Udrf06 01GB

Reachstackers 40-45 tonnes
Publ. no UDRF06.01GB
Maintenance Manual in original MAINTENANCE MANUAL
DRF 400-450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DRF 400-450
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A:6
Machine card.............................................................................................. A:7
Function descriptions ................................................................................. A:7
About the documentation .............................................................................. A:10
The documentation's parts ....................................................................... A:10
Ordering of documentation....................................................................... A:10
Feedback .......................................................................................................A:11
Form for copying .......................................................................................A:11
Maintenance Manual DRF 400-450 UDRF06.01GB

A:2
UDRF06.01GB Maintenance Manual DRF 400-450

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

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

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

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

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

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

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

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

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

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

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

Function group structure

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

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

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

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

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

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

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

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

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

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

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

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

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

valves, sensors, etc.

7
2
6
4
014496
Example of function description

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

Symbol explanation function descriptions

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

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

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

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

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

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

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

A:12

B:1
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:7
Fuel system ................................................................................................ B:8
AdBlue........................................................................................................ B:9
Clothing, etc. ............................................................................................ B:10
Several mechanics on the same machine................................................ B:10
Working under machine ........................................................................... B:10
Lifting heavy components .........................................................................B:11
Vibrations ..................................................................................................B:11
Noise ........................................................................................................ B:12
Solvents ................................................................................................... B:12
Fire and explosion risks............................................................................ B:13
Fluid or gas under pressure ..................................................................... B:15
Coolant ..................................................................................................... B:15
Refrigerant ............................................................................................... B:16
Air pollution .............................................................................................. B:16
Tensioned springs .................................................................................... B:17
Electric motors ......................................................................................... B:17
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:18
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:19
Non-ionised radiation ............................................................................... B:20
Environment.................................................................................................. B:21
General .................................................................................................... B:21

B:2

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

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

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

B:4 B Safety – Safety instructions
Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position, page B:4
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:7
• Fuel system, page B:8
• AdBlue, page B:9
• Clothing, etc., page B:10
• Several mechanics on the same machine, page B:10
• Working under machine, page B:10
• Lifting heavy components, page B:11
• Vibrations, page B:11
• Noise, page B:12
• Solvents, page B:12
• Fire and explosion risks, page B:13
• Fluid or gas under pressure, page B:15
• Coolant, page B:15
• Refrigerant, page B:16
• Air pollution, page B:16
• Tensioned springs, page B:17
• Electric motors, page B:17
• Rotating components and tools, page B:17
• Tyres and rims, page B:18
• Lifting equipment, page B:18
• Spare parts, page B:19
• Non-ionised radiation, page B:20
Service position
General
General
Service position is used for service, maintenance and other situations

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

• Machine parked, that is, applied parking brake.
• Boom fully retracted and lowered to horizontal position.
003603
• Engine off.
• System voltage off (with battery disconnector).
Machine with fully retracted and lowered boom

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

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

Turn the start key to position I and activate extension out, a loud
hissing sound is heard if there is pressure in the hydraulic system.
Activate lift, extension, and side shift several times.
3 Turn the start key to position 0 and turn off the system voltage.
4 Depressurize the attachment.

Open relief valve top lift.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to fine filter hydraulic oil.
Check that relief valve top lift is closed before the
engine is started.
002269
The figure above shows closed valve.

5 Depressurise the brake system by opening the drain valve on the

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

Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
Always completely depressurize the hydraulic and
brake systems before starting to work in these systems.
Hydraulic and brake systems are pressurized and the
oil can cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! Oil may
also be corrosive to mucous membranes in, e.g., eyes,
skin, and throat.
IMPORTANT
Always clean the area around components and
connections before loosening them. Dirt in oil systems
causes increased wear, which results in material
damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also start fires. Waste oils/fluids shall always
be handled and taken care of by companies that are
authorized for this work.

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

IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorized for
this work.
AdBlue
handling AdBlue.
CAUTION
AdBlue can irritate the skin and eyes and when inhaled.
Health hazard!
Handle with care and avoid contact with skin, use
gloves. In the event of contact with skin and spillages
on clothing, rinse the skin with large amounts of water
and replace contaminated clothing and gloves. In
the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
CAUTION
AdBlue spilled onto hot components evaporates
quickly.
Irritation of eyes and respiratory system.
Turn your face away. Evaporated AdBlue can harm
mucus membranes in, for example, the eyes and throat.
In the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillages on the ground must be absorbed with sand or
other absorbent, non-combustible material.

Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
Remove jewellery as it may conduct electricity and get caught in

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

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

Working under the cab
Working under the cab
On machines with lifting cab the cab must be secured in the raised
position with the intended locks.
A
001977
Lock on mast to secure vertically adjustable cab in raised

position.

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

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

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

Safety actions
• Use heavy gloves to protect against the cold and the transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.
Noise
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) is more damaging than low tones at the
same sound level. Noise in the form of impulse sounds may also be
damaging, e.g., hammer blows.
Risks
Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.
Safety actions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.
Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are flammable.
Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes in direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the central nervous

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

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

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

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

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

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

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

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

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

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

Fluid or gas under pressure

Lines with high pressure may be damaged during work and fluid or
gas may jet out.
There may be high pressure in a line even if the pump has stopped,
therefore gas or fluid may leak out when the connection for the hose
is loosened.
A gas cylinder exposed to outside forces may explode, e.g., if it falls on
a hard surface. Gas may flow out from damaged valves.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall first be drained of pressure
and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.
• Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
Coolant
The coolant in the machine’s cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.

Refrigerant
Refrigerant is used in the machine’s air conditioning system.
Work on the air conditioning system must be performed by

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

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

system), generates gases that are very dangerous to inhale.
Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
The following health-hazardous air pollution is especially prominent in

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

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

be found in aerosol) when cutting, grinding, or welding. May cause
mucous membrane irritation with asthma-like symptoms and impaired
lung function. Even brief exposures to high concentrations may cause
problems with persistent hypersensitivity.

Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.
Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines

Risks
Rotating components, e.g., fans or shafts, can cause severe injuries

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

Risks
If the machine's lifting equipment is not lowered or secured, there is a

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

system, see Hydraulic and brake systems, depressurising, page B:5.
Safety actions
• If possible, do not start to work before the boom is completely
lowered and fully retracted.
Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Boom nose extension
• Lift cylinder
• Valve block lift
• Extension cylinder
• Valve block extension
• Rotation motor unit
• Tilt cylinder
• Twistlock, lift shoe
• Control breaker (for hydraulic function)
• Emergency stop
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

Non-ionised radiation
WARNING
Extra equipment such as two-way radio, RMI, telephone,
etc. may emit non-ionised radiation.
Risk of interference with active or non-active medical
products.
Use a two-way radio, RMI, telephone, etc., when no
persons with active or non-active medical products
are nearby.
NOTE
When persons with active or non-active medical products are not
nearby, then telephone and two-way radio may be used in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.

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

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

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

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

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

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

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

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

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

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

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

C:1
Contents C Preventive maintenance

Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:5
Service schedule............................................................................................. C:7
Washing ........................................................................................................ C:13
Lubrication 500 hours ................................................................................... C:14
Lubrication 1000 hours ................................................................................. C:16
Checking for cracks ...................................................................................... C:19

C:2

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

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

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

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

see Service schedule, page C:7. The service schedule shall be
followed to ensure high machine reliability and safety.
Note completed service in the service log, see Check and service
log, page C:4.

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

Model:
Serial number:
Completed maintenance
Oper-
ating Operating
hours Actions hours Date Signature
50h 50h-check
500h 500h service
1000h 1000 service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000 service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000 service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000 service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000 service
9500h 500h service
10000h 2000h service

50h-check
On a new machine, the following checks shall be performed after 50
operating hours. The checks are performed to increase reliability and
safety.
1 Engine Reference
Bolted joints, attachments, mountings, hose clamps,
wear and chafing of hoses, cable harnesses, etc.
Sealing check oil, coolant, exhaust system
Fuel pre-filter, water draining Section 1 Engine, group 1.2.3 Fuel pre-filter
Air filter indicator, check Section 1 Engine, group 1.6.1 Air cleaning system
Air filter main cartridge, inspection
Air filter safety cartridge, inspection
Drive belt tension, checking Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Oil and oil filter, change Section 1 Engine, group 1.8 Lubrication system
Oil pressure
2 Transmission
Leakage check
Oil level, check Section 2 Transmission, group 2.6 Lubrication system
Transmission oil filter, changing Section 2 Transmission, group 2.6 Lubrication system
3 Driveline/Axle
Mounting propeller shaft, check-tightening Section 3 Driveline/Axle, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Driveline/Axle, group 3.3 Drive axle
4 Brakes
Leakage check
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check Section 4 Brakes, group 4.5.4 Parking brake unit
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Suspension, group 6.3 Tyres and rims
Wheel nuts, check-tightening Section 6 Suspension, group 6.3 Tyres and rims
7 Load handling
Hose connections, check-tightening
Chain tension spreading, checking and adjusting Section 7 Load handling, group 7.5.7 Spreader chains

Lower slide surfaces inner boom The lower glide surfaces of the inner boom should be lubricated
every 250 operating hours up to 1,000 operating hours, thereafter
Slide surfaces main beam attachment according to lubrication chart.
8 Control system
Check that there are no active error codes Section 8 Control system, group 8.3 Error codes
Locking of the cab (mechanically movable), checking Section 9 Frame, body, cab and accessories, group 9.10.4
Sliding cab
Leakage check, retightening as required
Oil level, check Section 10 Common hydraulics, group 10.6.8 Hydraulic oil
Fine filter hydraulic oil, changing Section 10 Common hydraulics, group 10.6.9 Fine filter hydraulic
oil
11 Common electrics
Batteries, check Section 11 Common electrics, group 11.3.1 Start battery

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

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

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

500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
0 complete machine
Checking cleanliness and C C C Check for and remove traces Section B Safety
leakage of combustible materials in the
engine compartment.
Take extra care on hot
surfaces such as exhaust
systems, manifolds or turbo.
If leaks of oil, fuel, or coolant
are detected, find the cause
and solve the problem.
Attachments (stub axles) C C Visual check in connection
with greasing.
Lubrication 500 hours L L L Lubrication 500 hours,
NOTE page C:14
Only:
Brake pedal
Link arms
Wheel hub steering axle
Wheel spindle steering axle
Lubrication 1000 hours L L Lubrication 1000 hours,

page C:16
Checking for cracks C* C* * Check every 1000h or every Checking for cracks, page
year. C:19
1 Engine
Bolted joints, attachments, C C C
mountings, etc.

Fuel tank C Clean if necessary. Section 1 Engine, group

1.2.1 Fuel tank
Fuel pre-filter C R R Drain water/impurities. Section 1 Engine, group
1.2.3 Fuel pre-filter
Change filter earlier if error
code is displayed.
Fuel filter R R Change filter earlier if error Section 1 Engine, group
code is displayed. 1.2.4 Fuel filter
AdBluetank C Cleaning Section 1 Engine, group
1.2.12 AdBluetank
AdBluefilter R Section 1 Engine, group

1.2.13 AdBluefilter
Valve clearance C C First check after 1000 h, then
every 2000 h. NOTE
After engine replacement or Performed by service
engine overhaul check/adjust shop authorized by
after 250 h. Volvo Penta.
Air filter main cartridge C/R C/R C/R Checking indicators, change Section 1 Engine, group
when indicated. 1.6.1 Air cleaning system
Air filter safety cartridge C C/R C/R Changed every other time
main cartridge is changed.
Exhaust system C C C Sealing check Section 1 Engine, group
1.6.3 Exhaust system
Charge-air hoses C C Sealing check Section 1 Engine, group
1.6.4 Intercooler
Radiator C C C External check and cleaning. Section 1 Engine, group
1.7.4 Radiator and
expansion tank
NOTE
Do not use high pressure
wash.
Drive belts C C R Replace as necessary or after Section 1 Engine, group

4000 h or every two years. 1.7.5 Cooling fan
Belt tensioner C
Coolant C C C / R* Level check. Section 1 Engine, group
1.7.7 Coolant
* Replace after 8000 h or
every four years.
For volume and quality, see
section F F Technical data.
Coolant, freezing point C C C For volume and quality, see
Turbo C
NOTE
Performed by service
shop authorized by
Volvo Penta.

Engine oil R R R For volume and quality, see Section 1 Engine, group
section F F Technical data. 1.8 Lubrication system
Engine oil filter R R R
2 Transmission (ZF 5WG261)
Transmission oil filter R R Section 2 Transmission,
group 2.6 Lubrication
Transmission oil R R For volume and quality, see system
Transmission, calibration C C Calibration of transmission is Section 2 Transmission,
recommended every 1,000 group 2.8 Control system
operating hours. transmission
3 Driveline/Axle
Propeller shaft C C C Bolted joints and universal Section 3 Driveline/Axle,
joint. group 3.2 Propeller shaft
Drive axle oil R R For volume and quality, see Section 3 Driveline/Axle,
section F F Technical data. group 3.3 Drive axle
Mounting drive axle C C Section 3 Driveline/Axle,
group 3.3 Drive axle
4 Brakes
Brake pedal C C Section 4 Brakes, group
4.1.1 Brake pedal
Oil pump brake system C C C Section 4 Brakes, group
4.3.1 Oil pump brake
system
Accumulator C C C Section 4 Brakes, group
4.3.4 Accumulator
Parking brake C/R C/R C/R Check pad thickness, change Section 4 Brakes, group
when needed. 4.5.4 Parking brake unit
Oil cooler C C C Clean when needed.
NOTE
wash.
Breather filter R Section 4 Brakes, group

4.8.11 Breather filter
Oil filter, brake system R R R Section 4 brakes, group
4.8.12 Oil filter brake
system
Oil brake system R For volume and quality, see Section 4 Brakes, group
section F F Technical data. 4.8.14 Oil for brake
system
5 Steering
Link arms C/L C/L C/L Check bearings. Lubrication 500 hours,
page C:14
Sensor steering wheel C C C Section 5 Steering, group
reading mini-wheel/joystick 5.2.12 Sensor steering
control wheel reading
6 Suspension
Steering axle suspension C C Section 6 Suspension,
group 6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel Section 6 Suspension,
suspension shall be checked. group 6.2.2 Wheel spindle
Max. 1.5 mm.

Wheel hub steering axle, C Check bearing pre-load. Section 6 Suspension,

check group 6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and pressure, Section 6 Suspension,
change as needed. group 6.3 Tyres and rims
Wheel nuts C C Check-tightening. Section 6 Suspension,
group 6.3 Tyres and rims
Rim C* * Checking for cracks, every Section 6 Suspension,
2,000 hours and in connection group 6.3.2 Rim
with tyre changes.
7 Load handling
Servo filter R R R Section 7 Load handling,
group 7.2.2 Servo filter
Cable racks boom and C C Hose and cable damage.
attachment
Slide plates boom C C Check wear, change as Section 7 Load handling,
needed. group 7.3.10 Lift boom
Slide plates side shift frame C C Check wear, change as Section 7 Load handling,
needed. group 7.4.6 Sideshift
frame
Chain spreading C C Tension chain when needed. Section 7 Load handling,
group 7.5.7 Spreader
chains
Slide plates spreader beam C C Check wear, change as Section 7 Load handling,
needed. group 7.5.8 Spreader
beam
Oil spreading motor unit R R For volume and quality, see Section 7 Load handling,
section F F Technical data. group 7.5.6 Spreader
motor
Oil rotation motor unit R R For volume and quality, see Section 7 Load handling,
section F F Technical data. group 7.6.6 Rotation
motor unit
Twistlocks C C C/R Checking that the parts are Section 7 Load handling,
properly tightened every 500 group 7.9.1.7 Twistlocks
hours.
Check of float position every
500 hours.
Check of vertical movement
every 2000 hours.
Check for cracks every other
year or every 4000 operating
hours.
Replace every 10,000
operating hours. Reset
time counter for twistlocks
after replacement.

Lift shoe, combi attachment C/R C Check for cracks every other Section 7 Load handling,
year or every 5000 operating group 7.9.2.14 Lift shoe
hours.
Replace every 10,000
operating hours.
C Check that deviation without Section 7 Load handling,
Weight indicator load is max. 0.5 ton. group 7.10.2 Weight
indicator
8 Control system
Overload system C C C Section 8 Control system,
group 8.2.1 Overload
system
C C C Section 8 Control system,
Service indicator, reset group 8.2.4 Service
indicator
Instruments and controls C C C Checking function.
Air conditioning unit C C C Checking function. Section 9 Frame,
body, cab and
accessories, group 9.4.
Check/performance test
of air conditioning.
Fresh air filter R R R Dependent on external Section 9 Frame, body,
environment, at latest every cab and accessories,
500 operating hours. group 9.4.1 Fresh air filter
Condenser C C C Clean when needed. Section 9 Frame, body,
cab and accessories,
group 9.4.8 Condenser
NOTE
wash.
Moisture filter C/R C/R C/R Checking, change if indication Section 9 Frame, body,
is grey. cab and accessories,
group 9.4.9 Moisture filter
Windshield wipers C C C Incl. washer, top up when
needed.
Lighting and audible signals C C C
Cab frame C C Check rust damage,
deformation or cracks.
Doors C C C Section 9 Frame, body,
Group 9.10.2 Doors
Sliding cab C C Check locking. Section 9 Frame, body,
group 9.10.4 Sliding cab
C C Checking and adjustment of
Hydraulic sliding cab chain tension.
Checking lock for door.
C C C Section 9 Frame, body,
Central lubrication cab and accessories,
group 9.14 Central
lubrication
Paint/coatings C Check the machine's painted Section 9 Frame, body,
surfaces for stone chips and cab and accessories,
scratches. group 9.15 Paint/coatings
Repair damage immediately
to avoid corrosion.

Handles and hand rails C C Checking the mountings.

Safety decals C C C Check that safety decals are See Operator's manual
legible, securely fastened, DRF 400-450, section
and not damaged. Clean dirty 3 Overview, group 3.2
decals and replace decals as Signs
needed.
Breather filter C/R R R Change at indication. Section 10 Common
hydraulics, group 10.6.6
Breather filter hydraulic oil
tank
Hydraulic oil filter R R Section 10 Common
Hydraulic oil filter,
Hydraulic oil filter R R Section 10 Common
(high-pressure filter) hydraulics, group 10.6.7
Hydraulic oil filter
Oil cooler C C Clean when needed.
NOTE
wash.
Hydraulic oil R For volume and quality, see Section 10 Common

section F F Technical data. hydraulics, group 10.6.8
Hydraulic oil
Fine filter hydraulic oil R R R Section 10 Common
Fine filter hydraulic oil
11 Common electrics
Fuses C C C Check that fuses are intact, Section 11 Common
change if needed. electrics, group 11.2.2
Fuses
Batteries C C C Section 11 Common
electrics, group 11.3.1
Start battery
Battery cable C C C Section 11 Common
electrics, group 11.3.1
Start battery
Position sensors C C C Should be free from grease
and dirt, clean as needed.
• Boom
• Attachment
• Hydraulic sliding cab
• Vertically adjustable cab
• Support jacks

Test-run
Test-run the machine and check:
• Instruments
• Brakes
• Gearshifting
• All load handling functions
• Steering
• Any noise
NOTE
On machines with manual sliding cabs, the cab must be secured in the rear position with both locks before operating.
After test-run
Check the following after test-run:
• Sealing (no leakage)
• Fluid levels
Washing
CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,
battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.

Lubrication 500 hours
1 Clean the area around each grease cup before greasing.
2 Lubricate the lubricating points of the machine with lubricating

grease, see section F Technical data.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's grease points are lubricated, see
section 9 Frame, body, cab and accessories, group 9.14
Central lubrication.
Points lubricated by the central lubrication are indicated
by *.
Wheel hub and wheel spindle

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

7 Repeat steps 4 - 7 on the left steering wheel.
Lubrication points wheel spindle

1. Upper lubrication point
2. Lower lubrication point

Link arms
8 Lubricate both link arms' outer and inner bearings with grease.
NOTE
On machines with central lubrication, check that the lubrication
1 2 reaches the actual lubrication points, see section 9 Frame,
body, cab and accessories, group 9.14 Central lubrication.
003587
Lubrication points link arm

1. Outer bearing
2. Inner bearing
Brake pedal
9 Lubricate the brake pedal's hinge with grease.
10 Wipe off excess grease.
Grease points brake pedal
1 Hinge doors and cover lid

11 Lift the door slightly and lubricate the hinge.
NOTE
Do not lift the door off the hinges.
12 Let the door down and wipe off excess grease.

13 Lift the cover lid slightly and lubricate the hinge.
NOTE
Do not lift the cover lid off the hinges.
013968
2
14 Let the cover lid down and wipe of excess grease.
1. Hinge, door
2. Hinge, cover lid

Lubrication 1000 hours
1 Lower and run out the boom completely and run out spreading
completely.
2 Turn off the engine and turn off the system voltage.
3 Clean the area around each grease cup before greasing.
4 Lubricate the machine's grease points with Lubricating grease

as shown on the diagrams below, see Section F Technical data.
Also do a visual check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's grease points are lubricated, see
section 9 Frame, body, cab and accessories, group 9.14
Central lubrication.
Points lubricated by the central lubrication are
indicated by *.

2
1
3
12 11 10 9 8 7 6 5
18
16
17
15
13
14
2 1
3
10
11
002263
5
18 10
Grease points, lubricating grease
1. Mounting lift boom * (2 pcs.) 10. Wheel spindles * (4 pcs)
2. Mounting attachment * (2 pcs.) 11. Wheel hubs (2 pc)
3. Bearing rotation yoke* (4 pcs, two per side) + 12. Joint steering axle *
brushing of ring gear
13. Slide beam mounting side shift frame *
4. Chain and chain wheel * spreading
14. Mounting lift legs, combi attachment * (4 pcs.)
5. Twistlocks * (4 pcs)
15. Lift shoe, combi attachment * (4 pcs.)
6. Chain sliding cab
16. Mounting lift legs (knee), combi attachment * (4 pcs.)
7. Universal joints (2 pc)
8. Brake pedal inside cab (2 pcs) 17. Support jacks * (14 pcs., 7 per support jack)
9. Gear sliding cab * 18. Link arms * (4 pcs)

5 Brush slide surfaces on the boom and attachment with white

lubrication paste as shown on the diagrams below, see section
F Technical data.
NOTE
The upper slide surfaces in the outer boom should be lubricated
at the same time as the other slide surfaces.
004874
Glide surfaces boom
004875
Glide surfaces attachment
6 Start the engine.
7 Operate the boom and spreading in and out, and side shift
attachment max. right - left, a few times without a load.
IMPORTANT
Wipe off excess lubrication paste.

On machines with central lubrication, check the grease levels in

the pump units on the frame and attachment.
Top up with lubricating grease if the grease levels in the reservoirs
are below the middle.
Filling takes place through the grease nipples on the pump units.
NOTE
If grease has penetrated out from the safety valve, it means
there is a stop in the system, this means that no points are
greased, see section 9 Frame, body, cab and accessories,
group 9.14 Central lubrication.
9 Lubricate electrical contacts with electrical contact grease, see

section F Technical data.
Pump unit central lubrication, example illustration

1. Filling point
2. Safety valve
Checking for cracks
DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
boom and attachment.
DANGER
All of the machine's welds shall be checked according
to recommended interval. The interval is calculated
according to the machine being used for normal
handling and on a level, smooth ground surface. For
other handling or, e.g., rough surface, the interval
should be shortened.
If the welds show signs of cracking, the machine
should be taken out of operation immediately and
contact Cargotec Support.
2 Clean every weld carefully before inspection.

3 Check for damage and cracks in the areas with high stress
concentration, see Checkpoints, page C:20. Check the whole
length of every weld.
When uncertain, welds can be tested with magnetic powder and
even penetrating fluid as follows:
a. The magnetic powder method is used to determine if there's a
crack or not, and where it is. See Magnetic powder method,
page C:20.
b. Confirmed cracks are investigated further with penetrating
fluid. See Checking cracks with penetrating fluid, page C:20.
Magnetic powder method

1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic powder and the following equipment:
001703
• Equipment: Yoke Tiede
• Method:
Rim a Alternating current AC
b Contrast colour
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
001704
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
Rim any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
6 Visually inspect the area.

1 2
If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
If the crack check indicates linear or point-shaped cracks, contact
Cargotec Support.
001705
Examples of cracks
1. Linear crack
2. Pointed crack
Checkpoints
1 Park the machine with attachment lowered as far down as possible
and spreading in the 40-foot position.

Steering axle mounts

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

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

0:1
0 Complete machine
Contents 0 Complete machine

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

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Complete machine, description
The Kalmar DRF 400-450 is a "Reachstacker" for handling containers.
The machine has a lift capacity of 40-45 tonnes depending on version.
It is powered by a six-cylinder, four-stroke diesel engine with direct

injection. The fuel tank is on the left-hand side of the machine.
The transmission is hydromechanical with gears in constant mesh.
It has five forward gears and three reverse. The engine's power is
transmitted using a torque converter.
The power transmission consists of a propeller shaft and a rigid drive

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

hydraulic cylinder. The steering axle is oscillation-mounted in the frame.
The wheels are fastened on the hubs using clamps. The drive axle has
twin wheels, the steering axle has single wheels.
Load handling consists of components and functions for handling loads.

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

dangerous situations and machine problems. The control system has
diagnostic possibilities that facilitate troubleshooting.
The frame supports the machine. The engine, transmission, drive axle,
and steering axle are installed in the frame. On the sides of the frame
there are tanks for fuel, hydraulic oil, and oil for the brake system. The
cab has a central location and can be moved fore-aft.
As an option the cab is available in a side-mounted height-adjustable

design.

