom joints - inspect X X X 1v
Plate fields and weldings - inspect X X X 1v
Cab air ventilation 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Fresh air filter - replace When necessary. 1v
Fresh air filter - clean Service interval 500 h / when necessary.
Air conditioning system - inspect and test X X X X X X X X X X X X X 1v
Condenser core - inspect Daily
Condenser core - clean X X X X X X X X X X X X 1v
Recirculation filter - replace Service interval 500 h / when necessary.
Cab air ventilation 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Fresh air filter - replace When necessary. 1v
Fresh air filter - clean Service interval 500 h / when necessary.
Refrigerant amount - inspect X X X X X X X X X X X X 1v
Refrigerant hoses - inspect X X X X X X X X X X X X 1v
AC compressor belt - inspect X X X X X X X X X X X X 1v
AC system - inspect X X X X X X X X X X X X X 1v
Service chart
Condenser core - inspect Daily.
Condenser core - clean X X X X X X X X X X X X 1v
Evaporator core - clean Service interval 1 h / when necessary.
VIsual inspection once a month.
Blower case components - inspect
Check more thoroughly every six months.
Heating system coolant amount - inspect Monthly.
Heating system coolant - change Service interval 8000 h / 4 years.
Heater core - clean Service interval 1 h / when necessary.
Heating system - inspect Service interval 1 h / when necessary.
Fire protection 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Service chart
Extinguishers must be inspected on an annual basis
Fire extinguishers - inspect
by a service shop authorized to inspect portable fire extinguishers.
Bogies 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Drive planetary gears - change oil X X X X 1v
Drive planetary gears - check oil level X X X X X X X X X X X X X 1v
Wheels - inspect X
Wheel bearings - grease X X X 1v
Bogie joints - grease Horizontal joints 100 h / 20g, rocker joint 100 h / 40 g.
Cable reel 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Cable - check X X X X X X X X X X X X X
Electric motor - check X X X X X X X
Electrical connections - check X X X X X X X
Slip rings and brushes - inspect X X X X X X X 1v
Torque unit - change oil X X X X 1v
Torque unit - check oil level X X X X X X X X X X X X X
Cable reeling torque - check / adjust X X X X X X X X X X X X 1v
Cable guiding device - check X X X X X X 1v
Vertical collector 150 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 max
Electrical connections - check X X X X X X X
Slip rings and brushes - inspect X X X X X X X X X X X X 1v
Swivel bushings - grease X X X X X X X X X X X X 3 months
Appendix 3
Maintenance measurements of the energy storage system Appendix 4
Time of Pressure accumulator sequence number

Details
meas. 1 2 3 4 5 6 7
Pressure accumulator surface temperature [ºC].
Gas preload pressure [bar].
1 Hour meter reading [h].
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Appendix 4 Maintenance measurements of the energy storage system
Time of Pressure accumulator sequence number

Details
meas. 1 2 3 4 5 6 7
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Date.
Measured by.
Pressure accumulator surface temperature [ºC]
Gas pre-charge pressure [bar]
13 Hour meter reading [h]
Date
Measured by.
Pressure accumulator surface temperature [ºC]
Gas pre-charge pressure [bar]
14 Hour meter reading [h]
Date
Measured by.
Pressure relief valve of the hydraulic
circuit of the energy storage system Appendix 5
Time Time
of Details Labelling of Details Labelling
meas. meas.
Set pressure [bar]. Set pressure [bar].
Hour meter reading [h]. Hour meter reading [h].

1 2
Date. Date.
Measurer. Measurer.

3 4
Date. Date.
Measurer. Measurer.
Hour meter reading

Hour meter reading [h].
5 [h].
6
Date. Date.
Measurer. Measurer.

7 8
Date. Date.
Measurer. Measurer.

9 10
Date. Date.
Measurer. Measurer.

11 12
Date. Date.
Measurer. Measurer.