0:4

1:1
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.2 Fuel system......................................................................................................1:8
1.2.1 Fuel tank .....................................................................................................1:9
1.2.3 Fuel pre-filter ...............................................................................................1:9
1.2.4 Fuel filter ................................................................................................... 1:11
1.2.12 AdBluetank ................................................................................................ 1:11
1.2.13 AdBluefilter ................................................................................................1:14
1.6 Air intake and exhaust outlet..........................................................................1:17
1.6.1 Air cleaning system ...................................................................................1:18
1.6.3 Exhaust system .........................................................................................1:21
1.6.4 Intercooler .................................................................................................1:21
1.7 Cooling system ..............................................................................................1:23
1.7.4 Radiator and expansion tank ....................................................................1:23
1.7.5 Cooling fan ................................................................................................1:23
1.7.7 Coolant ......................................................................................................1:25
1.8 Lubrication system .........................................................................................1:29
1.9 Control system engine ...................................................................................1:32
1.10 Ignition/heating...............................................................................................1:33
1.11 Start/stop........................................................................................................1:34

1:2

1 Engine – Engine 1:3
1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.
The engines are low emission engines and meet emission regulations
from the USA (California) and Europe. The new engines provide
considerable improvement, not only for exhaust emissions but also
for the power and torque curve.
The machine is equipped with Volvo TAD1360VE.

1:4 1 Engine – Engine
Engine alternative Volvo TAD1360VE,

function description
Volvo TAD1360VE is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.
°C
. bar
0 rpm
P I kph
II
III
1
8 <°
3 15 2 5 12
D794 UDS D790-1 D790-2 D795
13
D793 D797-R
11
7 6
H2O
SENSORS M M
19 4 9 17 18 10
14 16
014246
1. Ignition (S150) 11. Control unit frame rear (D797-R)
2. Control unit cab (D790-1) 12. Control unit KID (D795)
3. Control unit engine (D794) 13. Control unit, transmission (D793)
4. Preheating coil (E800) 14. Pump unit AdBlue
5. Control unit KIT (D790-2) 15. Control unit SCR (UDS)
6. Starter motor (M654) 16. Water valve
7. Electric components engine 17. Level and temperature sensor AdBlue
8. Accelerator pedal (B690) 18. Sensor exhaust temperature
9. Make-contact (closing switch) coolant level (B759) 19. Output shaft sensor (B758)
10. Sensor fuel level (B757)

Engine, component location
5
4
6
3
7
2 8
1 9
10
11
12
13
14
15
014494
16
Engine right side (in machine's direction of travel)

1. Transmission oil cooler 9. Fuel pre-filter
2. Water cooler 10. Water trap
3. Intercooler 11. Sensor water in fuel
4. Preheating coil 12. Fuel filter
5. Sensor boost pressure and boost temperature 13. Oil dipstick
6. Sensor oil pressure 14. Sensor oil level/oil temperature
7. Sensor crankcase pressure 15. Drain plug engine oil
8. Make-contact fuel pressure 16. Alternator

1:6 1 Engine – Engine
4
7
3
8
9
2
10
11
014495
12
13
Engine left side (in machine's direction of travel)
1. RPM sensor camshaft 8. Sensor coolant temperature
2. Sensor RPM flywheel 9. Water pump
3. Oil filling engine oil 10. Turbo
4. Connection cab heat 11. Oil filter (full-flow)
5. Thermostat 12. Oil filter (bypass)
6. Expansion tank 13. Starter motor
7. Sensor coolant level

1 2 P
0
I 3 4 5
II
III
9
8
10
014042
1. Accelerator pedal (B690) 7. Diagnostic socket motor, VODIA (engine option
Volvo)
2. Ignition (S150)
8. Control unit engine (D794)
3. Control unit KID (D795)
9. Sensor fuel level (B757)
4. Control unit KIT (D790-2)
10. Fuel tank
5. Control unit cab (D790-1)
6. Control unit frame rear (D797-R)

1:8 1 Engine – Fuel system
1.2 Fuel system

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

page 1:5.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
Fuel system, bleeding
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
1 Machine in service position, see section B Safety.
1
2 Open the hand pump (position 1) by pressing it in and turning
anticlockwise.
3 Bleed the fuel system by pumping the hand pump at least 250
times.
Pump quickly to maintain the pressure in the pump.
NOTE
Bleeding is not complete until there is no resistance in the pump.
4 Close the hand pump by pressing in and turning clockwise.

5 Start the engine and allow it to idle for about five minutes before
increasing speed.
014098
1. Hand pump

1 Engine – Fuel tank 1:9
1.2.1 Fuel tank
Fuel tank, cleaning
NOTE

2 Empty the fuel tank of fuel. Use a pumping device.
3 Remove the drain plug from the fuel tank.
4 Rinse the fuel tank clean through the fuel filler hole.
5 Reinstall the drain plug.
2
1
3
014099
1. Fuel filler
2. Drain plug, under tank
3. Fuel tank
1.2.3 Fuel pre-filter
Fuel pre-filter, draining condensation
NOTE
NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.
2 Place a container under the fuel pre-filter.

1:10 1 Engine – Fuel pre-filter
3 Open the drain tap on the underneath and allow the condensation
to run out. Close the tap when clean fuel without water runs out.
014045
Fuel pre-filter, replacement
NOTE
2 Drain the fuel pre-filter of fuel and water.

See Fuel pre-filter, draining condensation, page 1:9.
3 Disconnect the wiring (position 1) from the sensor for water in fuel.
4 Remove the fuel pre-filter from the filter holder. Collect any fuel
in a container.
5 Remove the water trap (position 3) from the old filter.
6 Clean the water trap using a soft cloth.
1
Check that the drain hole in the lower part is not blocked.
7 Install a new O-ring on the water trap and lubricate with diesel oil.
2 Install the water trap on the new fuel pre-filter.
8 Lubricate the O-ring on the new fuel filter with diesel oil.
9 Install the new fuel pre-filter on the filter holder.
3 Tighten the O-ring by hand until it just touches the filter holder.
Then tighten a further half turn, no more.
10 Connect the wiring to the sensor water in fuel.
014213
11 Bleed the fuel system, see Fuel system, bleeding, page 1:8.
1. Wiring 12 Turn on the system voltage and start the engine. Check that the
2. Fuel pre-filter filter seals tight.
3. Water trap

1 Engine – Fuel filter 1:11
1.2.4 Fuel filter
Fuel filter, replacement
NOTE
NOTE
Do not fill the fuel filter with fuel prior to installation. There is a risk
of contaminants entering the fuel system and causing malfunctions
or damage.

The fuel filter must be replaced when the engine is cold.
2 Place a container under the fuel filter.
3 Clean around the filter.
4 Remove the fuel filter with the filter removal tool.

5 Clean the fuel filter's mating surface on the filter holder.
6 Lubricate the O-ring on the new fuel filter with diesel oil.
7 Install the new fuel filter.
Tighten according to the instructions on the fuel filter.
8 Bleed the fuel system, see Fuel system, bleeding, page 1:8.
9 Fuel pre-filters must be replaced and the water trap emptied
at the same time as replacing the fuel filter, see Fuel pre-filter,
replacement, page 1:10.
10 Turn on the system voltage and start the engine. Check that the
fuel filter seals tight.
014218
1.2.12 AdBluetank
AdBluetank, component location
See Exhaust outlet, component location, page 1:18.
AdBluetank, cleaning
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.

1:12 1 Engine – AdBluetank
2 Remove the drain plug (position 1) on the underside of the AdBlue

tank. Drain any remaining AdBlue into a container.
3 Replace the drain plug gasket and reinstall the plug, tighten to
a tightening torque of 30 Nm.
NOTE
Only use gaskets that can withstand AdBlue.
1
014224
4 Remove the filler cap and filler pipe.

014225
5 Lower the filler cap and filler pipe in a water bath. Let them remain
for at least two minutes.
014226

1 Engine – AdBluetank 1:13
6 Detach and remove the tank connections.
014227 7 Check the strainer on the connections. Clean when needed.
NOTE
Always replace a damaged strainer.
014228
8 Flush the tank with hot water for at least ten minutes.
Then check that the tank is completely drained of water.
014229

1:14 1 Engine – AdBluefilter
9 Reinstall the tank connections.
014230
10 Reinstall the filler pipe.

11 Fill the tank with AdBlue. Refit the filler cap.
014231
1.2.13 AdBluefilter
AdBlue filter, replacement
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
CAUTION
Wait at least two minutes after switching the engine off
before removing the hoses for AdBlue so that the SCR
system has time to drain and depressurize.
2 Remove the plate covering the pump unit from below. The plate is
placed under the battery compartment on the machine's left-hand
side.

1 Engine – AdBluefilter 1:15
3 Remove the connection for the heating element.
NOTE
Pull the connection straight out.
014232 4 Drain any remaining AdBlue into a container.

Place a container under the pump unit. Connect a plastic tube to
the drain screw located on the filter holder. Open the screw and
allow the remaining AdBlue solution to run down into the container.
014233
5 Remove the hose from the filter holder by pressing in the catches.
014234

1:16 1 Engine – AdBluefilter
6 Remove the filter holder (position 1) from the pump unit. Remove
the filter insert (position 3).
NOTE
If the filter has been detached, it must be removed completely
before being reinstalled, even if it is to be reused.
7 Install a new O-ring (position 2) in the new filter holder.

Install a new filter insert in the filter holder.
Install the filter insert and filter holder as one unit in the pump.
Tighten the filter holder using a toque wrench.
3
NOTE
2 014235
Check that the drain valve is closed.
8 Install the hose to the filter holder. Check that the locks lock
1 securely.
9 Reconnect the connection to the heating element. Check that

the connection locks securely.
NOTE
Ensure that the connection is connected straight.
10 Start the engine and check sealing.

014236

1 Engine – Air intake and exhaust outlet 1:17
1.6 Air intake and exhaust outlet

Air intake and exhaust outlet, description
There is an air cleaner on the machine. The air cleaner is equipped
with an indicator that indicates when the air filter needs replacing. The
air cleaner has two filter inserts, one main insert and a safety insert.
The air cleaner is connected to the engine by the turbocharger.
Volvo Stage 3B engines are equipped with SCR technology to reduce

nitrogen oxides (NOx) in exhaust gases. SCR technology means that
AdBlue is injected into the exhaust gases before it reaches the SCR
catalyst. A sensor measures the exhaust gases' NOx levels. The SCR
is located on the left-hand side of the machine.
AdBlue contains deionised water mixed with 32.5% urea. The urea is
broken down into ammonia, which reacts with NOx to create harmless
nitrogen and water vapour.
The exhaust system consists of pipe and silencer.

1:18 1 Engine – Air cleaning system
Exhaust outlet, component location
2
6 1
10
8
9
014289
5
7
Exhaust outlet 6. Level and temperature sensor AdBlue

1. Control unit NOx 7. Exhaust pipe
2. Silencer with integrated SCR catalyst 8. AdBluetank
3. End-pipe 9. Pump unit
4. Heat shield 10. Heating valve
5. Injector unit
1.6.1 Air cleaning system
Air filter, changing

1 Engine – Air cleaning system 1:19
1 2 3 4 5 2 Clean the outside of the air filter housing.

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

1:20 1 Engine – Air cleaning system
5 Clean the dust reservoir.
6 Check the safety insert, change as needed. (The safety insert

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

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

1 Engine – Exhaust system 1:21
10 Reset the indicator.
1.6.3 Exhaust system
Exhaust system, checking
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, or muffler when the
machine is in operation or has recently been turned off!
2 Check the exhaust system's sealing and other wear.
3 Check that the exhaust system suspension is intact.
1.6.4 Intercooler
Intercooler, checking
CAUTION
Avoid the fuel cooler when cleaning with high-pressure
wash.

1:22 1 Engine – Intercooler
2 Clean the intercooler with compressed air.
NOTE
Do not use high pressure wash.
3 Check that the intercooler suspension is intact.
4 Check the sealing and check that the intercooler's hoses and
clamps are in good condition.
Charge-air pipe, checking
2 Check the charge air pipes for visible cracks and other external
damage. If the pipes are damaged or if connections leak, the
boost pressure will be too low and engine power is reduced.
014497
Charge-air pipe, example.

1 Engine – Cooling system 1:23
1.7 Cooling system

Cooling system, description
The engine radiator is located together with the intercooler and the
transmission oil cooler in one unit, a cooling unit.
page 1:5.
1.7.4 Radiator and expansion tank
Radiator, cleaning
2 Clean the radiator with compressed air.
NOTE
Do not use high pressure wash.
NOTE
Mind the fuel cooler.
3 Check that the cooling flanges are whole.
1.7.5 Cooling fan

Drive belt, inspection
Check after operating when the belts are warm.
It should be possible to press down the drive belt approx. 3-4 cm
between the belt pulleys.
The drive belt has an automatic belt tensioner and does not need to be
adjusted. Check the condition of the belts, replace if necessary, see
Drive belt, replacement, page 1:24.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
Alternator belt, checking

Check after operating when the belts are warm.
It should be possible to press down the alternator belt approx. 3-4 cm
between the belt pulleys.
The alternator belt has an automatic belt tensioner and does not need
to be adjusted. Check the condition of the belts, replace if necessary,
see Alternator belt, replacing, page 1:24.
IMPORTANT
Always change an alternator belt that looks to be worn
or has cracks.

1:24 1 Engine – Cooling fan
Drive belt, replacement

2 Remove the protective screen and the outer fan ring around the
cooling fan.
3 Remove the protective covers around the drive belts.
4 Insert a 1/2" wrench in the belt tensioner (position 1). Lift the
wrench up and remove the drive belt.
5 Slip the drive belt around the fan blade and remove it.
6 Check that the pulleys are clean and undamaged.
7 Run the new drive belt over the fan.
8 Lift up the 1/2" wrench and install the new drive belt.
9 Install the protective covers around the drive belts.
10 Install the protective screen and the outer fan ring around the
cooling fan.
11 Start the engine and perform function check.
1
014243
Alternator belt, replacing

2 Remove the protective screen and the outer fan ring around the
cooling fan.
3 Remove the protective covers around the drive belts.
4 Insert a 1/2" wrench in the belt tensioner (position 1). Lift up the
wrench and lift off the water pump drive belt.
5 Insert a 1/2" wrench in the belt tensioner (position 2). Depress the
2 wrench and remove the alternator belt.
6 Check that the pulleys are clean and undamaged.
7 Push the 1/2" wrench down on the belt tensioner (position 2) and
install the new alternator belt.
8 Lift up the 1/2" wrench on the belt tensioner (position 1) and
reinstall the water pump drive belt.
9 Install the protective covers around the drive belts.
10 Install the protective screen and the outer fan ring around the
1 cooling fan.
11 Start the engine and perform function check.
014244

1 Engine – Coolant 1:25
1.7.7 Coolant
Coolant level, check
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
A
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
B
Coolant should be filled in the system's expansion tank (position A).
The fluid level should be between MIN and MAX markings (position
C) on the expansion tank.
C
NOTE
Open very carefully as hot coolant may jet up.
004851
A Position for coolant reservoir (expansion tank) If the coolant level becomes too low, the warning light for low coolant
level (position 40) lights up on the instrument panel.
B Filling point
C Level marking, MIN and MAX NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
2 If needed, top up with ready-mixed recommended coolant. For

volume and quality, see section F F Technical data.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
IMPORTANT
On machines with ECC or AC, it is of the utmost
importance that the engine's cooling system be refilled
with coolant that contains the correct mixture of
anti-freeze fluid; otherwise there is a risk that the air
conditioning will freeze up and fail during use.

1:26 1 Engine – Coolant
Coolant, changing
Radiator performance is reduced due to deposits in the radiator and
radiator ducts. Clean the system in conjunction with changing the
coolant.
IMPORTANT
Cleaning may not be performed if there can be a risk
of freezing in the cooling system since the cleaning
solution does not have anti-freeze properties.
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system's expansion tank.
C
004851
A Position for coolant reservoir (expansion tank)

B Filling point
C Level marking, MIN and MAX

1 Engine – Coolant 1:27
2 Open all drain points. Drain the coolant from the radiator and
engine block with drain hose. The drain nipples are under the
radiator and on the right-hand side of the engine block.
3 Check that all coolant drains.
NOTE
There may be deposits inside the tap or the plug that must be
cleaned; otherwise there is a risk that coolant may remain and
cause freezing damage.
Check whether the installation has additional valves or plugs on
007394
the coolant line's lowest points. Allow the drain valves or plugs to
remain open and ensure that the heating knob is set to full heat
during cleaning.
Drain point engine.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If there still are impurities after flushing for some time, cleaning
with coolant can be performed. Otherwise continue with Cleaning
with coolant, page 1:27.
Cleaning with coolant

1 Fill the cooling system with 15-20 % concentrated coolant mixture.
Only use recommended concentrated coolant mixed with clean
water.
2 Drain the cooling system after 1-2 days of operation.
NOTE
In order to avoid dissolved materials getting into the cooling
system, drain quickly, within 10 minutes, without the engine
having been stationary for a long time.
Remove the filler cap from the expansion tank and any lower
radiator hose to increase the drain speed.
3 Immediately flush the system thoroughly with clean hot water to

prevent dirt getting on the internal surfaces. Flush until clean water
runs out. Make sure the heat control is at full heat during cleaning.
4 If impurities should remain after a long time of flushing, cleaning

can be performed with radiator cleaning agent and after-treatment
with neutraliser.
NOTE
Use only cleaning agent approved by the engine manufacturer.
Carefully follow the instructions on the packaging.

1:28 1 Engine – Coolant
Filling point
1 When the cooling system is completely free from impurities, close
the drain valves.
CAUTION
NOTE
Only use recommended coolant.
2 Add coolant so that the level lies between the MIN and MAX
markings. The engine must not be started until the system
has been bled and filled fully.
3 Start the engine when the system is bled and completely filled.
Open any bleeder valves some time after start, so that the trapped
air can escape.
Open all heat controls on the heater unit so that it is bled.
4 Stop the engine after about one hour and check the coolant level,
top up if needed.

1 Engine – Lubrication system 1:29
1.8 Lubrication system

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

page 1:5.
Oil and oil filter, change
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1 Run the engine until warm.
3 Remove the drain plug from the engine and drain the engine of oil.
007317

1:30 1 Engine – Lubrication system
4 Clean the filter holder (position1).

1
5 Remove all oil filters (position 2–4) using a filter extractor.
6 Clean the mating surface of the filter holder and check that no
gasket from the old filter remains in place.
7 Install new oil filters.
Lubricate the O-rings on the filters with engine oil.
Full flow filter: tighten to contact and then an additional one-half
to three-quarter turn.
Bypass filter: tighten to contact and then another three-quarter
turn.
8 Fit the drain plug when the oil has drained. Tighten to a maximum
torque of 60±10 Nm.
2
NOTE
4
Do not tighten the oil plug with higher tightening torque, the
3 threads will be damaged.
9 Fill engine oil. For volume and quality, see section F Technical
014240
data.
10 Start the engine, let it idle. Check that the oil pressure is normal.
1. Filter holder
2. Bypass filter 11 Switch off the engine and check the oil level, see Oil level, check,
page 1:30. Fill if necessary.
3. Full flow filter
4. Full flow filter
Oil level, check
NOTE
Safety.
The engine's oil filler pipe (position B) is located under the service
hatch in front of the cab on the left-hand side of the engine. The oil
dipstick is on the right-hand side of the engine.
2 The oil level can be checked both when the oil is cold and hot.
The STOP side of the dipstick is used for cold engine and the
OPERATING side is used for hot engine.
The dipstick has two marks between which the oil level should lie.
S TO
P
OP
ER A
TIN
G
014239

1 Engine – Lubrication system 1:31
3 Top up with new engine oil if necessary (position B). For volume
and quality, see section F Technical data).
Do not fill over MAX-level.
4 Fill - wait awhile - check on the dipstick.
NOTE
A B Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
014046
A Position for filling

B Filling point

1:32 1 Engine – Control system engine
1.9 Control system engine

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

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

1 Engine – Ignition/heating 1:33
1.10 Ignition/heating
Ignition/heating, description
The engine features preheating of the induction air, for faster start at
low temperatures. Preheating is activated when the ignition key is in
position II. When preheating is activated the preheating indicator light
comes on. The ignition sends signals to Control unit KIT (D790-2)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794).

page 1:5.

1:34 1 Engine – Start/stop
1.11 Start/stop
Start/stop, description
The engine is started and stopped with the ignition. The ignition sends
signals to Control unit KIT (D790-2) and Control unit cab (D790-1)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794). Starter motor and stop device are controlled by Control unit
engine (D794).
Start lock-out is available as an option, where a code has to be

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

This means that the engine switches off automatically after 3-30
minutes (depending on customer setup) irrespective of whether the
operator is sitting in the seat or not. The conditions are that the
machine is stationary and idling.
There is a stop button on the engine that can be used to stop the engine
in an emergency, e.g. if the engine cannot be stopped by other means.

page 1:5.

2:1
2 Transmission
Contents 2 Transmission
2 Transmission ......................................................................................................2:3
2.2 Torque converter/Clutch system ......................................................................2:7
2.3 Mechanical transmission..................................................................................2:8
2.6 Lubrication system ...........................................................................................2:9
2.7 Cooling system ..............................................................................................2:12
2.8 Control system transmission..........................................................................2:13

2:2

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

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

hydraulic system. The torque converter is a hydraulic clutch placed
between the engine's output shaft and the transmission's input shaft.
The hydraulic oil pumps and the oil pump for control and lubrication
of the transmission are connected to the torque converter via power
take-offs on the transmission.
The gear position is selected by modulating pressure via electrical

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

2:4 2 Transmission – Transmission
F
R
<° 1
D1
17 5 D1
D20 D5
6 2 15
D790-1 D790-2 D795
D793 D794 D797-F

8 16 19
D6
D22
D11 Pa
D12 13 7 10 11 12
°C 18
4 9
14
013962
1. Gear selector 11. Sensor drum speed (B752)
2. Control unit KIT (D790-2) 12. Sensor rpm output shaft (B7580)
3. Oil pump transmission 13. Sensor oil temperature transmission (B7660)
4. Oil filter transmission 14. Oil cooler transmission
5. Accelerator pedal 15. Control unit KID (D795)
6. Control unit cab (D790-1) 16. Control unit engine (D794)
7. Sensor engine rpm (B7530) 17. Declutch pedal (S220-1)
8. Control unit, transmission (D7930-2) 18. Break contact declutch (S220-2)
9. Solenoid valves for travel direction and gear position 19. Control unit, frame front (D797-F)
10. Sensor rpm turbine (B7510)

2 Transmission – Transmission 2:5
Transmission, component position
9
3
4
10
11
5
12
14 13 1
6
7
014043
1. Power take-off 9. Sensor rpm turbine (B7510)
2. Transmission oil dipstick and filling point 10. Sensor rpm drum (B7520)
3. Transmission oil cooler 11. Make-contact (closing switch) transmission oil filter
(S2710)
4. Thermostat
12. Oil filter transmission
5. Sensor engine rpm (B7530)
13. Sensor rpm output shaft (B7580)
6. Coarse strainer transmission oil
14. Output shaft
7. Sensor oil temperature sump (B7660)
8. Valve assembly transmission (A3)

2:6 2 Transmission – Transmission
1 2 3 4 5
10
6
9 7
013046
1. Accelerator pedal (B690) 6. Control unit frame rear (D797-R)
2. Control unit KIT (D790-2) 7. Control unit, transmission (D7930-2)
3. Control unit KID (D795) 8. Declutch pedal (S220-1)
4. Multi-function lever (S162) 9. Make-contact declutch (S220-2)
5. Control unit cab (D790-1) 10. Control unit, frame front (D797-F)

2 Transmission – Torque converter/Clutch system 2:7
2.2 Torque converter/Clutch system

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

page 2:5.

2:8 2 Transmission – Mechanical transmission
2.3 Mechanical transmission

Mechanical transmission, description
The transmission is built with all gears in constant mesh. It is shifted
by hydraulic pressurizing of clutch discs for each of the gears. The
discs connect the input shaft with the main shaft or tubular shaft,
depending on which gear has been selected. Shifting takes place
without disengaging the transmission from the engine.
Transmission option ZF has five forward gears and three reverse. The
electric shifting system is automatic.
The FORWARD and REVERSE clutches are electro-hydraulically

modulated, which means that the clutch pressure is built up gradually.
This allows for switching between FORWARD and REVERSE and vice
versa whilst travelling at a speed that is lower than the set limit.
See section 8 Control system, group 8.5.1.5 DRIVETRAIN.
Modulation also allows for smooth shifts between FORWARD and

REVERSE.
Declutch is controlled with a separate declutch pedal that is activated

at a certain brake pressure.
High modulation (i.e. smooth driving/intensive slippage between gears)

gives high wear on the transmission and high oil temperature. Sensor
for oil temperature gives a warning when the oil is hotter than 120 °C.
If the oil temperature sensor indicates 125 °C the transmission stops
working.

page 2:5.

2 Transmission – Lubrication system 2:9
2.6 Lubrication system

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

KID (D795) and performance is reduced, if the oil temperature goes
above 125 ºC the transmission declutches.

page 2:5.
Oil and oil filter, change
NOTE
Safety.
NOTE
Do not over-fill the transmission!
NOTE
It is recommended that the transmission is calibrated after changing
the oil.
1 Operate and warm up the transmission oil.
3 Place a container under the transmission.
4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the drain plug's washer seal is also removed.
Draining transmission oil

2:10 2 Transmission – Lubrication system
5 Clean the area around the oil filter.

6 Change both oil filters.
Lubricate the O-ring on the new oil filters with transmission oil.
Tighten to contact and then another two-thirds turn.
7 When the transmission oil has drained, fit the drain plug.
NOTE
Make sure that the washer for the oil plug is included.
010392
Oil filter transmission
8 Remove and clean the oil strainer with pure methylated spirit.
Check that the strainer is intact, change if needed.
NOTE
Make sure that the strainer is completely dry and free from
particles before installing it.
9 Install the oil strainer.

010317
NOTE
Check that the O-ring is intact, clean and in the correct position.
Change when needed.
10 Remove the oil dipstick for transmission oil and fill new
transmission oil through the oil dipstick's filler pipe until the oil level
is at the bottom marking on the oil dipstick marked "COLD".
The oil dipstick has three marks. The lowermost, marked "COLD",
is a rough estimate for cold transmission. The two uppermost are
marked "HOT" and are marks for maximum, MAX, and minimum,
MIN, oil level at operating temperature. The oil level must be
between MIN and MAX.
For volume and quality, see section F F Technical data.
11 Start the engine and let it idle.
12 Check that the drain plug for transmission oil seals tightly.
13 Check the transmission oil level with the engine running at idle and
top up to the marking for "COLD".
013047
Transmission oil dipstick and filling
14 Run the transmission to operating temperature by driving the

machine in all gears so that the transmission oil temperature is
80-90°C on the display.
a Use operating menu to check the transmission oil temperature
(position a, upper horizontal row in display).
000356
b 15 Check the transmission oil level and top up to the marking for
maximum level, MAX.
Operating menu oil temperature
16 Calibrate the transmission, see .
a Transmission oil temperature
b Hydraulic oil temperature

2 Transmission – Lubrication system 2:11
Oil level, check
NOTE
Safety.
The transmission's oil filler pipe and oil dipstick are located under the
service hatch in front of the cab.
1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 80-90°C on the
display).
The dipstick has three marks. The lowermost, marked "COLD", is
a rough estimate for cold transmission. The two uppermost are
marked "HOT" and are marks for maximum, MAX, and minimum,
MIN, oil level at operating temperature. The oil level must lie
between MIN and MAX when the transmission is hot at idle in
neutral.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
2 Fill the transmission oil through the filler pipe, if necessary. For
3 Fill - wait awhile - check the level marks on the oil dipstick.
013047
NOTE
Transmission oil dipstick and filling Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means risk
of transmission damage.

2:12 2 Transmission – Cooling system
2.7 Cooling system

Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:9.

page 2:5.

2 Transmission – Control system transmission 2:13
2.8 Control system transmission

Control system transmission, description
Control unit transmission controls shifting based on signals from
pressure, temperature, and speed (rpm) sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure in
the transmission, so that the selected gear gives the right speed.
For position of components see section 11 Common electrics, group

11.5.3 Control units.
In the event of a fault in the transmission, use the control unit's four
modes with reduced functionality in order to protect the transmission,
these are:
Mode Substitute clutch control
In this mode, the operator can use the machine as usual. On the
other hand, shifting and changing direction are not under the control
of normal modulating. The control unit uses the standard values for
modulating the clutches.
Mode Limp home
In this mode, the operator can use one of the transmission gears in
each direction, and in some cases only in one direction of travel. In
order to continue driving in the event of a fault with the restriction Limp
home the machine must be brought to a standstill, the gear selector
moved to neutral before the gear can be selected again.
Mode Transmission shut down
In this mode, the transmission is permanently in the neutral position

when the solenoid valves for the clutches and elements of power to
the transmission are switched off. Park the machine and switch off
the engine.
Mode TCU shut down
In this mode, the transmission is permanently in the neutral position

when all solenoid valves and all power to the transmission are switched
off. Park the machine and switch off the engine.
Machine assumes neutral position
The machine features a safety function that results in the transmission
shifting to neutral position if the operator leaves the operator's station.
The system uses the same switch in the operator's seat as the warning
for released parking brake to sense when the operator leaves the
operator's station.
If the buzzer sounds when the operator sits down in the seat and
releases the parking brake, the switch in the seat may not be working.
Then it is not possible to select any travel direction.
In an emergency the machine can be operated by bypassing the safety

system, for more information see section 8 Control system, group
8.2.2 By pass.

2:14 2 Transmission – Control system transmission
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
1 Release the load.
2 Activate switch for bypassing.
3 Select travel direction.
4 Drive the machine to service. Speed is limited to 10 km/h.
Transmission, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
1 Stop the machine on level ground, select neutral, and apply the
parking brake. Let the engine idle.
2 To select the function to calibrate, first navigate to the service

menu. Then press Enter.
000056
3 Enter the code for calibration.

The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu shall be activated

(Service, Diagnostics, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION DRIVETRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000062

2 Transmission – Control system transmission 2:15
5 Scroll with the arrow keys (1 and 2) and select DRIVE-TRAIN,

CALIBR DRIVE-TRN 4(4) menu 4 and confirm with Enter.
GEARBOX WARM UP If the oil temperature (ACTUAL TEMP) is lower than the target
MODE X temperature (TARGET TEMP), the transmission must be
ACTUAL TEMP XXX preheated.
000082
TARGET TEMP XXX If the oil temperature is too low:
A. Apply the footbrake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position and apply full throttle for 10 seconds,
run the engine at idle speed.
D. Repeat steps B and C until the oil is warm. When the
temperature is correct MODE changes from 0 to 1.
Toward the end of heating the engine speed may decrease
because the oil is too hot. If this occurs, leave the gear in neutral
and keep the engine speed at 1200 rpm for 20 seconds.
6 Select DRIVE-TRAIN, menu 3.
7 Check that the gear lever is in neutral position.
8 Start calibration by pressing Enter.

CALIBR DRIVE-TRN 3(X) The transmission will activate different gears during calibration.
AEB MAIN CODE XXX
AEB SUB CODE XXX NOTE
AEB CYCLE NR XXX
013388
SET X XXXXrpm If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.
IMPORTANT
Calibration can be cancelled at any time by selecting
to exit from the menu, releasing the parking brake, or
turning off the machine.
• If calibration is performed without problems the display shows

CALIBR DRIVE-TRN 3(X) main code (AEB MAIN CODE) number 7, which means that the
calibration is finished, see table Main code (AEB MAIN CODE)
AEB MAIN CODE XXX below.
AEB SUB CODE XXX
AEB CYCLE NR • If an error is identified during calibration the display shows a main
XXX
013388
code (AEB MAIN CODE) with a number between 8 and 14 for

SET X XXXXrpm component (see table 1. Main code (AEB MAIN CODE) below)
and a subcode (AEB SUB CODE) for action with a number
between 1 and 8. Follow instructions in table Subcode (AEB SUB
CODE) below for the identified subcode.
Table Main code (AEB MAIN CODE)
Co- Explanation
de
0. AEB mode not selected.
1. AEB mode selected, calibrating K1.
5. AEB mode selected, calibrating KV.
6. AEB mode selected, calibrating KR.

2:16 2 Transmission – Control system transmission
Co- Explanation
de
7. AEB mode selected, calibration finished.
8. AEB mode selected, calibration cancelled.
9. AEB mode selected, calibration cancelled when adjusting
K1.
K2.
K3.
K4.
KV.
KR.
Table Subcode (AEB SUB CODE)
Co- Action
de
1. Shut down and restart the machine if the error code is "0".
Repeat the calibration. If the fault persists, the transmission
may need to be inspected.
2. Switch off and start the machine. Check that the travel
direction lever is in neutral position. Repeat calibration.
3. Switch off and start the machine. Check that the parking
brake is applied. Repeat calibration.
4. Switch off and start the machine. Test the parking brake. If
the parking brake works satisfactorily, repeat calibration. If
the parking brake does not work satisfactorily, service the
parking brake. Repeat calibration.
5. Switch off and start the machine. Let the transmission reach
working temperature. Repeat calibration.
6. Let the transmission oil cool by allowing the engine to idle
in neutral. When the oil cools, the transmission control unit
(D7930-2) will resume the calibration.
7. Increase engine speed. Control unit transmission (D7930-2)
will resume the calibration when the rpm is within specified
interval.
8. Decrease engine speed. Control unit transmission (D7930-2)
will resume the calibration when the rpm is within specified
interval.
9 When calibration is finished without errors the display shows MAIN

CODE number 7.
10 Turn off the ignition to store the values.

3:1
3 Driveline/Axle
Contents 3 Driveline/Axle
3 Driveline/Axle......................................................................................................3:3
3.2 Propeller shaft..................................................................................................3:4
3.3 Drive axle .........................................................................................................3:5

3:2

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

3:4 3 Driveline/Axle – Propeller shaft
3.2 Propeller shaft

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

• After 50h:
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission with 156 Nm.
• After 500h:
Clean.
Check clearance in universal joints.
• After 1000h:
Grease universal joints with universal grease EP2.
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission with 156 Nm.
Grease nipple for universal joint, example

3 Driveline/Axle – Drive axle 3:5
3.3 Drive axle

Drive axle, description
The drive axle transmits the engine power to the wheels. After the
drive axle's input shaft there is a differential that changes the gear ratio,
distributes the power between the right and left drive wheel, and makes
it possible for the drive wheels to have different speeds when cornering.
The half shaft transmits the power from the differential to the wheel
hubs. At the wheel hubs there are hub reductions that change the gear
ratio between wheels and engine to reduce the stress on the half shaft.
014493
1. Hub reduction
2. Drive shaft (internal)
3. Differential (internal)
4. Drive axle housing
Drive axle, checking
1 Check the drive axle's attachment to the frame so that there is no

corrosion on structural elements (e.g., attaching bolts).

3:6 3 Driveline/Axle – Drive axle
2 Check-tighten the drive axle's attaching bolts to 2820 Nm.

3 Check-tighten the wheel nuts with a torque of 370 Nm.
4 Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
5 Check that drive axle seals tight.
6 Check the oil level in drive axle and the hub reductions.
Attaching bolts drive axle

3 Driveline/Axle – Drive axle 3:7
Drive axle oil, changing
NOTE
Safety.
1 Position the machine so that the drain plugs on the hubs are
lowest vertically. This applies to both drive wheels.
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (raise the machine under
the drive axle by the wheel) and rotate it to correct position.
3 Remove the drain plugs in the wheel hubs (position 1) on both

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

1. Drain plug
2. Level and filler plug
4 Remove the drain plug in the differential (position 3) (at bottom

of drive axle). Also remove the level and filler plug to facilitate
draining.
5 Clean the drive axle's breather (position 1) while the oil is draining.
6 Fit the drain plugs.
7 Fill oil in the hubs until the oil level is flush with the level and
filler holes (position 2). For volume and quality, see section F F
Technical data.
NOTE
The oil is very viscous, fill the oil slowly. Check the level in
stages so that the oil has time to settle.
8 Install the level and filler plugs on both hubs.

Differential drive axle
1. Breather drive axle 9 Fill oil in the differential until the oil level is flush with the level and
filler hole (position 2).
2. Level and filler plug
10 Install the level and filler plug on the differential.
3. Drain plug
11 Turn on the main electric power.
12 Check the oil level in the differential and hubs after a short
test-drive.

3:8

4:1
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:4
4.1.1 Brake pedal .................................................................................................4:4
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Oil pump brake system................................................................................4:7
4.3.4 Accumulator ................................................................................................4:9
4.5 Parking brake system ....................................................................................4:10
4.5.4 Parking brake unit ..................................................................................... 4:11
4.8 Temperature control, cleaning and oil brake system......................................4:13
4.8.11 Breather filter.............................................................................................4:14
4.8.12 Oil filter, brake system ...............................................................................4:15
4.8.14 Oil for brake system ..................................................................................4:16

4:2

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

• Power-assisted brake system, function description, page 4:5
• Parking brake system, function description, page 4:10
• Temperature control, cleaning and oil brake system, function
description, page 4:13

4:4 4 Brakes – Controls and instruments
4.1 Controls and instruments

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

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

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

brake pedal)

4 Brakes – Power-assisted brake system 4:5
4.3 Power-assisted brake system

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

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

4:6 4 Brakes – Power-assisted brake system
5
B
13 P
T
D790-2
D
D797-R D797-F
11 10 8 C
Pa
12
C D
D
9
4 Pa
3 7
B
ACC 6
C
P
004729
1. Oil pump brake system 8. Make-contact brake lights (S216)
2. Oil filter, brake system 9. Break contact (opening switch) oil pressure brake
system (S204)
3. Accumulator charging valve
10. Control unit, frame front (D797-F)
4. Accumulators
5. Brake valve
12. Brake lights (H411L & H411R)
6. Brake cylinders
13. Control unit KIT (D 790-2) Warning lamp brake
7. Wheel brakes pressure

4 Brakes – Oil pump brake system 4:7
Power-assisted brake system, component

position
2 3 4
1
6
8 7
004893
1. Brake valve 5. Make-contact brake lights (S216)
2. Oil pump brake system 6. Wheel brake
3. Break contact (opening switch) oil pressure brake 7. Accumulators brake system
system (S204)
8. Oil filter, brake system
4. Accumulator charging valve
4.3.1 Oil pump brake system

Oil pump brake system, checking
NOTE
Safety.
Checking pump pressure

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

Safety.

4:8 4 Brakes – Oil pump brake system
4 Connect a pressure gauge (0–25 MPa) to the test outlet for pump
pressure on the accumulator charging valve.
Pressure check connection pump pressure
6 Close the drain valve on the accumulator charging valve and

check the pump pressure during charging.
During charging the pressure should increase to 20.5±1.0 MPa
before the accumulator charging valve switches to cooling. The
pressure drops when the accumulator charging valve switches
to cooling.
7 Check the pressure during cooling.
During cooling the pressure should be max. 1.0–1.5 MPa at max.
engine rpm.
8 Turn off the engine.
Safety.
Close the accumulator charging valve
10 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
Checking accumulator charging

Safety.
13 Connect a pressure gauge (0–25 MPa) to the pressure check

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

4 Brakes – Accumulator 4:9
NOTE
16 Check that the pressure rises slowly to 20.5±1.0 MPa.

17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve shall switch to cooling at 15.5±0.5 MPa.
Safety.
Close the accumulator charging valve
NOTE
4.3.4 Accumulator
Accumulator, checking
1 Start the engine and let it idle for approx. 1 minute (until the
accumulator charging valve switches to cooling).
2 Turn off the engine and turn the start key to position I.
3 Apply and release the brake several times, and count the number
of times that the brake can be applied before the warning lamp for
low brake pressure is activated.
It should be possible to apply the brake at least 8 times before
the warning lamp is activated.
If the warning light for low brake pressure is activated earlier, one
of the brake system's accumulators is probably defective and
these should therefore be checked further.

4:10 4 Brakes – Parking brake system
4.5 Parking brake system

Parking brake system, function description
The parking brake consists of oil tank brake system, oil pump brake
system, oil filter brake system, accumulator charging valve, pressure
sensor and parking brake unit.
Oil pump brake system pumps oil (from the tank) which is cleaned
in the oil filter. The accumulator charging valve directs pressure to
the accumulators that store the pressure. The parking brake unit is
released with pressure from the accumulators by the parking brake
valve in the accumulator charging valve pressurizing the parking brake
caliper. Break contact (opening switch) parking brake gives signal so
that indicator light parking brake is turned on when the parking brake
is applied.
D 12
5
6 11
D790-1 D790-2
D797-F
7
C D D
4
8
C 9
ACC
Pa 10
3
H
P
T
2
P
004730
1. Oil pump brake system 7. Control unit, frame front (D797-F)

2. Oil filter, brake system 8. Solenoid valve, parking brake (Y642)
3. Accumulator charging valve 9. Brake caliper
4. Accumulators 10. Break-contact parking brake (S200)
5. Switch parking brake (S107) 11. Control unit KIT (D790-2)
6. Control unit cab (D790-1) 12. Indicator light parking brake (508)

4 Brakes – Parking brake unit 4:11
Parking brake system, component position
3 4
004894
6
1. Oil pump brake system 4. Solenoid valve, parking brake (Y642)

2. Accumulator charging valve 5. Parking brake unit
3. Break-contact parking brake (S200) 6. Oil filter, brake system
4.5.4 Parking brake unit
Parking brake unit, checking and adjusting
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Start the engine and run up hydraulic pressure until the

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

4:12 4 Brakes – Parking brake unit
6 Remove the cover from the brake caliper.

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

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

12 Check the function of the parking brake.

4 Brakes – Temperature control, cleaning and oil brake system 4:13
4.8 Temperature control, cleaning

and oil brake system
Temperature control, cleaning and oil brake
system, function description
The brake system is cooled with oil that is circulated through a cooler.
The cooler has a temperature-controlled electric fan that counteracts
overheating.
The temperature control system consists of oil tank brake systems,

oil pump brake system, oil filter brake system, accumulator charging
valve, wheel brake units, radiator, cooling fan, sensor oil temperature
brake system and thermal bypass valve.
Oil pump brake system pumps oil (from the tank) which is cleaned in
the oil filter. When the accumulators are charged, the accumulator
charging valve directs oil through the drive axle's brake units and cools
the brakes. The oil passes through the cooler back to the tank. An
electric cooling fan increases the air flow through the cooler when the
temperature needs to be reduced. A thermal bypass valve leads the
hydraulic oil past the cooler if the oil temperature is low and through
the cooler if the oil temperature is too high. The temperature sensor
controls activation of the fan and temperature warning in the display.
If the temperature in the brake system becomes too high, the machine's
speed is limited to protect the brakes.
11
D795
D797-F
D 9
D
C C
3
P 4
2 T
5
6 10
1 M
7
˚C
004274
8 ˚C
1. Oil pump brake system 7. Thermal bypass valve

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

4:14 4 Brakes – Breather filter
Temperature control, cleaning and oil brake

system, control system
1 2 3
8 7
6 5
006447
1. Oil filter, brake system 5. Tank heater
2. Oil tank brake system 6. Thermal bypass valve (in tank)
3. Breather filter 7. Oil cooler
4. Sensor oil temperature brake system (B762) 8. Cooling fan (M674)
Oil pump brake system, Accumulator charging valve, Drive

axle block, Wheel brake
See Power-assisted brake system, component position, page 4:7.
4.8.11 Breather filter
Breather filter, changing

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

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

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

2. Breather filter oil tank

4 Brakes – Oil filter, brake system 4:15
4.8.12 Oil filter, brake system
Oil filter brake system, changing
NOTE
Safety.
IMPORTANT
The filter protects the brake system from impurities. It
is very important that new impurities do not enter the
brake system when changing filter.
2 Depressurise the hydraulic and brake systems, see section B

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

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

7 Install the O-rings on the filter insert and filter holder. Lubricate
the O-rings with hydraulic oil.
8 Fit the new filter insert to the filter bracket.
9 Fit the filter holder and the drain plug.
10 Close the valves that were opened to drain the pressure in the
hydraulic system.
NOTE
000018

11 Start the engine and check that the filter holder does not leak.
12 Fit the cover plates over the space next to the transmission.

4:16 4 Brakes – Oil for brake system
4.8.14 Oil for brake system
Brake system oil, changing
NOTE
Safety.

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

2. Breather filter oil tank

5:1
5 Steering
Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.2 Power assisted system ....................................................................................5:4
5.2.12 Sensor steering wheel reading....................................................................5:7

5:2

5 Steering – Steering 5:3
5 Steering
Steering, general
The function steering means to steer the machine while operating. The
machine is steered with the rear wheels by a power-assisted steering
system.
Joystick or mini-wheel steering is available as an option and means

that the machine is steered electronically by a control in the driver
seat armrest.

5:4 5 Steering – Power assisted system
5.2 Power assisted system

Power assisted system, function description
The function power assisted system refers to steering the machine.
The machine's steering is power-assisted with pressure from hydraulic
oil pump 2.
Steering consists of steering wheel, steering wheel shaft, steering

valve, hydraulic oil pump, steering control valve, priority valve, steering
cylinder, link arms and wheel spindles.
The steering wheel influences (via the steering wheel shaft) the control
valve which, via a pilot pressure to the steering control valve, controls
the oil pressure from the hydraulic oil pump to the steering cylinder.
The priority valve, located on the steering control valve, gives priority
to supply oil to the control valve before other functions, e.g., load
handling. The steering cylinder acts on the wheel spindles. The link
arms are located between the steering cylinder and wheel spindles.
C 3 4
EF
P Ps P
LS Ts T
6
T
CL CR L R
2
LSO
LSP1 7
1
013969
1. Hydraulic oil pump 2 4. Steering control valve

2. Servo valve load handling and steering 5. Steering wheel
Including shuttle valves, pressure d=reducers and 6. Steering valve
solenoid valves
7. Steering cylinder
3. Priority valve
Joystick steering/mini-wheel, function

description

5 Steering – Power assisted system 5:5
Joystick control or mini-wheel steering means that the machine is

controlled by an electrical control in the left armrest of the operator's
seat. The electrical control sends signals to the control system. The
steering cylinder is pressurized by a control valve that is also controlled
by the control system.
Joystick control and mini-wheel function in the same way, the difference
is in the design of the control.
NOTE
The standard steering wheel alway has priority over joystick control
or mini-wheel steering. Joystick control or mini-wheel steering are
disabled as soon as a steering wheel movement is made.
D
D790-1 5
D790-3 6
ECU792 7
3 D790-2
4
D
D 8
C 9 10 11 12
EF
P Ps P
LS Ts T
2
T
LSO CL CR L R
LSP1
13
1. Hydraulic oil pump 2 6. Switch joystick or Switch mini-wheel 014500

2. Servo valve load handling and steering 7. Steering wheel
Including shuttle valves, pressure d=reducers and 8. Sensor steering column (B770)
solenoid valves
9. Priority valve
3. Control unit, steering (ECU 792)
10. Solenoid valve, steering (Y615)
4. Control unit KIT (D790-2)
11. Steering control valve
12. Steering valve
Control unit cab option (D790-3) (machines with
mini-wheel and combi attachment) 13. Steering cylinder

5:6 5 Steering – Power assisted system
Power assisted system, component position
3
2
1 4
013970
1. Servo valve load handling and steering 4. Steering cylinder
Including shuttle valves, pressure d=reducers and 5. Steering valve
solenoid valves
6. Hydraulic oil pump 2
2. Steering control valve
3. Priority valve

5 Steering – Sensor steering wheel reading 5:7
1 2 3
5
6
014501
Electric components
1. Sensor steering wheel reading (B770) 5. Control unit, steering (ECU 792)
2. Control unit KIT (D790-2) 6. Control unit cab option (D790-3)
3. Switch activate joystick or mini-wheel (S113) Only on machines with both combi attachment and
mini-wheel or joystick steering
Joystick or mini-wheel (R825)
4. Solenoid valve, steering (Y615)
5.2.12 Sensor steering wheel reading

Sensor steering wheel reading, checking
1 (product option mini-wheel or joystick steering)

2
Check that the joystick control and mini-wheel disconnect when the
steering wheel is turned.
Also check that the sensor for the steering wheel reading is secure in
its bracket and that the multi-function levers are secure by unfastening
the bottom of the steering wheel panel.
002628
1. Indicator ring
2. Sensor steering wheel reading (B770)

5:8

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

6:2

6 Suspension – Suspension 6:3
6 Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the driveline/axle, see section 3 Driveline/Axle, group3.3 Drive axle.

6:4 6 Suspension – Suspension
6.2 Suspension
Suspension, description
The steering axle cradle is mounted to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journaled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journaled wheel hubs where
the wheels are mounted.
Suspension, component location

Suspension refers to:
1 2 3 4 5 6 7 8
• Steering axle cradle
• Steering spindle
• Wheel hub
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front suspension
6. Steering cylinder
7. Rear suspension
8. Counterweight
6.2.1 Steering axle cradle
Steering axle cradle, checking
1 Machine in service position, see section B Safety, with transverse

wheels.

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

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

3 Measure with feeler gauge between axial bearing and axial
washer. Max. clearance: 1.5 mm.

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

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

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

6 Suspension – Tyres and rims 6:7
6.3 Tyres and rims

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

6:8 6 Suspension – Tyres and rims
CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
When removing drive wheels, make sure that the
wheels are secured when removing the spacer rings.
If the wheels move they may move the spacer rings,
which may result in crushing injuries.
When installing drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,
pieces of wood, metal filings, etc.
Check if tyre wear is abnormal, this could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.
Tyre and rim system, description

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

Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.

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

• Check that the lock ring and lugs are installed correctly.
• Check that there are no cracks in the rims' parts.
In case of damage, the tyre and rim must be removed and
checked.
012021
1. Lock ring
2. Rim flange
3. Rim bead seat taper
2 Check the air pressure in the tyres, see section Tyres, inflating,
page 6:15.
The pressure must be 1.0 MPa, inflate if necessary.
3 Check the tyres.
• Check for uneven and fast wear, this is caused by mechanical
defects such as, e.g., uneven brake action. Make sure that
such defects are repaired immediately.
• Remove penetrating objects such as crushed glass, pieces of
wood, metal filings, etc.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change, page 6:16.
4 If the tyres and rims have no defects, check-tighten the wheel nuts.
Tighten crosswise to a torque of:
• 400 Nm oiled screw.
000384
Examples: The figure shows inflation of drive wheel.

Tyre and rim system, removing and fitting (drive

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

a) Unscrewing the valve and releasing the air.
014571
b) If this does not work, undo the valve in the rim and release the air.
014573

c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Loosen the wheel nuts.
5 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
005124
6 Remove the nuts, washers and clamps.

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

9 Secure the inner drive wheel with lifting equipment.

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

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

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

a) Unscrewing the valve and releasing the air.
014571
b) If this does not work, undo the valve in the rim and release the air.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123

4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove wheel nuts and clamps.
6 Remove the wheel and position it safely so that it does not fall or
move.
005124
Installing
7 Fit the wheel.
8 Install clamps and wheel nuts. Tighten the wheel nuts crosswise
successively with increasing torque to 400 Nm oiled screw.
9 Inflate the tyre, see Tyres, inflating, page 6:15.
10 Lower the machine and remove the jack.
11 Test-drive the machine and check that the wheels are secure.
12 Check-tighten the wheel nuts crosswise to a torque of 400 Nm.
000383

6 Suspension – Tyres 6:15
6.3.1 Tyres
Tyres, inflating
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must
be dismantled and the rim checked for damage.
Never install rim components by striking with a
hammer while inflating. Never strike fully or partly
inflated tyres or rim sets.
Never inflate tyres before all parts are in place.
Wheels shall be inflated on the machine or in a
000384
protective device, designed and dimensioned so that

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

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

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

6:16 6 Suspension – Rim
Tyre, change
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre company.
Check the rim in connection with tyre change, see Rim, check, page
6:16.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimize risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and size.
Overdimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
1 Dismantle the rim, see Tyre, change, page 6:16.
2 Carefully clean the outside of the rim edge with a steel brush.
001703
3 Measure wear after the lock ring.