13 14
Date. Date.
Measurer. Measurer.
Lifting capacity table Appendix 6
Lifting Capacity Chart

32,5 30 27,5 25 22,5 20 17,5 15 12,5 10 7,5 5 2,5 0
40
37,5
35 12,7
32,5 10,2 12,5
30 10,0 12,2 13,6
MA
NT
SI
NE
27,5 9,5 11,8 13,2 14,1
N
160
25 8,5 11,2 12,9 13,9
22,5 6,6 10,4 12,5 13,8 14,5
20 8,9 11,8 13,6 14,7 15,2 15,1
17,5 10,4 12,3 13,8 15,5 16,2 15,8

VERTICAL LIFTING RANGE (METRES)
15 7,7 11,0 12,4 13,9 15,7 17,8 17,3 15,8
12,5 9,0 11,0 12,4 13,9 15,8 18,2 20,1 18,5 15,5
10 9,3 10,9 12,3 14,0 16,0 18,5 21,8 25,6 23,5
MANTSINEN 160
7,5 9,0 10,7 12,2 14,0 16,1 18,7 22,2 27,0 34,4
5 8,5 10,3 12,0 13,9 16,0 18,8 22,4 27,4 35,1
2,5 7,7 9,7 11,6 13,5 15,7 18,5 22,1 27,1 15,4
A_19
0 6,4 8,8 10,8 12,8 15,1 17,8 21,3 25,9 12,2 5,5
MANTSINEN 160 ES HybriLift®
Specifications:
-2,5 7,4 9,6 11,7 13,9 16,5 19,7 23,6 12,0 6,7
Boom: 17,5 m straight
Stick: 15,0 m
Undercarriage height: 5,0 m
7,8 10,0 12,2 14,5 17,1 20,1 12,7 Cab elevator: N2-5000
-5
5.5.2017
-7,5 9,6 11,5 13,5
32,5 30 27,5 25 22,5 20 17,5 15 12,5 10 7,5 5
HORIZONTAL LIFTING RANGE (METRES)
MANTSINEN
The lift capacities are stated in metric tonnes (t) at the end of the stick and are valid when the machine is used on a horizontal surface, within
360° swing area and without loading attachment.
Indicated loads are based on standard ISO 10567 and do not exceed 75 % of tipping load nor 87 % of calculative hydraulic capacity.
Appendix 6 Lifting capacity table
Lifting Capacity Chart

32,5 30 27,5 25 22,5 20 17,5 15 12,5 10 7,5 5 2,5 0
40
37,5
35 13,7
32,5 10,9 13,4
30 10,8 13,0 14,5
MA
NT
SI
N
27,5 10,2 12,6 14,1 15,1
EN
160
25 9,1 12,1 13,8 14,8
22,5 7,1 11,2 13,4 14,8 15,5
20 9,5 12,7 14,6 15,8 16,3 16,1
17,5 11,2 13,3 14,8 16,5 17,3 16,9

VERTICAL LIFTING RANGE (METRES)
15 8,3 11,9 13,3 14,9 16,7 19,0 18,5 16,9
12,5 9,7 11,9 13,4 15,0 17,0 19,4 21,5 19,8 16,6
10 10,2 11,8 13,4 15,1 17,2 19,8 23,2 27,3 25,1
MANTSINEN 160
7,5 9,9 11,6 13,3 15,1 17,3 20,1 23,7 28,9 36,7
5 9,3 11,2 13,0 15,0 17,3 20,2 24,0 29,4 37,5
2,5 8,5 10,7 12,6 14,6 17,0 20,0 23,8 29,2 16,4
A_19
0 7,2 9,7 11,8 14,0 16,4 19,3 23,0 28,0 13,1 6,0
MANTSINEN 160 ES HybriLift®
Specifications:
-2,5 8,3 10,6 12,8 15,2 18,0 21,4 25,1 12,8 7,2
Boom: 17,5 m straight
Stick: 15,0 m
Undercarriage height: 5,0 m
8,8 11,0 13,4 15,9 18,7 22,0 13,6 Cab elevator: N2-5000
-5
5.5.2017
-7,5 10,7 12,8 15,0
32,5 30 27,5 25 22,5 20 17,5 15 12,5 10 7,5 5
HORIZONTAL LIFTING RANGE (METRES)
MANTSINEN
The lift capacities are stated in metric tonnes (t) at the end of the stick and are valid when the machine is used on a horizontal surface, within
360° swing area and without loading attachment.
Indicated loads are based on standard ISO 10567 and do not exceed 75 % of tipping load nor 87 % of calculative hydraulic capacity.
Cab relays and fuses Appendix 7
F1 7.5A Horn. F31 5A Reserve.
F2 5A Water pump. F32 5A Reserve.
F3 10A Work lights 1. F33 5A Radio.
F4 1A Camera flip display. F34 5A Reserve (VHF Phone).
F5 5A Light switch. F35 10A Reserve (VHF Phone2).
F6 5A Camera supply. F36 5A Reserve.
F7 1A Sound module. F37 5A Reserve.
F8 10A Work lights 2. F38 5A Plug1.
F9 10A Work lights 3. F39 5A Plug2.
F10 10A Reserve (work lights 4). F40 5A Reserve.
F11 10A Wiper 1. F41 5A Reserve.
F12 10A CDC1700, proemion CANlink. F42 5A Reserve.
F13 10A Roof wiper. F43 5A Reserve.
F14 20A MCC. F44 5A Reserve.
F15 5A MCC. F45 5A Reserve.
F16 2A eVision, TTC48. F46 5A Reserve.
F17 5A Key switch E-stop. F47 5A Reserve.
F18 5A Reserve. F48 5A Reserve.
F19 10A Command phone. K1 Work lights 1.
F20 5A Reserve (scales). K2 Work lights 2.
F21 15A Reserve (seat). K3 Work lights 3.
F22 5A Reserve (seat). K4 Reserve (work lights 4).
F23 5A Reserve (camera2). K5 Horn.
F24 5A Inner light. K6 Wiper 1 medium / pulse.
F25 5A Reserve. K7 Wiper 1 fast.
F26 15A TTC48. K8 Wiper 1 stop.
F27 2A eVision, TTC48. K9 Roof wiper.
F28 25A Converter. K10 Wiper2 stop.
F29 5A Reserve. K11 Water pump.
F30 25A AC Condenser fan. K12 Camera flip display.
Base machine relays and fuses Appendix 8
F1 10A Stick work light. F38 5A TTC580_ID1 bat+. F80 7.5A TTC30_0xC_ID12 bat+.
F2 10A Stick work light. F39 10A TTC580_ID1 bat+. F81 7.5A TTC30_0xC_ID12 bat+.
F3 10A Stick work light. F40 10A TTC580_ID1 bat+. F82 2A TTC30_0xD_ID13 bat+.
F4 10A Stick work light. F41 10A TTC580_ID1 bat+. F83 2A TTC30_0xE_ID14 bat+.
F5 10A Boom work light. F42 7.5A Reserve. F84 7.5A TTC30_0xD_ID13 bat+.
F6 10A Boom work light. F43 7.5A Reserve. F85 7.5A Reserve.
F7 5A Beacon. F44 7.5A Reserve. F86 7.5A TTC30_0xD_ID13 bat+.
F8 10A Greaser 2. F50 2A TTC30_0xA_ID10 ignition. F87 7.5A Reserve.
F9 5A Reserve. F51 2A TTC30_0xB_ID11 ignition. F88 7.5A Reserve.
F10 10A Greaser. F52 2A TTC30_0xC_ID12 ignition. F89 7.5A TTC30_0xD_ID13 bat+.
F11 10A Reserve (ECU). F53 2A TTC30_0x11_ID17 ignition. F90 7.5A TTC30_0xE_ID14 bat+.
F12 10A Drive alarm. F54 5A Reserve (summation valve). F91 7.5A TTC30_0xE_ID14 bat+.
F13 15A Reserve (work light). F55 2A TTC30_0xD_ID13 ignition. F92 7.5A TTC30_0xE_ID14 bat+.
F14 15A Reserve (work light). F56 2A TTC30_0xE_ID14 ignition. F93 20A Reserve (Webasto).
F15 7.5A Reserve. F57 5A Half-effect speed sensor. F94 15A Undercarriage supply +30.
F16 7.5A Reserve. F58 15A Reserve. F95 15A Undercarriage supply +30.
F17 5A Swing filter, pump angle sensor. F59 10A Reserve. F96 15A Undercarriage supply +30.
F18 7.5A Reserve. F60 10A Reserve. F97 15A Undercarriage supply +30.
F19 5A Cabin lock sensor. F61 15A Reserve. K1 Stick work light.
F20 5A Boom cylinder pressure sensor. F62 10A Reserve. K2 Stick work light.
F21 20A Reserve. F63 15A Reserve. K3 Stick work light.
F22 5A TTC580_ID1 ignition. F64 10A Reserve. K4 Stick work light.
F23 5A Return / tool filters. F65 10A Reserve. K5 Boom work light.
F24 20A Reserve (ECU). F66 2A TTC30_0xA_ID10 bat+. K6 Boom work light.
F25 15A Reserve. F67 2A TTC30_0xB_ID11 bat+. K7 Beacon.
F26 5A Reserve (walkway). F68 7.5A TTC30_0xA_ID10 bat+. K8 Reserve.
F27 5A Pump, pilot pressure sensor. F69 2A TTC30_0xC_ID12 bat+. K9 Reserve.
F28 5A Greaser inductive sensor. F70 7.5A TTC30_0xA_ID10 bat+. K10 Greaser 2.
F29 15A Reserve. F71 2A TTC30_0x11_ID17 bat+. K11 Reserve.
F30 20A Reserve (AC fan). F72 7.5A Reserve. K12 Reserve.
F31 5A Greaser, FLm1, hybriLift filter, suction VLV. F73 7.5A TTC30_0xA_ID10 bat+. K13 Reserve.
F32 5A Attachment reserve. F74 7.5A TTC30_0xB_ID11 bat+. K14 Greaser 1.
F33 5A Undercarriage supply +15b. F75 7.5A TTC30_0xB_ID11 bat+. K15 ECU
F34 7.5A Reserve. F76 7.5A TTC30_0xB_ID11 bat+. K16 Drive alarm.
F35 7.5A Reserve. F77 7.5A TTC30_0x11_ID17 bat+. K17 Reserve (work light).
F36 7.5A Reserve. F78 7.5A TTC30_0x11_ID17 bat+. K18 Reserve (work light).
F37 7.5A Reserve. F79 7.5A TTC30_0xC_ID12 bat+.
Fastening of hydraulic hoses and pipes Appendix 9
JIC 37° adaptors