The lock ring's wear on the tyre bead often gives a mark, A in the
figure. The mark occurs between the lock ring's ends.
Measure wear depth at point A using a steel ruler and sliding
gauge. If wear exceeds 0.5 mm then the wheel rim, lock ring and
the tapered rim must be discarded and replaced with new parts.
Max 0,5 mm
001715

6 Suspension – Rim 6:17
4 Check the rim's diameter.

Measure the rim edge's circumference (O) with a measuring tape
and calculate the diameter (D). [D = Circumference (O) / 3.14]
Compare the value of the diameter with specified min.
measurement. If diameter is smaller, then the wheel rim, lock
ring, and the tapered rim must be discarded and replaced with
new parts.
D Information about min. diameter can be obtained from Cargotec.
O
001701
O. Circumference
D. Diameter
5 Check for damage in the areas with high stress concentration.

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

1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic powder and the following equipment:
001703
• Equipment: Yoke Tiede

• Method:
Rim a Alternating current AC
b Contrast colour
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
001704
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
Rim any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.

6:18 6 Suspension – Rim
6 Visually inspect the area.

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

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .....................................................................................................7:3
7.2 Lifting/lowering .................................................................................................7:4
7.2.2 Servo filter ...................................................................................................7:7
7.2.3 Pressure reducer.........................................................................................7:9
7.3 Extension .......................................................................................................7:10
7.3.10 Lift boom ...................................................................................................7:12
7.4 Side shift ........................................................................................................7:14
7.4.6 Side shift frame .........................................................................................7:16
7.4.7 Main beam attachment..............................................................................7:17
7.5 Spreading.......................................................................................................7:18
7.5.6 Spreading motor........................................................................................7:22
7.5.7 Spreading chains ......................................................................................7:23
7.5.8 Spreader beam .........................................................................................7:26
7.6 Rotation..........................................................................................................7:28
7.6.6 Rotation motor unit ....................................................................................7:31
7.7 Tilt ..................................................................................................................7:32
7.8 Levelling.........................................................................................................7:37
7.9 Load carrier....................................................................................................7:41
7.9.1 Twistlocks ..................................................................................................7:41
7.9.2 Lift legs ......................................................................................................7:50
7.10 Other functions...............................................................................................7:62
7.10.1 Support jacks ............................................................................................7:62
7.10.2 Weight indicator.........................................................................................7:63
7.10.3 Container counter......................................................................................7:67
7.10.4 Synchronised lift ........................................................................................7:68

7:2

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The function load handling refers to, e.g. to lift, lower, rotate, angle
or hold loads. Load handling also includes help functions to handle
loads, e.g. support jacks.
Load handling is divided into different sub-functions.
001109
• Lifting/lowering
• Extension
Lifting/lowering
• Side shift
• Spreading
• Rotation
• Tilt
001110
• Levelling
Extension • Load carrying (twistlocks and lift legs)
• Auxiliaries (e.g. support jacks)
Load handling is primarily controlled with the control lever while

certain functions have separate switches.
001113
Side shift
001114
Spreading
001115
Rotation
001116
Tilt
001117
Levelling

7:4 7 Load handling – Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, general
Damping
Lift and lower means to angle the boom up and down so that the
attachment is lifted and lowered. The lift boom is angled by two
lift cylinders that are pressurized by Control valve lift, lower and
extension. The lift function is controlled with the control lever (S815).
Damping
001109
Damping means that the speed of functions is reduced automatically
close to end-positions. This entails that mechanical parts are exposed
to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When

damping is activated, the relevant control unit reduces the control
current to the solenoid valve for the relevant function.
As an option the machine can be equipped with sensors on the

attachment that activate damping when the attachment approaches
a container.
Regeneration
Regeneration
1 2
To increase speed when lifting, oil from the rod side (2) is re-used
for the piston side (1), this is called regeneration. Engagement of
regeneration is controlled by the control system.
000455

7 Load handling – Lifting/lowering 7:5
Lifting/lowering, function description

Condition Reference value
Control switch Not activated
Twistlocks Locked or unlocked, not intermediate position
Overload system Boom up: passive
Boom down: passive or bypass activated
Contact Boom down: no alignment
D
D
1
2 20
D790-1 D791-1
D797-F D797-R D
D 3 18
>°
4 D 12 16 17 19
11
PSS PSL
5 Pa
PP
A1 VA
C-M 14
P C-
B1 T
C+
LS P D
10 C+M
Pa
C 6
A
15
H LSM 13
P LSP3X LSP1
EF
P 9
C
7 8
013984
1. Control lever (S815-P1) 12. Servo valve blocking right (Y6001) and Servo valve
blocking left (Y6002)
13. Valve block, lift cylinder
14. Lift cylinder
4. Servo valve lift (Y6005) or Servo valve lower (Y6004)
15. Sensor hydraulic pressure lift cylinder piston side
5. Control valve lift, lower and extension
left (B768-12)
6. Servo valve load handling and steering
16. Servo valve regeneration right (Y6051) and Servo
Including shuttle valves, pressure d=reducers and valve regeneration left (Y6052)
solenoid valves
17. Sensor boom angle (B771)
19. Sensor damping attachment (B769)
9. Priority valve
20. Control unit attachment (D791-1)
10. Accumulator
11. Servo filter

7:6 7 Load handling – Lifting/lowering
Lifting/lowering, component position
2 3 4
20
19
5
16 10 6
18 15
17
11
12 14 7
013986
13 8 9
1. Hydraulic oil pump 1-2 10. Control valve lift, lower and extension
2. Accumulator servo circuit 11. Servo valve boom out (Y6006)
3. Test outlet servo pressure 12. Servo valve boom in (Y6007)
4. Servo valve load handling and steering 13. Servo valve lower (Y6004)
Including shuttle valves, pressure d=reducers and 14. Servo valve lift (Y6004)
solenoid valves
15. Servo filter
5. Solenoid valve pump unloading extension in (Y6062)
16. Pressure sensor piston side [C+M] (B768-10) or
6. Load signal to hydraulic oil pump 2 (LSP1) (B768-12)
7. Load signal to hydraulic oil pump 1 (LSP3). Used for 17. Servo valve blocking (Y6001) or (Y6002)
machines with hydraulic cab movement .
18. Pressure sensor rod side [C-M] (B768-L11) or
8. Load signal to hydraulic oil pump 1 (LSP3X). Used (B768-13)
for machines without hydraulic cab movement.
19. Regeneration servo valve (Y6051) or (Y6052)
9. Load signal from control valve lift, lower and
extension (LSM) 20. Valve block, lift cylinder

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

2. Inner boom 7. Lift cylinder
3. Tilt cylinder right side 8. Mounting, lift cylinder
4. Mounting, attachment 9. Rear boom mounting
5. Tilt cylinder left side
Sensor boom angle
See Maintenance manual section 8 Control system, group 8.2.1

Overload system.
7.2.2 Servo filter
Servo filter, change
NOTE
Safety.

Safety.
3 Turn the start key to position 0 and turn off the system voltage.
4 Clean the outside of the filter housing and filter holder.

5 Remove the filter holder and remove the cartridge downward.
6 Clean the inside of the filter holder.
7 Place the new cartridge in the filter holder.

7:8 7 Load handling – Servo filter
8 Check that the O-ring on the filter holder is intact and in place.
9 Fit the filter and filter holder.
NOTE
11 Close relief valve top lift.
CAUTION
010475
engine is started.
Relief valve top lift, figure shows closed valve.
12 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The oil
should be in the middle of the level glass. Top up as needed, for
quality see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.

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

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

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

pressure reducer.
013987
5 Start the engine and check the servo pressure. Compare to the
pressure plate.
MPa Turn the steering wheel or activate a load handling function in
order to activate the hydraulic oil pumps. The servo pressure is
higher than the standby pressure of the hydraulic oil pumps.
MPa
MPa
MPa MPa MPa

MPa
MPa
MPa MPa
001029
920643.0024
The appearance of the pressure plate may vary but the

symbols are the same.

7:10 7 Load handling – Extension
7.3 Extension
Extension, general
Damping
Extension means to slide the inner boom in and out in the outer boom.
The inner boom is pushed in and out by the extension cylinder which
is pressurized by Control valve, lift, lower, and extension. Extension is
controlled with the Control lever (S815).
001110
Damping

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

7 Load handling – Extension 7:11
Extension, function description

Overload system Boom out: passive
D
1
2
D790-1
Pa 17
D797-F D797-R
3 13 D
D
D
4 14 18 m
12 PS PL
5 19
A1 VA 15
PP A1 VA
16
C-
P B1 VB C+
LS P D
6
11 D
C 7
A
H LSM
P LSP3X LSP1
EF
P 10
C
8 9
013988
1. Control lever (S815-P2) 10. Priority valve
2. Control unit cab (D790-1) 11. Accumulator servo pressure
3. Control unit, frame front (D797-F) 12. Servo filter
4. Servo valve, boom out (Y6006) or Servo valve, boom 13. Control unit frame rear (D797-R)
in (Y6007)
14. Servo valve blocking extension (Y6050)
5. Control valve lift, lower and extension
15. Valve block extension cylinder
6. Valve block pump unloading (cut-out)
16. Extension cylinder
17. Sensor, hydraulic pressure lift cylinder (B768-12)
Including shuttle valves, pressure d=reducers and
18. Servo valve regeneration (Y6046)
solenoid valves
19. Sensor boom length (B777)

7:12 7 Load handling – Lift boom
Extension, component location

Hydraulic oil pump, Servo filter, Servo valve with pressure reducer, relief valves and shuttle valves, Accumulator servo circuit, Control valve lift, lower and extension, Extension cylinder, Lift boom
Hydraulic oil pump, Servo filter, Servo valve with pressure
1
reducer, relief valves and shuttle valves, Accumulator
7 servo circuit, Control valve lift, lower and extension,
2 Extension cylinder, Lift boom
6 See Lifting/lowering, component position, page 7:6.

3
Valve block extension cylinder
5 1. Connection rod side [C-]
4 2. Drain [D]
3. Servo valve regeneration (Y6046)
4. Connection control valve [VB]
5. Connection control valve [VA]
6. Connection control valve [VA]
7. Servo valve blocking (Y6050)
000474
Valve block extension cylinder
Sensor boom length
See section 8 Control system, group 8.2.1 Overload system.
7.3.10 Lift boom
Slide plates lift boom, checking
NOTE
When adjusting side-mounted slide plates, it is important to check
the clearance for the whole boom's stroke.
1 Place the boom in the lowest position (fully retracted).

7 Load handling – Lift boom 7:13
2 Check wear of the side-mounted slide plates at the front edge

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

NOTE
2. Lower slide plates The inner boom must be centred in the outer boom.
4 Check thickness of the lower slide plates at the front edge of the
lift boom. If needed, remove the slide plate and measure the
thickness.
5 Check the clearance between the boom and stop at the leading
edge/top edge of the boom, clearance must be max. 3 mm.
Adjust the slide plates with spacer plates if needed.
6 Check the wear of the lower and side-mounted slide plates at the
rear edge of the lift boom. If needed, remove the slide plate and
measure the thickness.
NOTE
If the slide plate's thickness is less than 25 mm, the slide plate
may work loose from the bracket, which may result in boom
damage.
7 Check the clearance between the boom and slide plate, clearance
should be 1 mm. Adjust with spacer plates if required.
8 Check thickness of the upper slide plates at the rear edge of the
lift boom. If needed, remove the slide plate and measure the
1. Upper glide plates thickness.
2. Side-mounted slide plates Thickness should be at least 15 mm.
3. Lower slide plates

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

Side shift, general
Sideshift means moving the attachment sideways. The attachment
can be sideshifted ± 800 mm from the middle position.
Control valve attachment pressurizes the sideshift cylinders that push
001113
the attachment's main beam in relation to the lift boom. Sideshifting is
controlled with the Control lever (S815).
Side shift, function description

2
D790-1
D797-R D791-1
3 7
D D
8
C
P1 A
10
T1 B
5 4
PT T 9
LSP3X
6
013989
1. Control lever (S815-T1.1) 6. Hydraulic oil pump

2. Control unit cab (D790-1) 7. Control unit attachment (D791-1)
3. Control unit frame rear (D797-R) 8. Servo valve, side shift left (Y6020) or Servo valve
4. Solenoid valve, engagement of hydraulics for top lift side shift right (Y6021)
(Y6003) 9. Control valve attachment
5. Servo valve load handling and steering 10. Side shift cylinder
solenoid valves
Side shift, component position

Hydraulic oil pump, Shuttle valve
See Lifting/lowering, component position, page 7:6.

7 Load handling – Side shift 7:15
1 2 11
10
9
8
7
6
4
20 12
13
14
22 15
21
16
013990
19 18 17
1. Servo valve load handling and steering 10. Solenoid valve spreading (Y6018 and Y6019)
Including shuttle valves, pressure d=reducers and 11. Solenoid valve twistlocks (Y6039) and (Y6040)
solenoid valves
12. Side shift frame
2. Servo pressure from hydraulic oil pump 2 (PT)
13. Side shift cylinder
3. Solenoid valve, engagement of hydraulics for top lift
14. Main beam attachment
(Y6003)
15. Position sensor spreading (B769 and B777-3)
4. Relief valve, attachment
16. Sensor contact (B7204L/R and B7205L/R)
NOTE 17. Twistlock
The figure shows closed valve. The machine is 18. Twistlocks sensor (B7202L/R and B7203L/R)
supplied with the valve in the open position. 19. Lock cylinder twistlocks
5. Control valve attachment 20. Spreader boom
6. Solenoid valve, levelling (Y6035 and Y6036) 21. Load signal to hydraulic oil pump 2 (LSP3). Used for
machines with hydraulic cab movement .
7. Solenoid valve tilt (Y6010 and Y6011)
22. Load signal to hydraulic oil pump 2 (LSP3X). Used
8. Solenoid valve rotation (Y6008 and Y6009) for machines without hydraulic cab movement.
9. Solenoid valve side shift (Y6020 and Y6021)

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

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

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

plate.
Lower slide plates side shift frame, checking

1 Position axle stands or similar under the attachment's spreader
booms and lower the attachment the stands so that the side shift
frame's lower slide plates are released.
2 Turn off the engine and turn off the main electric power.
3 Place spacers between the crossmember and the attachment's

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

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

Take the strain off the lower glide plates by lifting the spreader
beam at the outside edge or by using wedges to change the
spreader beam's position on the attachment's main beam.
4 Remove the attaching bolts from the slide plate console.
5 Remove the slide plate's guide bolts.
6 Pull out the slide plate together with spacer plates and console.
7 Measure the thickness of the slide plate, replace if needed.
NOTE
The thickness of the slide plate should be at least 10 mm.
8 Place the slide plate in the correct position.

Check the clearance between spreader beam and glide plate.
Clearance should be max. 1 mm with all slide plates installed.
Fit or remove spacer plates until the distance is correct.
NOTE
Excessive clearance may result in damage to the spreader
beam during load handling.
9 Install the slide plate console.

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

7:18 7 Load handling – Spreading
7.5 Spreading
Spreading, general
Damping
Spreading means changing the width between the twistlocks.
Spreading has two 20 and 40 foot stops, other stops of different
distances are available as option, e.g. 30 foot stop.
001114
Control valve attachment pressurizes Valve block spreader motor that
controls pressure to the spreader motor. The spreader motor pulls the
spreader chains which pull out the spreader booms.
Spreading is controlled with the Control lever (S815). Inductive

position sensors indicate the spreader units' position.
Damping
close to end-positions. Three seconds after damping has been
activated, the function is cancelled. This entails that mechanical parts
are exposed to less stress when stopping in end-positions.


7 Load handling – Spreading 7:19
Spreading, function description

Twistlocks Unlocked or bypass activated
Overload system Passive
+ 2
D790-1
D
D797-R D791-1
3 7
D
8 D
C
12
P1 A
11
5 4 T1 B
PT T 9 10
LSP3X
013991
1. Control lever (S815-T1.x and S815-T4) 6. Hydraulic oil pump
2. Control unit cab (D790-1) 7. Control unit cab (D790-1)
3. Control unit frame rear (D797-R) 8. Servo valve for spreading out (Y6018) or Servo valve
for spreading in (Y6019)
5. Servo valve load handling and steering 10. Valve block spreading cylinder
Including shuttle valves, pressure d=reducers and 11. Hydraulic motor spreading
solenoid valves 12. End position sensor 20'-40' (B769)

7:20 7 Load handling – Spreading
30-foot stop, function description
30 foot stop is an option for spreading that is activated using the Switch
stop at 30' or 35'. When 30 foot stop is activated spreading stops at
30 foot. Two inductive position sensors indicate the position of the
spreading beams and activate damping. At 30 foot stop, two sensors
are used to control the stop.

2 D
1
35
30-
+
3
D790-1
D
D
D791-1
5
D
7
4 6
004864
1. Control lever (S815-T1.2 and S815-T4) 5. Control unit attachment (D791-1)
2. Switch for stop at 30'-35' (S1004) 6. End position sensor 20'-40' (B769)
3. Control unit cab (D790-1) 7. Servo valve for spreading out (Y6018) or Servo valve
4. Sensor, position 30' (B777-3)

7 Load handling – Spreading 7:21
Automatic spreading 20-40 foot, function

description
Automatic spreading 20 "-40" is an option for spreading that is

activated with Switch automatic spread 20 "-40". When the switch is
activated, spreading automatically switches to the next end position
when spreading is activated using the control lever. The buzzer on the
boom nose sounds during automatic spreading.
If the machine is also equipped with 30 foot stop and this is activated,
spreading stops at 30 foot. Activate spreading again to go to the next
position.
Automatic spreading works for both spreading in and spreading out.

Doors Closed
Parking brake Released
2 D
1
+
3
D790-1
D
D791-1
5 D
D
D
8 7 4 6
006422
1. Control lever (S815-T1.2 and S815-T4) 6. End position sensor 20'-40' (B769)
2. Switch automatic spreading 20'-40' (S1012) 7. Servo valve for spreading out (Y6018) or Servo valve
8. Buzzer automatic spreading
4. Sensor, position 30' (B777-3)
Spreading, component position
Valve block top lift hydraulics, Control valve attachment,

Spreading beam, Main beam attachment, Relief valve
attachment, Servo valve load handling and steering.
See Side shift, component position, page 7:14.

7:22 7 Load handling – Spreading motor
1 2 3 4 5 6 7
004904
1. Indicator plate 20' 5. Indicator plate 40'
2. Sensor for 20' and 40' damping and 30' stop (B769) 6. Spreading motor
3. Sensor damping 30', Stop automatic spreading 7. Spreading chains
20"-40" (B777-3)
4. Indicator plate, 30' or 35'
7.5.6 Spreading motor
Oil spreading motor unit, changing
NOTE
Safety.

7 Load handling – Spreading chains 7:23
1 Remove the drain plug.

2 Remove and clean the sight-glass.
3 Fit the drain plug when all the oil has drained.
NOTE
1. Filling point
2. Level glass
3. Drain plug
4 Top up the oil through the filling point (position 1) until the level is
in the middle of the sight glass as shown. For volume and quality,
see section F F Technical data.
013674
7.5.7 Spreading chains
Spreading chains, checking
1 Before adjusting, the clearance between the slide plates and

extension beams must be checked, as otherwise the chain's
mounts may be damaged, see Glide plates extension beam,
checking and adjusting, page 7:26.
20-foot position
2 Start the engine, move in the spreading to the 20-foot position
and turn off the engine.
3 Check that both spreading beams move toward the 20-foot stop
and that the distance between the spreading beam and the
spreading motor's mount is at least 3 mm.

7:24 7 Load handling – Spreading chains
4 Check the C-C measurement between the twistlocks.

C-C 20 foot: 5853±3 mm.
If the 20-foot setting is correct, go to step 8.
5 If necessary, adjust the distance by moving the washers between

high and left 20-foot stop. The number of washers must not be
changed.
NOTE
Note the distance that the stop is adjusted to.
Move out the spreading a bit in order to move the washers.
CAUTION
20-foot stop
Incorrect chain tension.
Risk of damage to the attachment.
If the 20-foot stop is adjusted, the spreader chains must
be adjusted by an equal amount.
6 Remove the cover plates on the attachment's main beam.
7 If the 20-foot stop is adjusted, the spreader chains must be

adjusted by an equal amount, see step 14.
NOTE
Check the vertical position of the chain tensioner to ensure that
the chain runs straight against the chain wheel.
005105

7 Load handling – Spreading chains 7:25
40-foot position
8 Start the engine and move out the spreading to the 40-foot position
and turn off the engine.
9 Check the C-C measurement between the twistlocks.
C-C 40 foot: 11985±3 mm.
If the 20-foot setting is correct, go to step 11.
10 If needed, adjust the 40-foot stop.
005106
40-foot stop
100 N Chain tension

815 m m 11 Start the engine and move the spreading out to the 40-foot
postition.
12 Wait 2 minutes and then check the tension of the chains.
13 Use a pull scale and measure how far the chain moves when
pulled out with a force of 100 N at 815 mm in from the main
beam's inner reinforcement collar, as shown in the figure.
Standard attachment: X = 8-13 mm.
Overheight attachment: X = 5-6 mm.
815m m
100 N
0 N
010486
100 N
X

7:26 7 Load handling – Spreader beam
14 If needed, adjust the tension of the chains.

Start the engine and run out the spreading until the chain
tensioners are visible in the inspection holes (approx. 250 mm).
Adjust the chains, hold the chain tensioner with a box-end wrench
so that the chain is not twisted while adjusting.
NOTE
Adjust the chain on the chain tightener max 2 mm at a time.
15 Repeat steps 11–14 until the tension of the chains is correct.

16
If the machine is equipped with 30- or 35-foot stop.
Start the engine and move the spreading out to the 30- or 35-
foot position. Switch off the engine and check the C-C dimension
between the twistlocks.
C-C 30 foot: 8918±3 mm
C-C 35 foot: 10488±3 mm
IMPORTANT
Check the distance of the stop from both 20" and 40".
17 Apply lubricating grease to the spreading chains.

18 Fit the cover plates onto the attachment's main beam.
7.5.8 Spreader beam
Glide plates extension beam, checking and

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

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

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

main beam.

7 Load handling – Spreader beam 7:27
4 Remove the attaching bolts from the slide plate console.

5 Remove the slide plate's guide bolts.
6 Pull out the slide plate together with spacer plates and console.
7 Measure the thickness of the slide plate, replace if needed.
NOTE
The thickness of the slide plate should be at least 10 mm.
8 Place the slide plate in the correct position.

Check the clearance between extension beam and slide plate.
Clearance should be less than 1 mm with all slide plates installed.
Use a spacer plate to adjust the clearance.
9 Install the slide plate console.
10 Install the slide plate guide bolt.
11 Lubricate the slide surface on the extension beam.
12 Start the machine and check the spreader's function. Try to lift
a container and check the extension beams' clearance in the
attachment's main beam.
The diagram shows inner slide plates in the attachment's

main beam.

7:28 7 Load handling – Rotation
7.6 Rotation
Rotation, general
The attachment can be rotated +195º -105º in relation to the machine.
Control valve attachment pressurizes Valve block rotation motor.

Valve block rotation motor controls pressure to the rotation motors
001115
that turn the attachment. Rotation is controlled with the Control lever
(S815). The voltage signal controls direction and speed (clockwise or
counter-clockwise).
Rotation, function description

1
2
D790-1
D797-R D791-1 D
3 7
D
8
C
10
P1 A
11
5 4 T1 B
PT T
LSP3X 9
6
013992
1. Control lever (S815-P3) 6. Hydraulic oil pump

3. Control unit frame rear (D797-R) 8. Servo valve, rotation clockwise (Y6008) or Servo
valve, rotation anticlockwise (Y6009)
5. Servo valve load handling and steering 10. Valve block hydraulic motor
Including shuttle valves, pressure d=reducers and 11. Rotation motor
solenoid valves

7 Load handling – Rotation 7:29
Rotation stop, function description
Rotation stop is an option to the rotation function that allows the

rotation to stop at ± 25° rotation from the centre position. In order to
turn the attachment more, the function must be bypassed using the
rotation stop switch (S1014).
Rotation stop uses a position sensor that indicates when rotation is

±25°, this is used to stop the rotation.

2 1 D
3
D790-1
D
D797-R D791-1
7 6
D
4 5
004865
± 25˚
1. Switch rotation stop (S1014) 5. Sensor rotation stop (B7225)

2. Control lever (S815-P3) 6. Control unit attachment (D791-1)
3. Control unit cab (D790-1) 7. Control unit frame rear (D797-R)
4. Servo valve, rotation clockwise (Y6008) or Servo
valve, rotation anticlockwise (Y6009)
Rotation, component location

Spreading beam, Main beam attachment, Relief valve
attachment, Servo valve load handling and steering.
See Side shift, component position, page 7:14.

7:30 7 Load handling – Rotation
1
1
2
2
3 3
4 4
6 5
004903
1. Hydraulic motor rotation 5. Rotation yoke
2. Disc brake 6. Ring gear
3. Planetary gear 7. Side shift frame
4. Gear 8. Sensor rotation stop (B7225)

7 Load handling – Rotation motor unit 7:31
7.6.6 Rotation motor unit
Oil rotation motor unit, changing
NOTE
Safety.
1 Remove the planetary gear's drain plug (position 6) and lead the
oil down into the container.
Remove the planetary gear's filler plug (position 3) for faster
draining.
2 Remove and clean the planetary gear's level glass (position 5)
while the oil drains.
3 Fit the level glass and drain plug.
1. Level glass, disc brake

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

7:32 7 Load handling – Tilt
7.7 Tilt
Tilt, description
The rotation yoke's suspension is jointed and has two cross connected
hydraulic cylinders that dampen the swings. The cylinders are
pressurised by the hydraulic system and joined by a damping block.
001116
There are four versions of tilt:
• Damping
• Damping with tilt lock (Tilt lock)
• Damping with controlled tilt (Controlled tilt)
• Damping with controlled tilt and tilt lock
If the machine is equipped with tilt lock an electrically controlled

blocking valve is used in the damping block.
If the machine is equipped with controlled tilt the hydraulic cylinders

are fed from a special section in the control valve on the attachment.
Tilt damping, function description

Tilt means that the attachment can swing back and forth in the
suspension to the boom so that the load hangs straight during the
whole lifting movement. Tilt damping means that the tilt movement
is counteracted.
001116
The attachment's mounting in the boom is jointed and has two

hydraulic cylinders that dampen the swings. The hydraulic cylinders
are cross-coupled to the damping block tilt. The damping block tilt is
fed with servo pressure from Attachment control valve, this is lead
to the tilt cylinders and creates overpressure in the tilt cylinders.
Adjustable chokes between the connections for piston and rod side in
the damping block create resistance which suppresses tilt movement.
2
C1-
A C2+
C
B C1+
C2- 3
1
000461

2. Damping block tilt
3. Tilt cylinders

7 Load handling – Tilt 7:33
Tilt lock, general
Tilt lock is an option for tilt damping that means that the tilt movement
can be locked.
004911
Tilt lock uses two solenoid valves in the damping block. One blocks
the connection between the tilt cylinders and the damping block whilst
Event menu tilt lock the other blocks the supply of servo pressure from the control valve
attachment. Tilt lock is activated by a switch on Control lever (S815).
When tilt lock is activated the machine's speed is limited to max. 5

km/h.
Tilt lock, function description
2
D790-1
D797-R D791-1
3 7
D
D
8
C1-
A C2+
10
B C1+
5 4 C2-
PT T 9
LSP3X
6
013993

3. Control unit frame rear (D797-R) 8. Solenoid valve tilt lock (Y6012)
4. Solenoid valve, engagement of hydraulics for top lift 9. Lock valve
(Y6003)
10. Tilt cylinder
solenoid valves

Tilt control, general
Tilt control is an option for tilt damping and means that attachment
tilting can be controlled within ±2 ° from the straight position, regardless
of boom position or cargo. The tilt angle varies depending on boom
angle and load.
Tilt control is controlled with Control lever (S815). An extra section in

Control valve attachment pressurizes the tilt cylinders through damping
block tilt so that the attachment is angled.
If the machine is equipped with tilt control, tilt lock is also included,
see Tilt lock, general, page 7:33.
Tilt control, function description

D
1
2
D790-1
D791-2
D797-R D791-1
3 D791-4 10
D 7
D D
8 11
C
C1-
P1 A A C2+
13
T1 B B C1+
5 4 C2-
PT T 9 12
LSP3X
6
013994
1. Control lever (S815-P4) 7. Control unit attachment option (D791-2) or Control

unit attachment right leg pair (D791-4)
8. Servo valve tilt out (Y6010) or Servo valve tilt in
(Y6011)
9. Control valve attachment
(Y6003)
11. Solenoid valve tilt lock (Y6012)
solenoid valves 12. Lock valve
6. Hydraulic oil pump 13. Tilt cylinder

7 Load handling – Tilt 7:35
Tilt, component position
Hydraulic oil pump, Shuttle valve, Lift boom

Relief valve attachment, Servo valve load handling and
steering
See Side shift, component position, page 7:14

Damping block tilt, Tilt cylinder
Damping block tilt, Tilt cylinder
1
1. Damping block tilt and Solenoid valve tilt lock (Y6012)
2. Tilt cylinder
2 2
000535
Rotation yoke
See Rotation, component location, page 7:29.
Tilt damping, adjusting
NOTE
Safety.
NOTE
The tilt damping may have to be adjusted after run-in due to
mechanical tolerances.
1 Engine at idle.
2 Lift the boom without load and check that the attachment hangs
horizontally during the whole lifting movement.

3 Adjust tilt damping as necessary by adjusting the screws on the

damping block. Adjust both screws equally.
Clockwise: increase damping.
Counter-clockwise: reduce damping.
4 Lift a loaded container, test drive and brake, check that the
container does not swing uncontrollably. If necessary, adjust
1 damping according to step 3.
5 Start the machine and check that the function is satisfactory.
005350
1. Adjusting screws

7 Load handling – Levelling 7:37
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the attachment is angled in the
horizontal direction. This enables the machine to handle loads on
uneven ground surfaces.
001117
The attachment's main beam is located in the sideshift frame. The
clearance between sideshift frame and the attachment's main beam
allow a movement of approx. 5º, which enables lifting of containers
that lean in relation to the machine. It is the dead weight of the
attachment that adapts the attachment's angle to the container.
Hydraulic levelling, general
Hydraulic levelling means that the sideshift frame is split and the
parts are connected by four hydraulic cylinders. Hydraulic levelling
increases mobility of the attachment. Hydraulic levelling has a passive
position where the attachment floats freely and an active mode where
inclination can be controlled. Levelling can be locked by blocking the
connection to the levelling cylinders.
Passive levelling means that an unloaded attachment lies in a floating

position and adapts itself to the incline of the container to be lifted.
Passive levelling shifts to active levelling as soon as the attachment is
loaded. Two pressure contacts are activated when the pressure on
the rod sides of the levelling cylinders becomes too high.
Active levelling means that inclination is controlled by pressurizing the

001860
hydraulic cylinders. Levelling is controlled using the control lever.
Levelling is monitored by sequence valves, which close when feed

pressure is high enough to bottom all cylinders.

7:38 7 Load handling – Levelling
Hydraulic levelling, function description

1
2
+ D790-1
D791-2 D
D797-R
3 D791-3 7
D D
9 8
C
13
P1 A
5 4 T1 B
PT T 10 11 12
LSP3X
013995
1. Control lever (S815-P1 and S815-T4) 7. Control unit attachment option (D791-2) or Control
unit attachment left leg pair (D791-3)
8. Solenoid valve, levelling (Y6034)
9. Servo valve levelling right (Y6035) or Servo valve
levelling left (Y6036)
(Y6003)
11. Over centre valve
solenoid valves 12. Valve block, levelling cylinder
6. Hydraulic oil pump 13. Levelling cylinder
Levelling block, general
Levelling lock is an option for hydraulic levelling that makes it possible

to lock levelling movement.
004912
Levelling lock uses two solenoid valves in Valve block levelling

cylinder that block pressures to and from the levelling cylinders.
Event menu levelling lock Levelling lock is activated by a switch on Control lever (S815).
When levelling lock is activated the machine's speed is limited to

max. 5 km/h.

7 Load handling – Levelling 7:39
Levelling lock, function description

2
1 D790-1
D791-2
D
D797-F
3 D791-3 7
D
8
C
9
P1 A
5 4 T1 B
PT T
LSP3X
C
6
013996
2. Control unit cab (D790-1) 7. Control unit attachment option (D791-2) or Control
unit attachment left leg pair (D791-3)
8. Solenoid valve, levelling (Y6034)
(Y6003) 9. Levelling cylinders
solenoid valves
Levelling, component location

Relief valve attachment

7:40 7 Load handling – Levelling
Over-centre valve levelling Valve block levelling cylinders, Levelling cylinders, Sideshift frame
Over-centre valve levelling Valve block levelling cylinders,
Levelling cylinders, Sideshift frame
3 4
2. Rotation yoke
2 3. Valve block levelling cylinders with Solenoid valve levelling
1 5 (Y6034)
4. Over-centre valve, levelling
5. Levelling cylinder
6. Side shift frame
7. Side shift cylinder
003604
7 6

7 Load handling – Load carrier 7:41
7.9 Load carrier

Load carrier, description
Load carrier means holding any loads. There are several ways of
holding loads.
• Twistlocks, rotation lift pins that hold the load in oval holes in the
corners on the load.
Used separately on top lifts attachment, in combination with lift
legs, combi attachment.
• Lift legs, hold the load with legs that grab around and under the
load.
Lift legs are used in combination with twistlocks on combi
attachment or separately, bottom lift.
7.9.1 Twistlocks
Twistlocks, general
The container is held in place on the attachment with four twistlocks.
Twistlocks are controlled with the control lever and Switch twistlocks.
A section in Control valve attachment pressurizes two hydraulic
cylinders connected in parallel, one in each spreader boom. Each
004868
hydraulic cylinder affects a linkage that turns two twistlocks. Four

position sensors, two in each spreader boom, sense the position of
the linkage and indicate if twistlocks are open or locked. Control lights
on the boom and in the cab show status for twistlocks.
Four position sensors, one at each twistlock, indicate when the

attachment has alignment with the container. This is used to control
when twistlocks can be activated. An indicator light on the boom
and one in the cab indicate when the attachment has full alignment.
An event menu shows which twistlocks have alignment (1 - 4). To
activate twistlocks, alignment is required at all four twistlocks.
When there is no alignment at any twistlock then Switch open

twistlocks on the control lever activates the horn.

7:42 7 Load handling – Twistlocks
Twistlocks, function description

Contact Full contact or bypass activated
D
2 1
5 6
D790-1 D790-2 D
D 3
D797-R D791-1
7 4
D D
C
11 14
D
P1 A
T1 B 13
9 8
PT T
LSP3X
12
10
013997
1. Switch lock twistlocks (S1003) 9. Servo valve load handling and steering
2. Control lever (S815-T2) Including shuttle valves, pressure d=reducers and
solenoid valves
3. Sensor contact left front (7202L),
10. Hydraulic oil pump
Sensor contact right front (7202R),
11. Servo valve, open twistlocks (Y6039) or Servo valve,
Sensor contact left rear (Y7203L) and
lock twistlocks (Y6040)
Sensor contact right rear (Y7203R)
13. Lock cylinder
14. Sensor for unlocked twistlocks (B7204) or Sensor for
6. Control unit KIT (D790-2) locked twistlocks (B7205)
(Y6003)

7 Load handling – Twistlocks 7:43
Twistlocks, component position


Lock cylinder twistlocks, Twistlocks, Sensor alignment,
Sensor twistlocks, relief valve attachment, Servo valve load
handling and steering
Overheight legs, general
Overheight legs is an option for twistlocks enabling lift of containers

with parts higher than the twistlock brackets.
006701
Overheight legs is a mechanical extension of twistlocks. The legs

consist of two pairs of legs that lower and retract via hydraulic
cylinders. Overheight legs are controlled by Switch overheight legs
(S1031). A section in the attachment control valve pressurises four
parallel-coupled hydraulic cylinders, two to each pair of legs. Each
cylinder is equipped with an over-centre valve that prevents the legs
from lowering due to their self-weight. Position sensors detect when
the legs are fully retracted. An extra indicator lamp on the boom
illuminates when the legs are fully retracted.
In the legs there are mechanical linkages to rotate twistlocks and

sense alignment at each twistlock.

Overheight legs, function description

Twistlocks Open
13
D
1
2
D790-1
D
D797-R D791-2 7
3
D
D
8 12
D
C
P1
A
5 4 B 11
T1
PT T
10
LSP3X 9
C
6
013998
1. Switch overheight legs (S1031) 7. Control unit attachment option (D791-2)
2. Control unit cab (D790-1) 8. Servo valve overheight legs up (Y6070) or Servo
valve overheight legs down (Y6071)
(Y6003) 10. Over centre valve
5. Servo valve load handling and steering 11. Hydraulic cylinder overheight legs
Including shuttle valves, pressure d=reducers and 12. Sensor overheight legs up left (B7231-L) or Sensor
solenoid valves overheight legs up right (B7231-R)
6. Hydraulic oil pump 13. Indicator light overheight legs up (H5001)

Overheight legs, component position
3 4
1 5
2
7
1 9
006703
10
1. Contact pin alignment 6. Hydraulic cylinder overheight legs

2. Rotation bar twistlocks 7. Over centre valve
3. Control unit attachment option (D791-2) 8. Sensor overheight legs up left (B7231L) and Sensor
overheight legs up right (B7231R)
4. Indicator light overheight legs up (H5001)
9. Overheight legs
5. Solenoid valve Overheight legs up (Y6070) and
Solenoid valve Overheight legs down (Y6071) 10. Twistlocks overheight legs

Relief valve attachment, Servo valve load handling and
steering.

7.9.1.7 Twistlocks
Twistlocks, checking
WARNING
Dropped load.
Fatal danger!
Twistlocks hold the load during load handling and
therefore it is crucial that twistlocks are checked
according to instructions and replaced at the slightest
sign of damage or wear.
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
1 Check that the twistlocks function correctly.

1 Lock and open the twistlocks, check that the indicator lights work,
both in the cab and on the attachment.
2 Clean the twistlocks from any dirt.
3 Under the rubber cover for twistlocks: check pin, link arm and
lock nut.
2
4 Clean the area around sensor contact.
5 5 Press in the alignment pin so that the head is flush with the
spreader beam's underside. Check the distance to sensor
alignment, the distance should be 3-4 mm. Adjust when needed.
NOTE
4 The contact pin should move easily and spring back completely.
000633
3 6 Check that the lock guide and lift pin can move freely.
7 Fit a pry bar between the lift pin (position 4) and the lock guide
1. Lock mechanism (position 5) and check the clearance, max. clearance: 1.5–2 mm.
2. Sensor contact
3. Contact pin
4. Lift pin
5. Lock guide

8 Turn twistlocks to locked position and check wear of the lift pin.
Change the lift pin as needed.
m Max. 4 mm
m
70
.
in
M
002311
Wear limits lift pin.
9 Clean the area around the lubrication body.

10 Grease the lift pin's bearing with universal grease "EP2".
11 Repeat steps 1-10 on all twistlocks.
Twistlocks, checking for cracks
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.
NOTE
Check for cracks shall take place every other year or every 4000
operating hours.
1 Remove the lift pins from the attachment.
NOTE
Twistlocks are heavy, be careful when removing.
2 Check for cracks within the marked area on the lift pins without
causing damage.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
002313
4 Install approved twistlocks.

Area for checking for cracks on lift pin.
NOTE
Use the new attaching nut and spherical bearing.

Twistlocks, checking vertical movement
WARNING
Dropped component.
Risk of crushing, product damage.
Twistlock weighs approx. 30 kg.
1 Check the vertical movement for twistlocks.

1
Press up the lift pin and check that the clearance is 1.5–2 mm.
2 Adjust twistlocks when needed. Step 3-6.
3 Remove the nut (position 1) from the lift pin and dismantle
twistlocks (position 2).
4 Replace the adjusting shim (position 3) with the most suitable from
the adjusting shim kit to obtain correct clearance for the vertical
movement. See Parts catalog for part number of the kit. See Parts
catalog for part number of the kit.
3
5 Assemble twistlocks. Tighten the nut to 700 Nm.
6 Check again the vertical movement for twistlocks.
1,5-2 mm
012582
2
1. Nut
2. Twistlocks
3. Adjusting shims
Twistlocks, checking float position
WARNING
In the event of irregular horizontal movement twistlocks
are exposed to fatigue.
Shortened life of twistlocks.
Check the float position every 500 hours of operation.

1 Check that the tightening torque on the nut (position A) is 700 Nm.
2 Move the lift pin around in the opening and check that the lift pin
A reaches all four corners and that the edges of the lift pin and the
opening are in contact with each other at the same time.
3 Adjust the vertical movement if the float position is not correct.
1 2
3 4
012583
Sensor contact, checking and adjusting

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

7:50 7 Load handling – Lift legs
Sensor twistlocks, checking and adjusting

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

Lift legs, general
1 2 3 2 4 1 1
The lift legs are designed to lift objects by grabbing around the object
with four "legs". To facilitate loading and transport, the front and back
legs can be controlled separately.
The lift legs are controlled with three switches on the dashboard panel.
The lift legs fold up and lower in a predetermined sequence that is

controlled by the machine's control system (the sequence is reversed
for folding up). The position of the legs (steps in sequence) can be
001854
1 2 3 2 3 controlled with the diagnostics menu, see tab 8 Control system, group
8.4.11.1 Combi, menu 14.
Overview, combi attachment
1. Knee
2. Lift legs
3. Lift shoe

7 Load handling – Lift legs 7:51
Operating position
1 2 3 4 5 6 7 6 5 4 3 2 1 Operating position
Operating position is a predefined position on the rear lift legs that
give the load a correct centre of gravity if the machine is driven
forward to the load with the rear legs lowered until contact with the
rear legs is obtained. If the front legs are lowered and grip around the
load in this position, the load's centre of gravity is centred so that
the load does not tilt during lifting. Providing that the load has even
weight distribution.
The function lift legs contains the following components.
001861
• Main beam attachment
• Knee (4 pcs.)
1. Sensor lift leg
• Legs (4 pcs.)
2. Hydraulic cylinder lift leg
• Control valve (2 pcs.)
3. Lift legs
• Control unit (2 pcs.)
4. Knee
• Hydraulic cylinders (8 pcs.)
5. Sensor knee
• Position sensor legs (4 pcs.)
6. Hydraulic cylinder knee and clamp
• Position sensor knee (4 pcs.)
7. Sensor operating position
• Position sensor alignment (4 pcs.)
• Position sensor clamp position (4 pcs.)
• Position sensor operating position (2 pcs.)

Lowering front lift legs, function description

16
17
1 D 19
20
A B A B A B A B A B
T1
D
P1
D
15 18
2
D 3
D791-1 D790-1 D791-4 D
D797-R D791-3 D
4
D 5
9 12
21
P1
D
T1
A B A B A B A B A B
14
13
7 6
PT T
LSP3X 11
C
10
8
013999

1. Switch lowering front legs (S1006) 12. Solenoid valve front legs down left (Y6013L) or Solenoid
valve front legs up left (Y6060L)
13. Hydraulic cylinder leg left front
3. Control unit attachment right leg pair (D791-4)
14. Sensor front leg left (B7219L)
4. Control unit attachment left leg pair (D791-3)
15. Solenoid valve front knee out right (Y6056R) or Solenoid
valve front knee in right (Y6057R)
16. Hydraulic cylinder knee right front
(Y6003)
17. Sensor front knee right (B7217R)
18. Solenoid valve rear leg down right (Y6014R) or Solenoid
valve rear leg up right (Y6061R)
solenoid valves
19. Hydraulic cylinder leg right front
20. Sensor front leg right (B7219R)
9. Solenoid valve front knee out left (Y6056L) or Solenoid
valve front knee in left (Y6057L) 21. Control light front legs down (H580)
10. Hydraulic cylinder knee left front
11. Sensor front knee left (B7217L)

Lowering rear lift legs, function description

27
1 16
25
17
D
19
23
20
A B A B A B A B A B
P1
T1
D
D 18 15 21
2 3
D790-1 D791-4
D797-R D791-3
5 4
D
D 12 9 22
D
P1
T1 A B A B A B A B A B
14
24
13
7 6
PT T 11
LSP3X
26
C
10 28
8
014000

1. Switch rear legs (S1007) 15. Solenoid valve rear knee out right (Y6058R) or Solenoid
valve rear knee in right (Y6059R)
16. Hydraulic cylinder knee right rear
17. Sensor rear knee right (B7218R)
18. Solenoid valve rear leg down right (Y6014R) or Solenoid
valve rear leg up right (Y6061R)
19. Hydraulic cylinder leg right rear
(Y6003)
20. Sensor rear leg right (B7220R)
21. Solenoid valve operating position right (Y6053R)
solenoid valves 22. Solenoid valve operating position left (Y6053L)
8. Hydraulic oil pump 23. Solenoid valve clamp shut right (Y6054R)
9. Solenoid valve rear knee out left (Y6058L) or Solenoid 24. Solenoid valve clamp shut left (Y6054L)
valve rear knee in left (Y6059L)
25. Hydraulic cylinder clamp right rear
10. Hydraulic cylinder knee left rear
26. Hydraulic cylinder clamp left rear
11. Sensor rear knee left (B7218L)
27. Sensor operating position left (B7212L)
12. Solenoid valve rear legs down left (Y6014L) or Solenoid
28. Sensor operating position right (B7212R)
valve rear legs up left (Y6061L)
13. Hydraulic cylinder leg left rear
14. Sensor rear leg left (B7220L)

Clamp with lift legs, function description

Lift legs Lowered

14 13
22 18
16 20
1
P1 B A B A B A B A B A
T1
12
2 3
D790-1 D791-4
23 D797-R D791-3
5 4
P1
T1 A B A B A B A B A B
7 6
PT T
LSP3X
15 19
21 17 11 10
8
1. Switch clamp/release legs (S1008) 12. Solenoid valve clamp shut right (Y6054R) or Solenoid 014001
valve clamp open right (Y6055R)
13. Hydraulic cylinder knee and clamp right front
14. Hydraulic cylinder knee and clamp right rear
15. Sensor clamping position front leg left (B7215L)
16. Sensor clamping position front leg right (B7215R)
(Y6003) 17. Sensor clamping position rear leg left (B7216L)
18. Sensor clamping position rear leg right (B7216R)
19. Sensor alignment front leg left (B7213L)
solenoid valves 20. Sensor alignment front leg right (B7213R)
8. Hydraulic oil pump 21. Sensor alignment rear leg left (B7214L)
9. Solenoid valve clamp shut left (Y6054L) or Solenoid 22. Sensor alignment rear leg right (B7214R)
valve clamp open left (Y6055L) 23. Indicator light alignment left front (H566L), Indicator
light alignment left rear (H567L), Indicator light
10. Hydraulic cylinder knee and clamp left front
alignment right front (H566R) and Indicator light
11. Hydraulic cylinder knee and clamp left rear alignment right rear (H567R).

Lift legs, component position

Main beam attachment, Knee, Hydraulic cylinder knee and clamp, Lift legs, Hydraulic cylinder legs, Lift shoe
Main beam attachment, Knee, Hydraulic cylinder knee and
1 2 3 2 4 1 1 clamp, Lift legs, Hydraulic cylinder legs, Lift shoe
1. Knee
2. Lift legs
3. Lift shoe
001854
1 2 3 2 3
Valve block top lift hydraulics, Relief valve attachment

1
2
3
8 9 8
7
004902
5
1. Control valve lift legs 6. Sensor clamping position (B7215 or B7216)

2. Solenoid valve operating position (Y6053) 7. Sensor alignment (B7213 or B7214)
3. Sensor operating position left (B7212L) or Sensor 8. Hydraulic cylinder lift leg
operating position right (B7212R)
9. Hydraulic cylinder knee and clamp
4. Sensor front legs (B7219) or Sensor rear lift legs
(B7220)
5. Sensor front knee (B7217) or Sensor rear knee
(B7218)

7.9.2.14 Lift shoe
Lift shoe, checking
1 Lower all lift legs.
2 Check that the plate for clamping position and the pin for alignment
move freely and spring back to basic position.
3 Press in the pin for alignment so that the head is flush with the
spreader beam's underside and check that the indicator light
alignment turns on.
NOTE
The contact pin should move easily and spring back completely.
4 Press in the plate for clamping position and check that the plate
moves easily and springs back completely and that indicator light
clamping position turns on.
1 NOTE
The plates for both lift legs (right and left) must be pressed in for
the indicator light to turn on.
3
001857
1. Indicator pin, alignment

2. Indicator pin, clamping position
3. Lift shoe
5 Check that the wear on the lift shoe is within the given parameters
as illustrated. Also check that the lift shoe does not show any signs
Min. 8 mm
of cracks and other external wear. Replace lift shoe as needed.

002312
Wear limits lift shoe.

6 Clean the area around the grease cup.

7 Lubricate the bearings for the clamping position plate with grease.
8 Repeat steps 2-7 on all lift legs.
Lift shoe, checking for cracks
DANGER
Material fatigue, reduced strength.
Fatal danger!
Replace lift shoes that shows signs of cracks, external
damage or lift shoes with more than 10,000 operating
hours.
NOTE
Check for cracks shall take place every other year or every 4000
operating hours.
1 Remove the lift shoes from the lift legs.
NOTE
Lift shoes are heavy, be careful when removing.
2 Check for cracks within the marked area on the lift shoes without
causing damage.
3 Install the lift shoes.
002314
Area for checking for cracks on lift shoe.

7:62 7 Load handling – Other functions
7.10 Other functions

7.10.1 Support jacks
Support jacks, function description
Supporting jacks increase forward stability and thus loading capacity in

the third row of containers or track two with railway freight. The support
jacks fold up and lower via hydraulic cylinders, one cylinder per support
jack. The support jacks on the frame between the drive wheels.
If the engine speed is increased to above 1000 rpm when the switch is
activated, the support legs lower automatically. The automatic function
works during lowering and retracting.

Parking brake Released
Transmission Neutral position
Machine at standstill Speed = 0 km/h
D 13
D
2 11
D790-1 D795
D
D794 D797-O
D 12 4
C
5
10 3
P
B
LS
7 T
C T1 A
8 6 9
004877
1. Switch support jacks (S1013) 7. Shuttle valve

2. Control unit cab (D790-1) 8. Hydraulic oil pump 1 & 2
3. Sensor support jacks up (B7222L and B7222R) or 9. Valve block support jack cylinder
Sensor support jacks down (B7221L and B7221R)
10. Hydraulic cylinder support jacks
4. Control unit frame option (D797-O)
5. Solenoid valve support jacks down (Y6064) or
Solenoid valve support jacks up (Y6063) 12. Control unit engine (D794)
6. Control valve option frame 13. Indicator light support jacks down (H517)

7 Load handling – Weight indicator 7:63
Support jacks, component position
2
3
1
4
004901
8 7
1. Control valve option frame 5. Support jacks

2. Hydraulic cylinder support jacks 6. Support plate
3. Sensor support jacks up (B7222L and B7222R) 7. Lower bracket
4. Upper bracket 8. Sensor support jacks down (B7221L and B7221R)
7.10.2 Weight indicator

Weight indicator, function description
The weight indicator shows the weight of the lifted load. The dynamic
scale shows the load regardless of position of boom and extension.
The weight indicator uses Sensor boom length (B777), Sensor boom
angle (B771) and Sensor hydraulic pressure lift cylinder (B768) to
calculate the weight of the load. For more information about sensors,
see section 8 Control and monitoring system, group 8.2.1 Overload
system.


7:64 7 Load handling – Weight indicator
1 7
D790-1 D795
D797-F D797-R
6 4
D
D
5
005118
Pa Pa Pa Pa 2m <˚ 3
1. Control unit cab (D790-1) Sensor hydraulic pressure lift cylinder rod side left
2. Sensor boom length (B777) (B768-11),
3. Sensor boom angle (B771) Sensor hydraulic pressure lift cylinder piston side
right (B768-10) and
Sensor hydraulic pressure lift cylinder rod side right
5. Control unit, frame front (D797-F) (B768-13)
6. Sensor hydraulic pressure lift cylinder piston side left 7. Control unit KID (D795)
(B768-12),
Weight indicator, checking
1 Lift a known weight.
2 Check that the weight indicator shows the right weight ±0.5 ton. If
deviation is greater, calibrate the weight indicator.
a
c
b
000357
Operating menu dynamic scale

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

000056

7 Load handling – Weight indicator 7:65
4 Enter the code for calibration.

1 23
4 5 NOTE
000060
5 Scroll to SCALE with the arrow keys and press ENTER.