The tightening method of the JIC 37° adaptors is FFWR (Flats From Wrench Resistance). The man-
tle nut of the adaptor is tightened by hand, after which the nut is turned by a certain number of sides of the
nut's head (FFWR column in the table below). One side of the head (1 FFWR) means 60 degrees.
Reference
UNF thread Nominal size (NS) FFWR
moment [Nm]
7/16 - 20 4 18
1/2 - 20 5
2 23
9/16 - 18 6 30
3/4 - 16 8 1½ 57
7/8 - 14 10 81
1.1/16 - 12 12 1¼ 114
1.5/16 - 12 16 160
1.5/8 - 12 20 228
1.7/8 - 12 24
1 265
2.1/2 32 360
ORFS (O-Ring Face Seal) adaptors

The tightening method of the ORFS adaptors is FFWR (Flats From Wrench Resistance). The man-
tle nut of the adaptor is tightened by hand, after which the nut is turned by a certain number of sides
of the nut's head (FFWR column in the table below). One side of the head (1 FFWR) means 60 degrees.
Reference
UNF thread Nominal size (NS) FFWR
moment [Nm]
9/16 - 18 4 26
11/16 - 16 6 42
13/16 - 16 8
½-¾ 57
1 - 14 10 85
1.3/16 - 12 12 122
1.7/16 - 12 16 156
1.11/16 - 12 20
⅓-½ 200
2 - 12 24 256
SAE flange (split)