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

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

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

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

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

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

7:66 7 Load handling – Weight indicator

CALIBR SCALE 6(X)
24 Extend the boom completely.
LOAD SENSOR BOOM 0t
EXTENDED LE RI 25 Wait approx. five seconds to stabilise the pressure.
CALIBR XXXX XXXX
010454
PRESENT XXXX XXXX 26 Check that the weight is set to 0 t. If not, scroll using the minus
key to 0 t and save the setting using ENTER.
Checking calibration
CALIBR SCALE 7(X)
ALLOWED LOAD XXXXXKg
PRESENT LOAD XXXXXKg 28 Lift a reference load and check that the control system calculates
LOAD STR.AXLE XXXXXKg the correct weight of the load that the machine is lifting.
006804
LOAD-CENTER XXX.XXm PRESENT LOAD = Reference load ± 500 kg. Weight is given in
kg.
If the weight is not right, repeat calibration.
29 Operate the machine without load, stop the machine and check
that PRESENT LOAD = 00000 ± 500 kg.
Check in different working positions, see figure. The boom should
not reach end-positions when checking.
NOTE
Check when stationary. (Operation generates dynamic forces.)
010455
30 Back out of calibration with the R-key. When the code menu
appears, press Enter.
Printer, description
The printer is an option for the scales function, making it possible to

save weights and print out lists of saved weights.
The printer is connected to Control unit KID (D795) and is located on

the instrument panel on the right side of the steering wheel.
The printer is controlled via operating menu printer in the display,

where the operator chooses which weights shall be saved as well
as what is to be printed.
004907
Position printer

7 Load handling – Container counter 7:67
7.10.3 Container counter

Container counter, function description (product
alternative top lift)
Container counter counts the number of lifts performed with the

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

decide when a container is lifted. The container counter counts a lift
when alignment disappears with locked twistlocks and twistlocks do
not open again within 8 seconds.
Condition

4
D795
1. Sensor contact left front (7202L),
D791-1 Sensor contact right front (7202R),

3 D Sensor contact left rear (Y7203L) and
D Sensor contact right rear (Y7203R)
1 2 2. Sensor locked twistlocks left (B7205L)
Sensor locked twistlocks right (B7205R)
004297
Container counter, function description (product

alternative bottom lift)
Container counter counts the number of lifts performed with the

machine. The counter has two counter units that can be reset
separately.
The container counter counts a lift when the clamping function is

activated and lift is initiated as well as release of clamping position is
not activated within 10 seconds.
Condition

7
D795
1. Sensor clamping position front leg left (B7215L) and Sensor
clamping position rear leg left (B7216L)
D791-3 D791-4
2 4 2. Control unit attachment left leg pair (D791-3)
D D 3. Sensor clamping position front leg right (B7215R) and Sensor
1 5 3 6 clamping position rear leg right (B7216R)
5. Sensor alignment front leg left (B7213L) and Sensor alignment
004884
rear leg left (B7214L)

6. Sensor alignment front leg right (B7213R) Sensor alignment rear
leg right (B7214R)

7:68 7 Load handling – Synchronised lift
7.10.4 Synchronised lift

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

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

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

description, page 7:5 and Extension, general, page 7:10.

D
+
2
D790-1 D795
5 D797-R D797-F
D
004883
3m <˚ 4
1. Control lever (S815) 4. Sensor boom length (B777)

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

8:1
8 Control system
Contents 8 Control system

8 Control system ...................................................................................................8:3
8.2 Monitoring ........................................................................................................8:6
8.2.1 Overload system .........................................................................................8:6
8.2.2 Bypass ........................................................................................................8:8
8.2.3 Speed limitation...........................................................................................8:8
8.2.4 Service indicator..........................................................................................8:9
8.2.5 Load centre limitation ..................................................................................8:9
8.2.6 Height limitation...........................................................................................8:9
8.3 Error codes ....................................................................................................8:10
8.4 Diagnostics ....................................................................................................8:12
8.4.1 CAN/POWER ............................................................................................8:14
8.4.2 LIGHTS .....................................................................................................8:15
8.4.3 CAB ...........................................................................................................8:16
8.4.4 CLIMATE ...................................................................................................8:17
8.4.5 HYD...........................................................................................................8:17
8.4.6 ENGINE ....................................................................................................8:18
8.4.7 TRANSM ...................................................................................................8:19
8.4.8 BOOM .......................................................................................................8:20
8.4.9 ATTACH ....................................................................................................8:21
8.4.10 OP .............................................................................................................8:22
8.4.11 EXTRA ......................................................................................................8:23
8.4.13 RMI............................................................................................................8:25

8:2

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

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

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

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

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

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

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

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

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

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

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

• Operating menu engine and transmission
• Operating menu engine
• Operating menu transmission and hydraulics
• Operating menu electrical system
• Operating menu service
014251
• Operating menu heating and air conditioning
Examples of available operating menus • Operating menu statistics
• Operating menu dynamic scale
• Operating menu checking dynamic scale
• Operating menu load handling
• Operating menu service interval
• Operating menu printer
• Operating menu code lock
Event-controlled information
Under certain conditions, the control system calls the operator's

attention to important information with figures on the display. Examples
of warnings are warning for overloading when the overload system
is activated.
Warnings are described in connection with each function. The following

event menus are available:
• Overload forward
• Overload on steering axle
• Alignment, top lift attachment
• Alignment bottom lift attachment
• Twistlock
• Support jacks
• Height limitation
• Fixed scale
• Open door
• Rotation stop
• Speed limitation for levelling lock or tilt lock
• Speed limitation at overload on steering axle
• Automatic spreading 20"-40"
Service menu
Service menu
The service menu is the gateway to the machine's diagnostic system.

Different parts of the Service menus are made available by pressing
"Enter" and entering different codes. The different service menus are:
000056
• Error codes, description, page 8:10

• Diagnostics, general, page 8:12

8:6 8 Control system – Monitoring
8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
• Overload system
• Load centre limitation
• Height limitation
• Speed limitation
• Service indicator
8.2.1 Overload system

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

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

load handling capacity. All hydraulics are blocked, e.g., lift, when the
overload system is activated. With Switch bypass, certain parts of
the overload system can be bypassed. This enables lowering and
retraction of the boom to avoid danger.
See Electric overload system, function description, page 8:7.
The overload system uses a number of sensors. The number of

sensors is also controlled by the weight indicator option, see tab 7
Load handling, group 7.10.2 Weight indicator.
Analogue Analogue
B768-R1 B768-R2 B768-L1 B768-L2
B777 B771
Electric overload system X X X X X X
Overload system, checking

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

8 Control system – Overload system 8:7
8.2.1.3 Electric overload system
Electric overload system, function description

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

3. Sensor hydraulic pressure lift cylinder (B768-L1,
-L2, -R1, -R2)
6
D795
D797-R D797-F D793

3 4 2 7
m D
1
004889
D 5 <° D D Pa Pa
1. Sensor, hydraulic lift cylinder left (B768-L1 and 4. Control unit frame rear (D797-R)
B768-L2) and
Sensor, hydraulic pressure lift cylinder right (B768-R1
and B768-R2)
7. Control unit, transmission (D793)

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

depending on the machine's equipment:
• Switch bypass
• Switch bypassing load centre and height limitation
• Switch rotation stop
Bypassing the safety system makes it possible to:

• lower load at overload
• lock and open twistlocks without full contact
• Spread 20'-40' with locked twistlocks
• bottom lift without full alignment
• manual steering of recirculation damper by ECC or EHC
• releasing parking brake in case of defective switch parking brake
or Sensor operator in seat
• raising above height limitation
• rotation past rotation stop
• load handling past the limit for load centre limitation.
• lift, lower and extend with active error on the overload system
• selection of travel direction in case of defective Sensor operator in
seat, speed is limited to 10 km/h
• machine engages neutral when no one is sitting in the operator's
seat
DANGER
Bypassing the safety system results in a risk of tipping
forward, and is done at your own risk.
Risk of fatal accidents and property damage!
Only use bypass of the safety system in emergency
situations.
8.2.3 Speed limitation

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

value by limiting gear position and engine rpm.

8 Control system – Service indicator 8:9
8.2.4 Service indicator

Service indicator, resetting
2 Navigate first to the service menu and press Enter.
000056
3 Enter code for resetting service indicator.
1 23
4 5 NOTE
000060

4 Reset the service indication by pressing Enter. NEXT SERVICE is

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

Load centre limitation, description
Load centre limitation prevents the load from moving too close to the
machine. Load centre limitation is controlled by the control system with
signals from Sensor boom angle and Sensor boom length. This is
used for example in connection with cab lift to prevent the container
damaging the cab.
For details about lift, lower and extension, see section 7 Load handling.
8.2.6 Height limitation

Height limitation, description
Height limitation is a part of the control and monitoring system and

prevents the machine from lifting higher than a pre-set height without
the operator being informed.
Height limitation is controlled by the control system with signals from

Sensor boom angle and Sensor boom length. When the boom angle
and extension indicate that the permitted height is reached, lift and
extension are blocked, display information for height limitation is also
activated.
For details about lift, lower and extension, see section 7 Load handling.

8:10 8 Control system – Error codes
8.3 Error codes

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

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

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

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

• Automatically on display.
The error code is acknowledged with function key Reset (R).
002207
When the error code has been acknowledged the display returns
to previously selected menu. If the error code is active, it is stored
Example of automatic display figure in the error code list under operating menu for service.
If the error code is active it is repeated to remind the operator
of the error status, stop every 3rd minute, warnings every 5th
minute.

8 Control system – Error codes 8:11
• In the error code list under operating menu for service.

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

8:12 8 Control system – Diagnostics
8.4 Diagnostics
Diagnostics, general
The machine has built-in functions for troubleshooting called
DIAGNOSIS diagnostic test. The diagnostic test consists of several menus that are
CAN/POWER LIGHTS CAB shown in the display. The menus are grouped for faster access.
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH The following pages show compilations of the diagnostic menus. The
006853
workshop manual has a more detailed description of each diagnostic
OP EXTRA RMI
menu.
The diagnostic test is divided into the following groups:

• CAN/POWER, menu overview, page 8:14
• LIGHTS, menu overview, page 8:15
• CAB, menu overview, page 8:16
• CLIMATE, menu overview, page 8:17
• HYD, menu overview, page 8:17
• ENGINE, menu overview, page 8:18
• TRANSM, menu overview, page 8:19
• BOOM, menu overview, page 8:20
• ATTACH, menu overview, page 8:21
• OP, menu overview, page 8:22
• EXTRA
– COMBI, menu overview, page 8:23
– SLIDING-CAB, menu overview, page 8:24
– SUPPORT JACKS, menu overview, page 8:24
• RMI, menu overview, page 8:25
Diagnostic menu, description

1 The diagnostic tests are built up of menus. The menus are grouped
2 3 4 according to logical areas. With the diagnostic menus it is possible to
read off how the control unit interprets input signals as well as what
7 DIAG CAB 2(10) output signals are sent by the control unit.
FRONT WIPER
SWITCH (1-3) 2 Signal values (position 5) in the menu indicate measured values by
6 the relevant control unit. The control units have internal voltmeters
OUTPUT 11 5
004856
FEEDBACK 0 and ammeters that measure the signal on the connectors out to
components or in from components.
1. DIAG = Diagnostic menus Output signals are control of solenoid valves, lights, relays, etc.
2. Menu group (CAB = cab functions)
Input signals are sensor signals, signals from controls and switches,
3. Menu number feedback control signals, etc.
4. Total number of menus in the loop
The figure shows an example of a menu, here for diagnostics of
5. Signal value windshield wiper. The table below indicates what you can read out
6. Variable from the menu figure.
7. Menu heading

8 Control system – Diagnostics 8:13
Pos. Designation Description

1 DIAG Indicates that diagnosis has been selected. There is also initiation (INIT) and calibration (CALIB).
2 CAB Indicates which menu group is selected. These groups are available:
CAN/POWER - for diagnosis of CAN-bus and electric power supply.
LIGHTS - for diagnosis of lighting and lights.
CAB - for diagnosis of components in cab.
CLIMATE - for diagnosis heat and ventilation system.
HYD - for diagnosis of common hydraulics and brakes.
ENGINE - for diagnosis of engine.
BOOM - for diagnosis of lift, lower and extension.
ATTACH - for diagnosis of attachment.
OP - for diagnosis of overload system.
EXTRA - for diagnosis of optional functions.
HIST - not used.
3 2 Number of current menu (menu group CAB contains several menus in a loop).
4 (10) Total number of menus in the group CAB.
5 Variable Which signal is being measured. Here are a few examples.
SWITCH refers to switch windscreen wiper.
OUTPUT refers to status of a feed, in this case feed to the wiper motor.
FEEDBACK refers to feedback signal, in this case signal from the wiper motor when it operates.
6 Signal value Measuring value or status for the signal for the variable on the same line.
7 FRONT WIPER Name of the function that can be controlled. FRONT WIPER means front windscreen wiper.
Diagnostics, operating instructions

To choose diagnostics, do the following:
1 Navigate to the service menu.
2 Push Enter.
000056
3 Enter the code for diagnostics.

1 23
4 5 NOTE
000060

4 Select group by scrolling with the arrow keys (1 and 2) and confirm
DIAGNOSIS with Enter.
CAN/POWER LIGHTS CAB
Each group consists of a sequence of numbered menus. The first
CLIMATE HYD ENGINE menu for selected diagnostic menu is shown in the display, use
TRANSM BOOM ATTACH arrow keys (1 and 2) to change menu.
000084
OP EXTRA HIST

8:14 8 Control system – CAN/POWER
8.4.1 CAN/POWER
CAN/POWER, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CAN/POWER 1(21) DIAG CAN/POWER 2(21) DIAG CAN/POWER 3(21)

PRESENT REDCAN STATUS PRESENT REDCAN STATUS PRESENT DRIVE-TRAIN
COMMUNICATION MODE X RED.CON.CITIES CAN BUS STATUS
NUMBERS OF UNITS X XYXYXYXY ENGINE X
SEGMENT ERROR X 1234ROFD TRANSMISSION X

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

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

797-R FRAME 797-R FRAME 797-O FRAME
POWER XX.XXV 24V SENSOR SUPPLY XY POWER XX.XXV
RED.POWER Le X Ri X 5V REF X.XXV RED.POWER Le X Ri X
EME STOP POWER X

797-O FRAME 795 DISPLAY 793 TRANSMISSION
24V SENSOR SUPPLY XY POWER XX.XXV
5V REF X.XXV RED.POWER Le X Ri X IGNITION POWER XX.XXV
SENSOR SUPPLY XX.XXV

791-1 ATTACHMENT 791-2 ATTACHMENT 791-3 ATTACHMENT
POWER XX.XXV POWER XX.XXV POWER XX.XXV
RED.POWER Le X Ri X RED.POWER Le X Ri X RED.POWER Le X Ri X

791-4 ATTACHMENT 24V SENS.SUP 791-1 XY REDCAN STATUS CHECK
POWER XX.XXV 24V SENS.SUP 791-2 XY PRESS ENTER
RED.POWER Le X Ri X 24V SENS.SUP 791-3 XY
006841
24V SENS.SUP 791-4 XY SEGMENT ERROR X

8 Control system – LIGHTS 8:15
8.4.2 LIGHTS
LIGHTS, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG LIGHTS 1(13) DIAG LIGHTS 2(13) DIAG LIGHTS 3(13)

WORKING LIGHT CAB WORKING LIGHT ATTACH WORKING LIGHT BOOM
SWITCH X SWITCH X SWITCH X
OUTPUT LE XX RI XX OUTPUT LE XY RI XY OUTPUT LE XY RI XY
OPTINAL OUTPUT XY OPTIONAL OUTPUT XY

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

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

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

SWITCH LIGHTS
OUTPUT XXX
006809

8:16 8 Control system – CAB
8.4.3 CAB
CAB, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CAB 1(10) DIAG CAB 2(10) DIAG CAB 3(10)

WASHER FRONT WIPER REAR WIPER
SWITCH X SWITCH (1-3) X SWITCH X
OUTPUT FRONT XY OUTPUT XY OUTPUT XY
OUTPUT REAR-ROOF X FEEDBACK X FEEDBACK X

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

FUEL SEAT HEATER AUT. LUBRICATION
SENSOR VALUE XXXOHM SWITCH X CHASSI
PROC XXX OUTPUT XY
OUTPUT XY
DIAG CAB 10(10)

AUT. LUBRICATION
ATTACHMENT
006837
OUTPUT XY

8 Control system – CLIMATE 8:17
8.4.4 CLIMATE
CLIMATE, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CLIMATE 1(8) DIAG CLIMATE 2(8) DIAG CLIMATE 3(8)

PRESENT INPUT SIGNAL TEMP COIL XXX PRESENT INPUT SIGNAL
REQUIRED TEMP XXX TEMP COOLANT XXX PRESSURE SWITCH X
PRESENT TEMP XXX TEMP AMBIENT XXX OPT DOOR SWITCH X
WATER VALVE FEEDB. XXX TEMP DE-ICE XXX
DIAG CLIMATE 4(8) DIAG CLIMATE 5(8) DIAG CLIMATE 6(8)

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

OUTPUT WATER VALVE OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
006810
8.4.5 HYD
HYD, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG HYD 1(6) DIAG HYD 2(6) DIAG HYD 3(6)

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

PRESSURE SWITCHES P-BRAKE PRESENT OUTPUT SIGNAL
BRAKE PRESSURE X SWITCH X/Y PRESSURE TO ATTACHM.
BRAKE LIGHT PRESS. X FEEDBACK SWITCH X VALVE XY
006844
DECLUTCH PRESSURE X VALVE XY

8:18 8 Control system – ENGINE
8.4.6 ENGINE
ENGINE, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OLS EXTRA RMI
DIAG ENGINE 1(10) DIAG ENGINE 2(10) DIAG ENGINE 3(10)

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

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

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

EATS STATUS
TANK LEVEL XX
TANK TEMP XX
014708
IND. SEVERITY XX

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

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

OPERATING STATE PRESENT VALUE
NOT USED SHIFT IN PROGRESS X OUTPUT SPEED XXXXrpm
OPERATING MODE X ENGINE SPEED XXXXrpm
ENGAGED X

NOT USED NOT USED NOT USED

PRESENT SENSOR INPUT PRESENT VALUE
AXLE RATIOx1000 XXXXX NOT USED
TRANSM. TEMP XXX RADIUS XXXX
CONV. TEMP XXX SPEED LIMIT XXXX
DIAG TRANSM. 13(14) DIAG TRANSM. 14(14)

ACTIVE ERROR CONVERTER STATUS (Nm)
ERROR 1 XX ERROR 4 XX TORQUE IMPELLER XXXX
ERROR 2 XX ERROR 5 XX TORQUE TURBINE XXXX 013959
ERROR 3 XX ERROR 6 XX

8:20 8 Control system – BOOM
8.4.8 BOOM
BOOM, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG BOOM 1(8) DIAG BOOM 2(8) DIAG BOOM 3(8)

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

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

OUTPUT BOOM OUT PRESENT INPUT SIGNAL
REFERENCE XY BOOM LOW SPEED
REQUIRED VALUE XXX UP/DOWN X/X
006838
FEEDBACK XXX IN/OUT X/X

8 Control system – ATTACH 8:21
8.4.9 ATTACH
ATTACH, menu overview
DIAGNOSIS DIAG ATTACHMENT 1(22)

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

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
SIDE SHIFT LE X RI X LOCK TW X TILT LOCKING X
PISTOL X UNLOCK TW X LEVELLING LOCKING X
30/35 STOP X BY-PASS HEIGHT X AUTO 20'-40' X

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
LOW SPEED 20/40 X ALIGNMENT LE RI LE RI
30/35 STOP X FRONT X X LOCKED TW X X
EXTENSION 60CM X REAR X X UNLOCKED TW X X

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

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

OUTPUT SPREADER IN PRESENT OUTPUT SIGNAL OUTPUT TILT OUT
REFERENCE XY TILT LOCKING 1 XY REFERENCE XY
RQUIRED VALUE XXX TILT LOCKING 2 XY REQUIRED VALUE XXX
FEEDBACK XXX BUZZER AUTO 20-40 XY FEEDBACK XXX

OUTPUT TILT IN PRESENT OUTPUT SIGNAL OUTPUT LEVELLING RI
REFERENCE XY LOCK LEVELLING 1 XY REFERENCE XY
REQUIRED VALUE XXX LOCK LEVELLING 2 XY RQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX

OUTPUT LEVELLING LE PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
REFERENCE XY ROTATION STOP LENGTH TO
RQUIRED VALUE XXX SWITCH X CONTAINER (cm) XXXX
006813
FEEDBACK XXX SENSOR STOP X DAMP DOWN X

8:22 8 Control system – OP
8.4.10 OP
OP, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG OP 1(6) DIAG OP 2(6) DIAG OP 3(6)

STEERING AXLE X LIFT CYL LE RI
BOOM ANGLE X BY-PASS X C- X.XXV X.XXV
EXTENSION X C+ X.XXV X.XXV
DIAG OP 4(6) DIAG OP 5(6) DIAG OP 6(6)

PRESENT INPUT SIGNAL ALLOWED LOAD XXXXXKg BOOM ANGLE XXX
BOOM ANGLE X.XXV PRESENT LOAD XXXXXKg BOOM EXTENSION XXX
BOOM EXTENSION X.XXV LOAD STR.AXLE XXXXXKg BOOM HEIGHT XXX
006840
LOAD-CENTER XX.XXm BOOM HEIGHT NOSE XXX

8 Control system – EXTRA 8:23
8.4.11 EXTRA
8.4.11.1 COMBI
COMBI, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
DIAG COMBI 1(17) DIAG COMBI 2(17) DIAG COMBI 3(17)

SWITCHES PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
FRONT LEG UP/DOWN X/Y CLAMPING SENSORS ALIGNMENT SENSORS
REAR LEG UP/DOWN X/Y FRONT LEGS LE X RI X FRONT LEGS LE X RI X
CLAMP IN/OUT X/Y REAR LEGS LE X RI X REAR LEGS LE X RI X

END POS SENSORS FRONT END POS SENSORS REAR LEGS IN DRIVE
KNEE LE X RI X KNEE LE X RI X POSITION LE X RI X
LEG LE X RI X LEG LE X RI X

INDICATION LAMPS INDICATION LAMPS INDICATION LAMPS
ALIGNMENT CLAMP
FRONT LE XY RI XY FRONT XY FRONT LEGS UP XY
REAR LE XY RI XY REAR XY FRONT LEGS DOWN XY

PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
FRONT LEGS DOWN FRONT LEGS UP REAR LEGS DOWN
KNEE LE XY RI XY KNEE LE XY RI XY KNEE LE XY RI XY
LEGS LE XY RI XY LEGS LE XY RI XY LEGS LE XY RI XY

PRESENT OUTPUT SIGNAL SEQUENCE MODE PRESENT OUTPUT SIGNAL
REAR LEGS UP LE RI CLAMP
KNEE LE XY RI XY FRONT X X OUT LE XY RI XY
LEGS LE XY RI XY REAR X X IN LE XY RI XY
DIAG COMBI 16(17) DIAG COMBI 17(17)

PRESENT OUTPUT SIGNAL FORCE CONTROL (+/-)
DRIVE POSITION
X: 'VALVE'
006845
LE XY RI XY

8:24 8 Control system – EXTRA
8.4.11.2 SLIDING-CAB
SLIDING-CAB, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
DIAG SLID-CAB 1(4) DIAG SLID-CAB 2(4) DIAG SLID-CAB 3(4)

SWITCHES PRESENT INPUT SIGNAL OUTPUT FORWARD
FORWARD X LOW SPEED X REFERENCE XY
REVERSE X CAB DOWN (LIFT) X REQUIRED VALUE XXX
OPENED DOORS X FEEDBACK XXX
DIAG SLID-CAB 4(4)

OUTPUT REVERSE
REFERENCE XY
REQUIRED VALUE XXX
006843
FEEDBACK XXX
8.4.11.3 SUPPORT JACKS

SUPPORT JACKS, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMII
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
DIAG S-JACKS 1(4) DIAG S-JACKS 2(4) DIAG S-JACKS 3(4)

SWITCHES PRESENT INPUT SIGNALS OUTPUT VALVE
UP X S-J UP XY
DOWN X UP LE X RI X S-J DOWN XY
DOWN LE X RI X
DIAG S-JACKS 4(4)

INDICATOR LAMP
DOWN XY
008649

8 Control system – RMI 8:25
8.4.13 RMI
RMI, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG RMI 1(3) DIAG RMI 2(3) DIAG RMI 3(3)

MIU SW VER XXXX.XXXX SIGNAL QUALITY ERROR XX.XX.XX.XX
MIU TIME XXXX.XX.XX GSM XXX GPRS XXX ERR.VALID XX.XX.XX.XX
WLAN XXX RADIO XXX ACT.ERR. XX.XX.XX.XX
012029
SMS XXX:UNS.DATA XXX

8:26

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

9 Frame, body, cab and accessories ...................................................................9:3
9.1 Controls and instruments .................................................................................9:4
9.2 Safety and emergency equipment .................................................................9:10
9.3 Seats.............................................................................................................. 9:11
9.4 Heating, ventilation and air conditioning ........................................................9:14
9.4.1 Fresh air filter ............................................................................................9:25
9.4.8 Condenser.................................................................................................9:25
9.4.9 Moisture filter.............................................................................................9:25
9.5 Wiper/washer system.....................................................................................9:27
9.6 Lighting system ..............................................................................................9:28
9.7 Signalling system ...........................................................................................9:31
9.8 Entertainment and communication ................................................................9:33
9.9 Glass/windows/mirrors...................................................................................9:34
9.10 Cab structure and suspension .......................................................................9:35
9.10.2 Doors.........................................................................................................9:35
9.10.4 Sliding cab.................................................................................................9:36
9.10.5 Vertically adjustable cab............................................................................9:38
9.11 Cab interior ....................................................................................................9:41
9.12 Frame.............................................................................................................9:42
9.13 Body structure................................................................................................9:43
9.14 Central lubrication ..........................................................................................9:44
9.15 Paint/coatings ................................................................................................9:46

9:2

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

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

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

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

Controls and instruments, overview
Overview
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
004852
14
1. Left instrument panel

2. Gear and multi-function lever (S162)
3. Steering wheel panel
4. Steering wheel
5. Switch direction indicators (S161)
6. Panel for load handling functions
7. Emergency stop switch (S250)
8. Switch parking brake (S107)
9. Control lever (S815)
10. Operator’s seat
11. Accelerator pedal (B690)
12. Brake pedal
13. Declutch pedal (S220-1)
14. Electrical distribution box with fuses
15. Hour meter (P708)
A. Joystick or mini-wheel

9 Frame, body, cab and accessories – Controls and instruments 9:5
Left instrument panel

16. Switch fan (S118)
17. Switch temperature (S117)
2 9 3 0 3 1 18. Switch air distribution (S139)
2 4 ..2 8
19. Switch work lights cab roof (S105-1)
1 9 ..2 3 20. Switch work lighting attachment (S105-2)
18 21. Switch work lighting boom (S105-3)
17 22. Switch rotating beacon (S110)
013031
16
23. Switch hazard lights (S109)
24. Switch headlights (S100)
25. Switch seat heater (S143)
26. Switch electrically heated rearview mirrors (S199-4)
27. Spare
28. Switch supplemental heater (S199-1)
29. Spare
30. Spare
31. Socket 24 VDC (E084)

Steering wheel panel

Steering wheel panel
36
35
34 32. Warning light low battery charging
33
32 33. Warning light low brake pressure
34. Indicator active error codes
35. Warning light bypass of hydraulic functions
36. Indicator light activated joystick or mini-wheel steering
37..41 49 37. Warning light high coolant temperature
38. Warning light low oil pressure in engine
42..46 39. Indicator light preheating
47 48 40. Warning light low coolant level engine
41. Warning light high oil temperature in transmission
42. Warning light low fuel level
43. Warning light high temperature hydraulic oil
50 51 52 53 44. Indicator light high beams
45. Indicator light direction indicators
46. Indicator light parking brake
47. Indicator light locked twistlocks
48. Indicator light alignment
49. Indicator light unlocked twistlocks
50. Panel warning and indicator lights
51. Display control system
64
54 52. Indicator control system
63 53. Ignition (S150)
55
62 54. Switch defroster
56
55. Switch windshield wiper roof, interval
000399
61 60 59 58 57
56. Switch windshield wiper roof, continuous
Steering wheel panel with panel for warning and indicator 57. Switch interior lighting
lights
58. Switch windshield wiper rear, interval
59. Switch windshield wiper rear, continuous
60. Function keys control and monitoring system
61. Travel direction indicator, Forward Neutral Reverse
62. Switch shifting program A, automatic shifting
63. Switch shifting program 1, locked to 1st gear
64. Switch shifting program 2, locked to 2nd gear

Panel for load handling functions

65 66 67 68
65. Switch lowering front legs (S1006)
66. Switch lowering rear legs (S1007)
67. Switch by-passing rotation stop (S1014)
6 9 ..7 2 Switch bypassing height limitation (S1015)
Switch bypassing LC-limitation (load centre) (S1015)
68. Switch, automatic cab tilt (S199-5)
73 69. Switch lock twistlocks (S1003)

70. Switch clamp/release clamping position legs (S1008)
74
76 Switch overheight legs (S1031)
75
71. Switch for stop at 30" (S1004)
013032
72. Switch hydraulic sliding cab (S177)
Switch hydraulic vertically adjustable cab (S177)
Switch hydraulic tilting of cab (S1010)
73. Indicator light support jacks down (H517)
74. Switch support jacks (S1013)
75. Switch automatic spreading 20"-40" (S1012)
76. Bypass switch (S1005)

Operating menus, overview
1 2 3 4
12
5
11 6
10 9 8 7
014498
13 14 15 16
1. Operating menu engine and transmission 9. Operating menu printer
2. Operating menu dynamic scale 10. Operating menu checking dynamic scale
3. Operating menu engine 11. Operating menu service
4. Operating menu transmission and hydraulics 12. Operating menu heating and air conditioning
5. Operating menu electrical system 13. Operating menu statistics, operating hours
6. Operating menu container counter 14. Operating menu statistics, fuel consumption
7. Operating menu service interval 15. Operating menu statistics, driving distance
8. Operating menu statistics 16. Operating menu statistics, lift statistics

Event menus overview
1 2 3 4
15 6
14 7
13 8
006734
12 11 10 9
1. Event menu start interlock 9. Event menu, height limitation
2. Event menu overload forward 10. Event menu fixed scale
3. Event menu overload on steering axle 11. Event menu open door
4. Event menu overload on steering axle 12. Event menu rotation stop
5. Event menu, top lift alignment 13. Event menu tilt lock
6. Event menu alignment bottom lift 14. Event menu levelling lock
7. Event menu twistlocks 15. Event menu automatic spreading 20"-40"
8. Event menu support jacks

9:10 9 Frame, body, cab and accessories – Safety and emergency equipment
9.2 Safety and emergency equipment

Safety and emergency equipment, description
A good working environment has protective and warning equipment to
make the operator's work safer.
The machine may be equipped with the following:
2
9
3
010464
4 8 7 6 5 4
1. Rotating beacon For vertically adjustable cab there is always a seatbelt

as well as safety chains by the doors.
2. Electrically powered high-volume horn
8. Fire extinguisher
3. Buzzer to indicate alarm/forgotten action, e.g., if the
operator leaves the cab without first applying the Fire extinguishers can also be located externally.
parking brake.
If the machine is supplied with a fire extinguisher, it
4. Camera with monitor should be of the type ABE according to EN 3 pt. 1, 2,
4 and 5. With such a fire extinguisher, it is possible
Used to give better visibility to the front and rear when to extinguish fires in both solid organic materials and
operating the machine. The monitor is located inside fluids. Adapted fire extinguishing equipment can be
the cab on the left side. ordered from Cargotec.
5. External rearview mirrors (power mirrors and
9. Reverse alarm
electrically heated )
10. Emergency exit cab, right door (and opening rear
Used to provide increased visibility for operating and
window )
load handling. One rear-view mirror on each side.
(not shown on diagram)
6. Horn
7. Seat belt

9 Frame, body, cab and accessories – Seats 9:11
9.3 Seats
Seats, description (product alternative standard
seat)
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
1 2 The seat has the following equipment:
• mechanical adjustment
3 • armrest right
• seat belt
• armrest left
4
• seat heating
• head restraint
8 6
006825
7
Controls for standard seat
1. Adjustable lower back (lumbar) support
2. Adjustable arm rest, right
3. Adjustable arm rest, left
4. Adjustable tilt, backrest
5. Adjustable suspension position
6. Adjustable seat angle
7. Adjustable seat height
8. Longitudinal adjustment

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

9120)
BE-GE 9120 is the same seat as the standard seat but equipped with
1 2 air suspension. The air suspension automatically adapts the seat
height and suspension to the operator's weight. The air suspension
is supplied by a special compressor installed on the underside of
3 the cab.
4 several adjustment features and meets high comfort requirements.
The seat has the following equipment:

• mechanical adjustment
• air suspension (with external compressor)
5 • armrest right
• seat belt
8 • armrest left
6
006826
7 • seat heating
Controls BE-GE 9120 • head restraint
2. Adjustable arm rest, right
3. Adjustable arm rest, left
4. Adjustable tilt, backrest
5. Adjustable suspension position
6. Adjustable seat angle
7. Adjustable seat height

9 Frame, body, cab and accessories – Seats 9:13
Seat, description (product alternative

Isringhausen 6800)
several adjustment features and meets high comfort requirements.
Isringhausen 6800 seat has the following equipment:

• head restraint
• armrest
• air suspension (with external compressor)
• air-adjusted lower back (lumbar) support
• seat belt
• seat heating
11
10
34 567
004691
9 8 2
Controls Isringhausen 6800
2. Adjustable seat
3. Seat height lowering
4. Seat tilt
5. Seat height raising
6. Backrest tilt
7. Adjustable suspension
8. Seat heating
9. Level damping, On/Off
11. Arm rest

9:14 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating and ventilation unit, function description
(product alternative EHC)
The heating and ventilation unit (EHC) handles heating and

ventilation. (The heating and ventilation unit cannot add cooling.)
The temperature in the cab is thermostat-controlled by Control unit

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

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

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:15
1 2 3 17
D D 16
D
4 ˚C D
D
˚C
D 6
7 D
D790-1 D790-2 D795
15 D D794
11
M 10
M
14 D
˚C
5 M ˚C 9
D D 8 12
13
M
004301
1. Switch fan (S118) 10. Control unit engine (D794)
2. Switch temperature (S117) 11. Water valve (Y673)
3. Switch air distribution (S139) 12. Heat exchanger
4. Sensor cab temperature (B775-1) 13. Actuator recirculation (M612)
5. Sensor temperature outlet fan (B775-2) 14. Fan motor heat (M657)
6. Sensor outdoor temperature (B774) 15. Damper motor (Y672)
7. Control unit cab (D790-1) 16. Switch defroster on Control unit KIT (D790-2)
8. Engine 17. Operating menu on Control unit KID (D795)
9. Sensor engine temperature
Air conditioning, function description (product

alternative ECC)
Air conditioning (ECC) manages heating, ventilation, cooling and
dehumidification.
The temperature in the cab is thermostat-controlled by Control unit

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

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

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

2 1 3 26
D D 25
D
4 ˚C D
D
˚C
D D 6
7 D790-1 D790-2 D795
D
15 D D797-R D794
M 16
D 12 D
14 22 23
5 ˚C Pa ˚C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
10
˚C
8 11
004302
1. Switch temperature (S117) 15. Damper motor (Y672)
2. Switch fan (S118) 16. Control unit frame rear (D797-R)
3. Switch air distribution (S139) 17. Magnetic clutch (M645)
4. Sensor cab temperature (B775-1) 18. Compressor
5. Sensor temperature outlet fan (B775-2) 19. Condenser
6. Sensor outdoor temperature (B774) 20. Moisture filter
7. Control unit cab (D790-1) 21. Pressure switch (S246)
8. Engine 22. Expansion valve
9. Water valve (Y673) 23. Sensor temperature in refrigerant circuit (B775-3)
10. Sensor engine temperature 24. Heat exchanger for cooling
11. Heat exchanger 25. Switch defroster on Control unit KIT (D790-2)
12. Control unit engine (D794) 26. Operating menu on Control unit KID (D795)
13. Actuator recirculation (M612)
14. Fan motor heat (M657)

Heating, ventilation and air conditioning,

component position
1 2 3
16
15
14
13
6
7
12
8
11
004299
10 9
1. Operating menu on Control unit KID (D795) 9. Expansion valve
2. Switch defroster on Control unit KIT (D790-2) 10. Cab fan (M657)
3. Sensor outdoor temperature (B774) 11. Fresh air and recirculation damper (M612)
4. Control unit cab (D790-1) 12. Fresh air filter
5. Sensor cab temperature (B775-1) (inside of the left 13. Heat exchanger (cold and heat)
control panel, behind a grating)
14. Sensor temperature refrigerant (B775-3)
6. Switch air distribution (S139)
15. Air distributor (Y672)
7. Switch temperature (S117)
16. Sensor temperature outlet fan (B775-2) (in air
8. Switch fan (S118) distributor)

1 2
6 5 4 3
004862
1. Condenser 4. Moisture filter
2. Water valve (Y673) 5. Compressor
3. Pressure switch (S246) 6. Magnetic clutch compressor (M645)
General recommendations for work on the air

conditioning unit
CAUTION
Authorisation is required to perform repairs on the
climate control unit.

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

early spring to late autumn as well as in winter during long periods
of high humidity.
In winter, during cold and dry periods of low operation, the compressor
should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are lubricated.
1 Check that the condenser is not clogged – clean condenser fins
with compressed air as needed.
2 Check that the compressor turns on and off without error.
3 Check that the drain for the cooling element's condensation water
is not clogged.
4 Check that there is no refrigerant leakage. In case of leakage, oil

and gas often form a dusty, dirty spot.
5 Start the engine and engage the cooling function with setting on
maximum cooling.
Let the engine run at min. 1,500 rpm. (At temperatures below
approx. 0 ºC, the cooling function will not start due to low pressure
in the system.)
6 Set the fan to intermediate speed.

7 After running for 10 minutes, check that there are no bubbles

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

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

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

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

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

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

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

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

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

Action in the event of leakage in the system

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

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

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

connections by applying leakage indicator around all sealing
surfaces and check whether gas bubbles arise.
12 Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.
13 Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then, open the cock on the pressure side, use vacuum suction
for at least 30 minutes. Preferably longer.
14 First close both valves on the pressure gauge set. Then turn off
the vacuum pump. Work in this order, otherwise the air will rush
back. Wait approx. 15 min and check on the pressure gauges that
the vacuum does not change.
15 Move the yellow hose to the refrigerant cylinder and open the
valve on the cylinder.
16 Bleed the yellow hose by unloading the service connection at the

manometer set until pure gas flows out.
17 Open the cock on the suction side and allow the gas to flow
around until the pressure gauges indicate the same pressure as
in the tube.
18 Start the compressor and set the cooling thermostat and fan to
max.

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

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

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

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

9 Frame, body, cab and accessories – Fresh air filter 9:25
Supplemental heater, description
1
Supplemental heater, an option for the heating unit, uses excess heat
in the engine's cooling system to keep the cab warm.
An additional electric water pump pumps the cooling water through

the heating system when the engine is off. The cab fan pumps air
into the cab. The supplemental heater switches off automatically
when the temperature in the cab is 6 °C below the set value on the
air conditioning. The supplemental heater is activated with Switch
supplemental heater when the ignition is on.
3 2
004909
1. Switch supplemental heater (S199-1)
2. Control unit, cab KCU (D790-1)
3. Circulation pump supplemental heater (M667)
9.4.1 Fresh air filter
Fresh air filter, changing

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

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

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

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

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

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

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

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

Lighting system, function description
The function of the lighting is to increase safety during operation and
load handling.
The lights are turned off automatically after 5 minutes of idling so that
the lights do not drain the batteries. Extra work lights are turned off after
2 minutes. The lighting illuminates automatically when the operator sits
in the set, selects a gear, or if the accelerator pedal is pressed down.
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.

9 Frame, body, cab and accessories – Lighting system 9:29
1 2 3 26 4
23
5
6
31
24 24
28 29
22 22
27 M
D790-1 D790-2
8 7 14 34 19
D797-R D797-F D791-1
30
Pa
11 11
9 9 20 20
12 12 15 17 17 15
10 10 16
13 13 18 18 16 21 21
006428
25 25 32 32
33 33
1. Switch work lighting cab (S105-1) 19. Control unit attachment (D791-1)
2. Switch work lighting attachment (S105-2) 20. Work lighting attachment (E406-L & E406R)
3. Switch work lighting boom (S105-3) 21. Extra work lighting, attachment (E404-4L & E404-4R)
4. Switch headlights (S100)
5. Multi-function lever (S162) 22. Work lighting cab (E404-1L & E404-1R)
6. Lever direction indicator (S161) 23. Relay extra work lights boom (K304)
7. Control unit cab (D790-1) 24. Extra work lighting boom (E404-5L & E404-5R)
8. Control unit frame rear (D797-R) 25. Work lighting boom (E404-3L & E404-3R)
9. Tail lights (H412L & H412R) red
26. Switch rotating beacon (S110)
10. Brake lights (H411L & H411R)
27. Rotating beacon (H428)
11. Direction indicators rear (H426 & H427)
28. Break-contact door (S226-LE & S226-RI)
12. Running lights rear (H416-2 & H417-2)
29. Interior lighting
13. Back-up lights (E405L & E405R), white
30. Make-contact brake lights (S216)
31. Switch interior lighting on Control unit KIT (D790-2)
15. Direction indicators front (H422 & H423)
16. Running lights front (H416-1 & H417-1) 32. Extra work lighting front (E404-7L & E404-7R)
17. Headlights low beams (E400L & E400R) 33. Extra work lighting front (E404-8L & E404-8R)
18. Headlights high beam (E402L & E402R) 34. Control unit KIT (D790-2)

9:30 9 Frame, body, cab and accessories – Lighting system
Lighting system, component position

The function of the lighting is to increase safety during operation and
load handling. The machine has the following lights:
NOTE
F Technical data.
1 2 3 4 5 6 7 8
21, 22, 23, 24
006426
20 18, 19 17 16 15 14 13, 12, 11 10 9
1. Rotating beacon (H428) Headlights high beam (E402L & E402R)
2. Interior lighting 14. Make-contact brake lights (S216)
3. Control unit KIT (D790-2) 15. Control unit, frame front (D797-F)
4. Multi-function lever (S162) 16. Switches, see Controls and instruments, overview,
page 9:4
5. Work lighting cab (E404-1L & E404-1R)
17. Break-contact door (S226-LE & S226-RI)
6. Extra work lighting boom (E404-5L & E404-5R)
7. Work lighting boom (E404-3L & E404-3R)
19. Relay extra work lights boom (K304)
9. Work lighting attachment (E406-L & E406R)
21. Running lights rear (H416-2 & H417-2)
Extra work lighting, attachment (E404-4L & E404-4R)
22. Back-up lights (E405L & E405R), white
10. Extra work lighting front (E404-7L, E404-8L, E404-7R 23. Tail lights (H412L & H412R) red
& E404-8R) Brake lights (H411L & H411R)
11. Direction indicators front (H422 & H423) 24. Direction indicators rear (H426 & H427)
12. Running lights front (H416-1 & H417-1)
13. Headlights low beams (E400L & E400R)

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

Signal system, function description
The function of the signals is to increase safety during operation and
load handling. This can take place with light and sound. The machine
has the following signal systems:
NOTE
F Technical data.
1 2 3
5
6
18
16
17
14 19
15 M
4 7 20
D790-1 D790-2 D795
D797-R D797-F D791-1

8 12 21
10 10
9 9 22
11 13 13
004303
1. Switch rotating beacon (S110) 13. Direction indicators front (H422 & H423)
2. Switch hazard lights (Hazard) (S109) 14. Horn (H850)
3. Switch parking brake (S107) 15. Rotating beacon (H428)
4. Control unit cab (D790-1) 16. Relay loud horn (K3016)
5. Multi-function lever (S162) 17. Loud horn (H850-1)
6. Lever direction indicator (S161) 18. Make-contact operator in seat (S230)
7. Control unit KIT (D790-2) 19. Buzzer cab (H853)
8. Control unit frame rear (D797-R) 20. Control unit KID (D795)
9. Direction indicators rear (H426 & H427) 21. Control unit attachment (D791-1)
10. Back-up lights (E405L & E405R) 22. Buzzer automatic spreading (H9003)
11. Back-up alarm (H965)

9:32 9 Frame, body, cab and accessories – Signalling system
Signalling system, component position
1 2 3 4 5
16, 17
6
006427
15 13, 14 12 11 10 9 8 7
1. Rotating beacon (H428) 10. Switches, see Controls and instruments, overview,
2. Control unit KIT (D790-2) page 9:4
3. Buzzer cab (H853) 11. Horn (H850)

4. Control unit KID (D795) 12. Make-contact operator in seat (S230)
5. Control unit attachment (D791-1) 13. Control unit cab (D790-1)
6. Buzzer automatic spreading (H9003) 14. Relay loud horn (K3016)
7. Direction indicators front (H422 & H423) 15. Control unit frame rear (D797-R)
8. Control unit, frame front (D797-F) 16. Direction indicators rear (H426 & H427)
9. Loud horn (H850-1) 17. Back-up alarm (H965)

9 Frame, body, cab and accessories – Entertainment and communication 9:33
9.8 Entertainment and

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

documentation for each product.

9:34 9 Frame, body, cab and accessories – Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component position
The function of the window panes is to enclose the cab and to give
C the operator good visibility. The window panes are tinted.
D
The following panes may be of laminated glass:
• Side windows front, position E
• Windshield (front window), position B
The rear-view mirrors are of the type convex mirror. Outside rear-view
mirrors are located on the frame and an inside rear-view mirror is
located in the cab.
A E B 001512
As an option, the machine can be equipped with power mirrors
A Side windows and electrically heated rearview mirrors.
B Windscreen (front window) As an option the machine can be equipped with a back-up
C Roof window (reversing) camera and a screen in the cab to improve visibility to
D Rear window the rear. The back-up camera is located on the counterweight. The
monitor is installed on an adjustable stand on the left door pillar.
E Side windows, front

9 Frame, body, cab and accessories – Cab structure and suspension 9:35
9.10 Cab structure and suspension

Design and suspension, description
The cab has a flat floor with a bracket for the operator's seat. It is
suspended in the cab substructure via heavy-duty rubber insulators
located on the cab's underside. This is to minimize vibrations from
1 the frame to the cab. There is an insulator at four points, one in each
corner. Each insulator bracket has a rubber bushing and a bolt.
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
There are different types of cab mountings:

• Manual sliding cab, description, page 9:36
• Hydraulic sliding cab, general, page 9:36
• Vertically adjustable cab, general, page 9:38
NOTE
Cab mounting does not affect cab design.
9.10.2 Doors
Doors, description
The cab has two doors, the left is the driver's door and the right is the
emergency exit. The doors have:
• hand rail
• handle
• keylock
• opening window (emergency exit door )
There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be controlled with the diagnostics menu, see section
8 Control system, group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2
SLIDING-CAB, menu 1.
Doors, checking

9:36 9 Frame, body, cab and accessories – Sliding cab
2 Visually inspect the door's mounting points.

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

Manual sliding cab, description
Manual sliding cab means that the cab can be moved forward
to facilitate access for service and maintenance in the engine
compartment.
The cab is slid fore and aft by hand. Two cable chains on each side
protect hoses and cables to and from the cab when the cab is moved.
The cab is secured in the rear position during operation with two lock
devices at the cab's trailing edge.
A
DANGER
The cab is heavy and the machine may never be
moved without secured cab.
Fatal danger! Risk of crushing!
Secure both sides of the cab with lock devices and
pins before starting to operate.
WARNING
000270
B C
A Position, lock device It is important that the lock devices are intact!
B Lock pin They should be checked regularly. However, this is
C Lock handle for securing cab not included as a part of the service schedule for
preventive maintenance!
Hydraulic sliding cab, general
The cab can be moved forward to facilitate access for service and
maintenance in the engine compartment.
Hydraulic sliding cab also means that the cab can be slid hydraulically
during operation to increase driver visibility. The cab is pulled back and
forth by a hydraulic motor that is connected to a chain secured in the
cab substructure. The position of the cab is locked automatically by the
hydraulic motor when sliding cab is not used.

9 Frame, body, cab and accessories – Sliding cab 9:37
Damping

Hydraulic sliding cab, function description

Doors Closed
3
D790-1
D797-O
4
P1
A 11
X
TP 10
T1 B
7
6 9
PT LSHY
LSP3
014006
1. Switch (S197) 6. Control valve option frame

2. Contact closed door (one sensor for each door) 7. Shuttle valve
3. Control unit cab (D790-1) 8. Main pumps
4. Control unit frame option (D797-O) 9. Valve block sliding cab
5. Servo valve sliding cab forward (Y6016) and Servo 10. Hydraulic motor sliding cab
valve cab movement backward (Y6016) 11. End position sensor (B769-2)

9:38 9 Frame, body, cab and accessories – Vertically adjustable cab
Hydraulic sliding cab, component location
6 2
1 2 3 4 5 6
5 3
001862
000624
1. Sensor damping (rear edge of cab on left side) 1. Load signal (LS)
2. Indicator plate damping 2. Pressure supply (P)
3. Chain sliding cab 3. Tank return (T1)
4. Hydraulic motor sliding cab 4. Connection, hydraulic motor (B)
5. Control valve sliding cab 5. Tank return (TP)
6. Indicator plate damping 6. Connection, hydraulic motor (A)
9.10.5 Vertically adjustable cab

Vertically adjustable cab, general
Vertically adjustable cab means that the cab can be raised or lowered
hydraulically during operation to increase driver visibility. The vertical
adjustment of the cab is controlled by a hydraulic cylinder in a stand
that secures the cab. The cab can be secured manually in the raised
position with two safety locks.
For safety reasons, the machine's speed and transmission are locked
to second gear when the cab is raised.
Damping


9 Frame, body, cab and accessories – Vertically adjustable cab 9:39
Vertically adjustable cab, function description

Doors Closed
Lift and lowering of the boom is limited if the door is open with raised cab.
3
D790-1
D797-O
4 13
9
5
10 11 12
P1 A
X B
TP
T1 T3
7
6
PT LSHY
LSP3
014007
1. Switch vertically adjustable cab (S) 7. Shuttle valve
2. Contact closed door (one sensor for each door) 8. Main pumps
3. Control unit cab (D790-1) 9. Accumulator
4. Control unit frame option (D797-O) 10. Load control valve
5. Servo valve raise cab (Y6016) and Servo valve lower 11. Hydraulic cylinder, vertically adjustable cab
cab (Y6017) 12. Sensor lowered cab (B777-2)
6. Control valve option frame 13. Sensor damping end position (B769-2)

9:40 9 Frame, body, cab and accessories – Vertically adjustable cab
Vertically adjustable cab, component location
1
6 2
3 3
5
4 4
000624
005110
1. Sensor cab end-position lowered cab (B777-2) 1. Load signal (LS)

2. Sensor damping end position (B769-2) 2. Pressure supply (P)
3. Stand, vertically adjustable cab 3. Tank return (T1)
4. Hydraulic cylinder, vertically adjustable cab 4. Connection, hydraulic motor (B)
5. Cab substructure vertically adjustable cab 5. Tank return (TP)
6. Safety lock 6. Connection, hydraulic motor (A)

9 Frame, body, cab and accessories – Cab interior 9:41
9.11 Cab interior

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

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

9:42 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:
4
6
006855
1
1. The rear section of the frame with drive axle mounts 5. Boom mounting
2. Cab mounts (4 points) 6. Engine compartment with engine and transmission
mounts
3. Steering axle mounts
4. The rear section of the frame with counterweights

9 Frame, body, cab and accessories – Body structure 9:43
9.13 Body structure

Body, description
The body's function is a part of the frame. There are fenders to deflect
dirt, footsteps and handrail to facilitate access on the frame, engine
hood to deflect dirt and objects from the engine compartment and a
counterweight to balance the machine's lifting capacity.
3
2 1
002213
1. Fenders
2. Hood engine compartment
3. Counterweight

9:44 9 Frame, body, cab and accessories – Central lubrication
9.14 Central lubrication

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

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

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

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

9 Frame, body, cab and accessories – Central lubrication 9:45
Central lubrication, checking
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling the
connections at the distribution block. A blocked hose remains
pressurized and the connection becomes firm.
NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2 Turn the start key to position I.