The screws are tightened crosswise in four different phases, until the correct torque is reached. The
threads of the fastening screws and the underside of the screw's head are lightly lubricated with the
MOLYKOTE G-RAPID PLUS lubricant grease or similar.
Flange 3000 psi (ISO 61) Flange 6000 psi (ISO 62)
Flange Flange
Screw [Nm] Screw [Nm]
size size
1/2’’ M8 24 1/2’’ M8 24
3/4’’ 3/4’’ M10 50
1’’ M10 50 1’’ M12 92
1.1/4’’ 1.1/4’’ M14 130
1.1/2’’ 1.1/2’’ M16 210
2’’ M12 92 2’’ M20 400
2.1/2’’
3’’
3.1/2’’
M16 210
4’’
5’’
Appendix 9 Fastening of hydraulic hoses and pipes
Flare 37° flanges
1. Clean the pipe end carefully and 2. Lubricate the O-ring with the 3. Set the nozzle in the end of the
check that there are no defects in Gleitmo 750 grease or similar. pipe. When necessary, the nozzle
the cone. Place the O-ring carefully in the can be gently knocked with a plastic
groove of the nozzle. Check that hammer.
there is no surface damage in the
nozzle.
4. Lubricate the gasket of the nozzle 5. Lubricate the threads of the fas- 6. Tighten the flange in four different
with the Gleitmo 805 grease or tening screws and the underside of phases evenly in a crossed
equivalent. Unlike in the figure, the the head lightly with the sequence. The recommended
gasket may be on the end face of MOLYKOTE G-RAPID PLUS lubri- screw torques are shown in the
the nozzle. cant grease or equivalent. table below.
Flange 3000 psi (ISO 61) Flange 6000 psi (ISO 62) Flange ISO 6164
Flange Flange Flange
Screw [Nm] Screw [Nm] Screw [Nm]
size size size
1’’ 45 1’’ M12 75 2’’ M16 200
M10
1.1/4’’ 50 1.1/4’’ M14 120 2.1/2’’ M20 280
1.1/2’’ 1.1/2’’ M16 180 3’’ M24 460
75
2’’ M12 2’’ M20 230
2.1/2’’ 110
3’’ 190
4’’ M16 90
5’’ 130
(PHUJHQF\VWRS
EXWWRQ
(PHUJHQF\FDE
Rescue Card
ORZHULQJ
3UHVVXUH
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6DIHW\JDWHZLWK
ORFN
RESCUE CARD
0DLQVZLWFK
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)LUHH[WLQJXLVKHU
%DWWHU\
+LJKYROWDJH
Appendix 10
Appendix 10 Rescue Card
RESCUE CARD
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Undercarriage relays and fuses Appendix 11
F1 7.5A Cable reel, rail clamp. F18 7.5A Reserve (driving lights high beam).
F2 2A 0xF_ID15, 0x15_ID21 ignition. F19 15A Reserve.
F3 7.5A Reserve (driving lights low beam). F20 5A Reserve (greaser 3 inductive sensor).
F4 5A Reserve (FLm2). F21 30A Reserve.
F5 7.5A Reserve (unc. safety gate). F22 5A Reserve (greaser 3 empty).
F6 2A TTC580_ID ignition. F23 2A TTC580_ID2 ignition.
F7 5A Reserve (camera supply). F24 10A TTC580_ID2 bat+.
F8 7.5A Reserve (FLm3). F25 10A TTC580_ID2 bat+.
F9 10A Reserve (portal lights). F26 10A TTC580_ID2 bat+.
F10 15A Reserve. F27 10A Reserve (greaser 3).
F11 7.5A Reserve. K1 Reserve (driving lights low beam).
F12 30A Unc +15 connector relay. K2 Reserve (portal lights).
F13 2A 0x15_ID21 bat+. K3 Unc +15 connector relay.
F14 7.5A 0x15_21 bat+. K4 Reserve (driving lights high beam).
F15 7,4 0xF_ID15 bat+. K5 Reserve.
F16 5A Reserve (service light). K6 Reserve (greaser 3).
F17 2A 0xF_ID15 bat+.

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160 ES

Mantsinen Group Ltd Oy reserves the right to make technical changes.

The original language of this document is Finnish.

1 General about the machine

1.1 Main components

S/N: 160ES268113 Ver: 170203 1 General about the machine 7

8 1 General about the machine S/N: 160ES268113 Ver: 170203

S/N: 160ES268113 Ver: 170203 1 General about the machine 9

10 1 General about the machine S/N: 160ES268113 Ver: 170203

1.3 Type plates

S/N: 160ES268113 Ver: 170203 1 General about the machine 11

2 Safety and environmental factors

2.1 The notations and symbols used in the operation manual.

2.2 Warning and attention stickers

General attention symbol

Life-threateningly high electric currents

12 2 Safety and environmental factors S/N: 160ES268113 Ver: 170203

Life-threateningly high electric currents

Danger of a hydraulic leak

Danger of a falling load

Cab elevator arms high

S/N: 160ES268113 Ver: 170203 2 Safety and environmental factors 13

Falling under a machine

Danger of getting crushed.

Max allowed load (Safe Working Load).

14 2 Safety and environmental factors S/N: 160ES268113 Ver: 170203

Emergency lowering of the cab elevator

See the instructions

Fastening loop of the emergency rope

Fastening loop of the emergency rope

Lifting point of the machine

S/N: 160ES268113 Ver: 170203 2 Safety and environmental factors 15

Machine lifting point

Authorized personnel only

General attention symbol

Wear hearing protection

16 2 Safety and environmental factors S/N: 160ES268113 Ver: 170203

Oil level indicator

Boom greasing point

Slewing ring bearing greasing point

S/N: 160ES268113 Ver: 170203 2 Safety and environmental factors 17

2.4 Working conditions

18 2 Safety and environmental factors S/N: 160ES268113 Ver: 170203

2.5 Load handling

2.6 Driving the machine

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2.7 Electric system

2.8 Servicing the machine

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2.9 Working in thunderstorm

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2.10 EmergencyStop buttons

When one of the EmergencyStop buttons has been

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2.11 Cab safety gate

2.12 Safety gates of maintenance platforms / access bridges

2.13 Emergency cab lowering

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2.14 In case of fire

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2.15 Emergency exit with rope

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