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

9:46 9 Frame, body, cab and accessories – Paint/coatings
9.15 Paint/coatings
Paint and surface finish, description
The machine is finished with an alkyd based single component paint
that is applied by brush or sprayed. For colour code (RAL), see
machine card.
Check the machine often for stone chips, impact damage, and
scratches to the paintwork, repair these immediately to avoid corrosion
on the underlying metal. Only use touch-up paint for minor stone chip
damage and scratches, major damage to paintwork should be repaired
by a paint shop.
NOTE
Before performing touch-ups, the surface area must be carefully
cleaned.
For information on other surface and material colours, contact

Cargotec.

10:1
Contents 10 Common hydraulics

10 Common hydraulics .........................................................................................10:3
10.2 Safety valves..................................................................................................10:4
10.3 Tanks and accumulators ................................................................................10:5
10.4 Pumps............................................................................................................10:6
10.4.2 Axial piston pump with variable displacement...........................................10:7
10.5 Hoses, pipes and valves ................................................................................10:9
10.6 Temperature control, cleaning and hydraulic oil...........................................10:10
10.6.6 Breather filter hydraulic oil tank ...............................................................10:12
10.6.7 Hydraulic oil filter .....................................................................................10:12
10.6.8 Hydraulic oil.............................................................................................10:14
10.6.9 Fine filter hydraulic oil..............................................................................10:16

10:2

10 Common hydraulics – Common hydraulics 10:3
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering,
and certain cab functions with hydraulic pressure.
The brake system is completely separate, and is found in section 4

Brakes.
Pressure plate
On the machine there is a pressure plate with the most important

pressure information (stamped in). The pressure plate is located on
the left side of the frame in front of the cab steps.
Pressure levels vary with the equipment and therefore they are unique
to each machine. When checking pressures, these should correspond
to the values on the pressure plate.
1 2 3 4
MPa
5
MPa
6
MPa MPa MPa
MPa
MPa
MPa MPa
000441
9 8
920643.0024
The appearance of the pressure plate may vary but the symbols are the same.
1. Gas pressure servo accumulator 6. Feed pressure control valve lift legs
2. Steering pressure 7. Max. brake pressure
3. Hydraulic oil pressure accumulator brake system 8. Servo pressure lift and extension
4. Gas pressure brake accumulators 9. Max pressure hydraulic oil pumps
5. Feed pressure control valve attachment

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

Safety valves, component position
1 2
004896
1. Relief valve attachment (figure shows closed valve)
2. Accumulator drain valve

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

Tanks and accumulators, component position
Tank
1 2 1 3 4 Tank
1. Filler plug hydraulic oil
2. Cap for hydraulic oil filter
3. Level glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs hydraulic oil
5 5
001457

10:6 10 Common hydraulics – Pumps
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from four pumps. Two of them
1
are for the working hydraulics, one for cooling and filtering of the
hydraulic oil, and one for the brake system.
2
The pumps are mounted and powered from the transmission's power
3
take off.
4
The right hydraulic oil pump (pump 1, position 2) supplies the control
valve for lift and extension and also supplied the attachment's control
valve. For boom in, pump 2 disengages.
The left hydraulic oil pump (pump 2, position 4) supplies the control
steering system and the control valve for lift and extension. The
priority valve makes sure that there is always pressure for the
steering system, the residual flow goes to the control valve for lift
and extension.
There are spacer blocks fitted to the pressure side of the pumps. The
spacer blocks are equipped with non-return valves that prevent the
oil from being pumped around between the pumps instead of out
in the hydraulic system.
The fixed pump (position 3) feeds the brake system's brake and
cooling circuit across an accumulator charging valve, see section 4
013960
Brakes, group 4.3.1 Oil pump brake system.
1. Pump cooling and filtration The fixed pump (position 1) continuously circulates the hydraulic oil
through the cooler and hydraulic oil filter.
3. Oil pump brake system

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

displacement
Axial piston pump with variable displacement,
D790-1 4
1 3
D797-R
P P
2
LS D D P1
EF
LS
5
P
8 7 6 C
LSM
PT
9
LSO
10
LSP3X T LSP1
C C
11 12
014002
No 1 No 2
1. Control valve lift and extension 8. Solenoid valve pump relief (Y6062)
2. Control unit frame rear (D797-R) 9. Shuttle valve
3. Control valve attachment 10. Shuttle valve
4. Steering control valve 11. Hydraulic oil pump 1
5. Priority valve 12. Hydraulic oil pump 2
6. Solenoid valve top lift hydraulics (Y6003)
7. Servo block including pressure reducer, relief valves
and shuttle valves

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

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

1 hydraulic oil pump 1.
5 Check the standby pressure for one pump at a time as follows:
2 Hydraulic oil pump 1: 2.8 MPa
Hydraulic oil pump 2: 3.0 MPa
Settings apply to standard machine, certain machines may have
higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
6 Increase engine speed to approx. 1,100 rpm and move the
extension function to relief (overflow).
Run out the boom to max. and continue to request max. extension
with the control lever. This will move the extension function to
relief.
014362

7 Check the max. pressure for hydraulic oil pump 1, the pressure
should match the stated value on the pressure plate.
MPa All pumps should give the same pressure. The order between
pumps is not important.
M P a
9 Move the pressure gauge to hydraulic pump 2 and repeat steps
3-8.
M P a
M P a
011086
M P a M P a M P a M P a M P a M P a M P a
A 4 9 1 9 5 .0 4 0 0

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

Hoses, pipes and valves, component position
1
2 3
014004
1. Servo valve load handling and steering 3. Collection block filtered returns
Incl. shuttle valves, pressure d=reducers and 4. Priority valve
solenoid valves
2. Collecting block unfiltered returns

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

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

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

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

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

component position
3
2
014562
7 6 5 4
1. Cooling fan and cooler hydraulic oil 5. Breather filter hydraulic oil tank
2. Fine filter hydraulic oil 6. Tank heater
3. Hydraulic oil filter 7. Sensor hydraulic oil temperature (B776)
4. Hydraulic oil filter (high-pressure filter) 8. Bypass valve

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

3 Remove the filter housing.
Press down and turn approx. 1/8 turn clockwise.
4 Replace the filter insert.
Handle the filter cartridge as environmentally hazardous waste.
5 Fit the filter housing.
Press down and turn approx. 1/8 turn counter-clockwise.
6 Reset the filter indicator by pressing down the button in the middle
1. Cover plate for oil filter on the glass centred on the filter cartridge.
2. Filling point hydraulic oil
10.6.7 Hydraulic oil filter
Hydraulic oil filter, changing
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter
cartridge as environmentally hazardous waste. Note position of
the parts.
1. Cover plate for oil filter


10 Common hydraulics – Hydraulic oil filter 10:13
5 Clean the filter holder's parts. Be especially thorough with the

magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and cover plates. Tighten the bolts crosswise.
8 Check the oil level, see Hydraulic oil, level check, page 10:14.
Magnetic rod
Hydraulic oil filter (high-pressure filter), changing
NOTE
Safety.
IMPORTANT

Safety.
3 Remove the drain plugs in the bottom of the filters.

Let the oil drain. Wait a while since the oil drains slowly.
4 Remove the filter holders.
NOTE
Filter holders are heavy, loosen them with care.
5 Clean the filter holders.

6 Remove the filter inserts.
NOTE
Note the position of the O-rings.
7 Install the O-rings on the filter inserts and filter holders. Lubricate
the O-rings with hydraulic oil.
8 Fit the new filter inserts to the filter bracket.
003602
9 Fit the filter holder and the drain plug.

High-pressure filter, under machine

10:14 10 Common hydraulics – Hydraulic oil
NOTE
11 Close relief valve top lift.
CAUTION
010475
engine is started.
Relief valve top lift, figure shows closed valve.

12 Turn on the main electric power and start the engine.
13 Check that the filter holders do not leak.
14 Check the oil level, see Hydraulic oil, level check, page 10:14.
10.6.8 Hydraulic oil

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

10 Common hydraulics – Hydraulic oil 10:15
Hydraulic oil, changing
NOTE
Safety.
IMPORTANT
2 Remove the filler cap and pump out the hydraulic oil in a collection
container.
3 When most possible oil has been pumped out. Place a container
under the hydraulic oil tank's drain plug and drain the last hydraulic
oil.
4 Fit the drain plug when the oil has drained.
NOTE
1. Cover plate for oil filter
5 If the hydraulic oil filters are to be changed, change them before
2. Filling point hydraulic oil filling the tank with oil, see Hydraulic oil filter, changing, page
3. Level glass hydraulic oil 10:12.

6 Fill new hydraulic oil in the filler holes on the filter's cover
plates. This filters the oil and protects the hydraulic system from
contamination.
Fill oil until the oil level is in the middle of the level glass. For
CAUTION
Do not overfill!

10:16 10 Common hydraulics – Fine filter hydraulic oil
10.6.9 Fine filter hydraulic oil
Fine filter hydraulic oil, changing
NOTE
Safety.
IMPORTANT
2 Remove the cover.

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

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electrical protection........................................................................................ 11:4
11.2.2 Fuses ........................................................................................................ 11:4
11.3 Batteries......................................................................................................... 11:9
11.3.1 Start battery............................................................................................... 11:9
11.4 Alternator ..................................................................................................... 11:11
11.5 Distribution of electricity ............................................................................... 11:12
11.5.1 Voltage feed ............................................................................................ 11:12
11.5.2 Electrical distribution box......................................................................... 11:17
11.5.3 Control units ............................................................................................ 11:17
11.6 Communication ............................................................................................ 11:20
11.6.1 CAN bus .................................................................................................. 11:20
11.6.2 Redundant CAN-bus ............................................................................... 11:20
11.6.3 CAN-bus drivetrain .................................................................................. 11:20
11.6.5 RMI (Remote Machine Interface) ............................................................ 11:21
11.6.6 Kalmar CAN Customer Gateway............................................................. 11:21

11:2

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

11:4 11 Common electrics – Electrical protection
11.2 Electrical protection

Electrical protection, component position
1. Main fuses, boom nose
1 2 3 4
2. Control switch
3. Circuit fuses, electrical distribution box cab
4. Main fuses, boom mounting
5. Main fuses, electrical distribution box frame
6. Circuit fuses, electrical distribution box frame
7. Battery disconnector
5
4
F5
93
D7
F5
F5
68
8-1
X1
F5
8-2
K1
8-3
7 K3
K2
K4
004885
11.2.2 Fuses
Fuses, description
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
The electrical system has three main circuits (30-, 15-, and
15E-voltage), see Distribution of electricity, description, page 11:12.
The main circuits are fused several times with main fuses and circuit
fuses.

11 Common electrics – Fuses 11:5
Main fuses
Main fuses
1 2
The main fuses divide the machine's voltage feed into smaller parts
to maintain as many functions as possible in case of damage to
cables harnesses.
By the cab's and frame's electrical distribution boxes there are fuse
plates that describe the different fuses.
3
4
5
6
004925
Main fuses
1. Control breaker voltage (15E) to control units on
boom and attachment, (25 A)
2. Ground connections for boom and attachment,
(25 A)
3. Electric power feed relay K1, electric power to
ignition voltage (15), (50 A)
4. Battery voltage (30) to cab, engine, and
transmission, (50 A)
5. Electric power feed relay K2, power to control
breaker voltage (15E), (50 A)
6. Ignition voltage (15) to control units on frame,
engine, and transmission, (50 A)

11:6 11 Common electrics – Fuses
Circuit fuses
Circuit fuses
Circuit fuses are grouped in fuse holders that are located in the
electrical distribution box on the frame and the electrical distribution
box in the cab.
By the fuse holders there are fuse plates with information about fused
function and fuse rating.
C
D
013034
A Circuit fuses cab battery voltage (30) and

ignition voltage (15) (F58-4)
B Circuit fuses cab ignition voltage (15) (F58-5)
C 30-fuses (battery voltage) (F58-1)
D 15-fuses (ignition voltage) (F58-2)
E 15E-fuses (control breaker voltage) (F58-3)

11 Common electrics – Fuses 11:7
SUPPLY POWER
A1 10A KCU (KALMAR CAB UNIT)
X2044980 1
B2 5A KCU,START UP (KALMAR CAB UNIT)
F58-4 15
C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
E5 10A OPT RADIO
MAIN POWER
F6 25A OPT SEAT HEATER, TURNABLE SEAT
F58-4 30
G7 15A OPT WORK LIGHT
CAB
H8 15A OPT AIRCUSHIONED SEAT
A1 25A KCU (KALMAR CAB UNIT)
F58-5 15 SUPPLY POWER CAB

B2 10A KIT (KALMAR INFORMATION TERMINAL)
C3 15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)
D4 5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)
E5 10A SERVICE
F6 5A OPT MAP READING LIGHT
G7 10A OPT CONVERTER 12V
014092
H8 10A OPT COMPRESSOR HORN
Circuit fuses electrical distribution box cab
A1 30A CAB
A42174.0200
B2
F58-1 30 MAIN POWER

C3 15A ENGINE
D4 10A ENGINE
E5 5A TRANSMISSION
F6
G7 30A OPT ENGINE/EATS VOLVO
H8
A1 25A KDU, FRONT (KALMAR DISTRIBUTION UNIT)
B2 5A ENGINE, ECC
F58-2 15 SUPPLY POWER
C3 25A KDU, REAR (KALMAR DISTRIBUTION UNIT)
D4 10A KDU, OPT (KALMAR DISTRIBUTION UNIT)
E5 5A TRANSMISSION
F6
G7
H8 5A ENGINE
A1 25A ATTACHMENT
B2 10A KDU,FRONT (KALMAR DISTRIBUTION UNIT)

F58-3 15E SUPPLY POWER
C3
D4 10A KDU,OPT (KALMAR DISTRIBUTION UNIT)
E5
EMERGENCY
F6
G7
014128
H8 5A FEEDBACK K2
Circuit fuses electrical distribution box frame

11:8 11 Common electrics – Fuses
Fuses, changing
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
1 Turn off the system voltage (battery disconnector).
2 Remove the cover from the fuse holder.
3 Check that the fuses are intact. Change when needed.

11 Common electrics – Batteries 11:9
11.3 Batteries
11.3.1 Start battery
Start battery, checking
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed in
the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
1 Check the battery voltage from the operating menu for electrical
system.
With the engine off, the battery voltage should be 23–25 V.
With engine at max. engine speed (2,000 rpm), the battery voltage
should be 27–29 V.
000354
Operating menu for electrical system 3 Check that the batteries are clean on the top to prevent leakage
currents between cells, which can cause reduced battery capacity.
Wipe clean with a cloth and clean warm water without detergent.
4 Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
5 Check the fluid level in the battery cells. Top up with battery water
if needed.
The electrolyte level should be 10 mm above the cells.
NOTE
Use only distilled water if topping up is necessary.
Battery cables, checking
DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no
machine parts wear or chafe against the battery cables.
Change damaged battery cables.
The following battery cables should be checked for clamping, risk of

rubbing and damage to the battery cables. Rectify incorrect clamping
and risks of rubbing. Change battery cables that show signs of damage.
Diesel-powered machines
• Plus-cable between battery and battery disconnector.

11:10 11 Common electrics – Start battery
• Plus-cable between battery disconnector and starter motor.

• Plus-cable between starter motor and alternator.
• Plus-cable between battery disconnector and main fuses.
• Plus-cable between starter motor and preheating relay.
• Plus-cable between preheating relay and preheating coil.
• Ground cable between battery and frame.
• Ground cable between engine and frame.

11 Common electrics – Alternator 11:11
11.4 Alternator
Alternator, component position
014499

11:12 11 Common electrics – Distribution of electricity
11.5 Distribution of electricity

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

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

• Operator’s door is opened
• Interior lighting is lit
• Flashing hazard lights are activated
• Start key in position I
Start-up
Start-up
D791-2
(D791-3 / D791-4)
The following takes place at start-up:
Startup signal
D791 1. Start-up signal to Control unit cab (D790-1).
D790-1 D790-2 D795

000036
D797-R D797-O D797-F
Start-up signal is sent

2. Control unit cab (D790-1) initiates connection of redundant
KDU Attachment
(option) voltage feed. See Redundant voltage feed of control units,
description, page 11:14.
KDU Attachment 3. Control unit cab (D790-1) activates ignition voltage (15).
See Ignition voltage (15), description, page 11:15.
D790-1 D790-2 D795
4. Control unit cab (D790-1) establishes redundant CAN-bus.
See Redundant CAN-bus, description, page 11:20.
5. Control unit cab (D790-1) activates CAN-bus drivetrain. See
CAN-bus drivetrain, description, page 11:20.
000037
D797-R D797-O D797-F

6. Control unit cab (D790-1) activates control breaker voltage (15E).
Redundant CAN-bus communication See Control switch voltage (15E), description, page 11:16.

11 Common electrics – Voltage feed 11:13
System down in powerless mode

The system goes down in powerless mode when:
• Start key in position 0 and no activity signal has been sent.
• Start key in position 0, hold circuit's run time has expired and no
activity signal has been sent.
• Start key in position 1 and automatic engine shut-down has been
activated.
The following takes place when the system goes down in powerless
mode.
1. Cab control unit (D790-1) cuts off emergency stop switch voltage
(15E).
See Control switch voltage (15E), description, page 11:16.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:15.
3. Redundant voltage feed to control units is cut off.
4. Cab control unit (D790-1) disconnects the redundant CAN bus.
See Redundant CAN-bus, description, page 11:20.
5. Cab control unit (D790-1) disconnects the redundant voltage feed.
See Redundant voltage feed of control units, description, page
11:14.
6. Control unit cab (D790-1) awaits start-up signal. Other electronics
are powerless.
11.5.1.1 Battery voltage (30)
Battery voltage (30), description

The battery voltage feeds voltage:
• Control system at start. See Start-up of electrical system,
description, page 11:12.
• Starter motor
• Main relays (15-voltage)
• Control switch relays (15E-voltage)
• Engine
• Transmission

11:14 11 Common electrics – Voltage feed
11.5.1.2 Redundant voltage feed of control units
Redundant voltage feed of control units, description

The redundant voltage feed only feeds the control units' control logic
A
and buses, and is controlled completely by Control unit cab (D790-1).
D791-2
The control units' outputs remain without power and are supplied with
Startup signal voltage first when ignition voltage is activated.
D791
The redundant voltage feed for each control unit is independent of
D790-1 D790-2 D795 other control units. If a control unit is not working the voltage feed to
other control units is not affected.
When all control units have redundant voltage feed and bus
communication, the system is ready to receive, process signals.
D797-R D797-O D797-F
When redundant voltage feed is activated the following takes place.
1. Start-up signal is sent to Control unit cab (D790-1), see A in
B illustration.
D791-2
2. A hold circuit is activated in Control unit cab (D790-1) which
activates the control unit's control logic.
D791
3. Control unit cab (D790-1) activates redundant voltage feed to the
other control units, see B in illustration.
D790-1 D790-2 D795
Control unit cab (D790-1) has four outputs for voltage feed, other
control units have two inputs for redundant voltage feed. In case
of failure of one feed, the control unit is supplied from the other
feed.
000031
D797-R D797-O D797-F
A Start-up signal is sent

B All control units are supplied with voltage

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

The ignition voltage feeds the power electronics.
Startup
2 The ignition voltage is activated by:
• Start key in position I
D790-1 • Flashing hazard lights (Hazard) activated
1
D1 D2
When ignition voltage is activated the following takes place.
D795 1. Battery disconnector in position 1. Voltage feed to Control unit
3 cab (D790-1), ignition, switch flashing hazard lights, door switch
K315-1 and interior lighting.
D790-2 2. Switch for start-up signal gives pulse to Control unit cab (D790-1).
- + 4 CAN bus communication is established (not drive-train).
D797-F 3. Start key in position I or flashing hazard lights activated.
D3
4. Control unit cab (D790-1) feeds voltage to power relay ignition
D4 (K315-1) and relay ignition key lock (K315-2) in electronic box
D797-R frame.
5. Ignition voltage supplies control units, relays, solenoid valves and
D5 other electronics.
D797-O
Drivetrain’s CAN bus establishes communication.
D6
D793
K315-2
006815
D794
Power feed ignition circuit
D1 Diagnostic menu CAN/POWER 4
D3. Diagnostic menu CAN/POWER 8

11:16 11 Common electrics – Voltage feed
11.5.1.4 Control breaker voltage
Control switch voltage (15E), description

The control switch voltage supplies functions which require a control
S250 switch, e.g. working hydraulics.
D1
1 The control switch is activated with Switch control switch.
D790-1
Condition for activating control switch voltage is that Switch control
2 4 switch is not pressed in.
D7 D6 D2 • Start key in position I
D3 • Ignition voltage (15)
K3009-1 K3009-2 • Switch, control switch not activated.
D797-F
- + 5 When control switch voltage is activated the following takes place.
D797-O 1. Ignition voltage is connected to Control unit cab (D790-1).

3
2. Control unit cab (D790-1) activates control breaker (K3009-1) in
D4 electronic box frame and control breaker voltage (15E) feeds the
D791 circuit until relay (K3) in electronic box frame.
D5 3. 15E-feed sends a voltage signal to Control unit cab (D790-1) and
verifies that Power relay control breaker (K3009-1) is active but
006816
(D791-2)
D8 (D791-3) that Power relay control breaker (K3009-2) is inactive.
(D791-4)
This verifies that the control breaker is working.
Power feed, control breaker circuit
4. Control unit cab (D790-1) activates power relay control breaker
D1. Diagnostic menu CAN/POWER 5 (K3009-2) in the electrical distribution box and the control breaker
D2. Diagnostic menu CAN/POWER 5 voltage supplies voltage to the control units (not drivetrain).
D3 Diagnostic menu CAN/POWER 8 5. When Switch control breaker (S250) is pressed down the ignition
voltage to Control unit cab (D790-1) is cut off, and thus the control
D4 Diagnostic menu CAN/POWER 12 current to Power relay control breaker (K3009-1) and Power relay
D5 Diagnostic menu CAN/POWER 16 control breaker (K3009-2). Power supply to the control units is
cut off and the functions stop.
D6. Diagnostic menu CAN/POWER 5
As extra safety the cab control unit (D790-1) also sends status
D7. Diagnostic menu CAN/POWER 5 for Switch, control breaker (S250) on the CAN bus. In this way
D8-2 Diagnostic menu CAN/POWER 17 functions are also cut off at signal level.
D8-3 Diagnostic menu CAN/POWER 18
D8-4 Diagnostic menu CAN/POWER 19

11 Common electrics – Electrical distribution box 11:17
11.5.2 Electrical distribution box

Electrical distribution box, component position
5 6
4 7
3
2 13
1 8
14
15
16
9 17
10
11
12
006449
1. Circuit fuses battery voltage (30) F58-3 10. Power relay ignition K315-1
2. Circuit fuses ignition voltage (15) F58-2 11. Power relay control switch K3009-1
3. Circuit fuses control switch voltage (15E) F58-3 12. Power relay control switch K3009-2
4. Diagnostic socket motor, VODIA (engine option 13. Not used
Volvo)
14. Circuit fuses cab battery voltage (30) and ignition
5. Diagnostic socket transmission voltage (15) F58-4
6. Main fuses 15. Diagnostic socket machine
7. Control unit, transmission (D793) 16. Circuit fuses cab ignition voltage (15) F58-5
8. Main fuses 17. Voltage converter
9. Relay ignition K315-2
11.5.3 Control units

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

11:18 11 Common electrics – Control units
Indicator lamps control unit cab

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

light is physically controlled by voltage feed to the
4 control unit.
Light 2 Flashes green when redundant voltage feed control
3 unit and redundant CAN-bus communication is active.
2 No power in system.
006767
1 Green light when power electronics and 15-voltage
are supplied with voltage.
Indicator lamps control unit cab
Light 3 Long yellow single flashing light at communication with
Control unit KID (D795), which is a prerequisite for
trouble-shooting.
Short yellow single flashing light at communication
with Control unit engine (D794) and Control unit
transmission (D793).
Double flashing yellow light (short and long flashes)
at communication with display and engine or
transmission.
Light 4 Red light at active error.
Indicator lamps control units on frame and attachment
Table Indicator lamps control units on frame and attachment
1
2 Light 1 Green light when there is battery voltage to unit. The
light is physically controlled by voltage feed to the
3 control unit.
4 Light 2 Flashes green when any redundant voltage feed left,

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

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

11 Common electrics – Control units 11:19
Control units, component position
1 2 3 4 5
15
7
14
010503
13 12 11 10 9 8
1. Control unit cab (D790-1) 10. Control unit, transmission (D793)
2. Control unit KID (D795) 11. Control unit engine (D794)
3. Control unit KIT (D790-2) 12. Control unit frame rear (D797-R)
4. Control unit, frame front (D797-F) 13. Control unit cab option (D790-3)
5. Control unit frame option (D797-O) Only on machines with both combi attachment and
mini-wheel or joystick steering
14. Control unit CAN-gateway RMI (D795-2)
7. Control unit attachment option (D791-2)
15. Control unit Kalmar CAN customer gateway (D795-2)

11:20 11 Common electrics – Communication
11.6 Communication
Communication, general
1 The machine's communication is handled by a so-called CAN bus
system. The CAN bus system consists of control units connected
together to form a network.
D791-2
The idea with the network is to share information. Signal values are
sent out by the control unit that, e.g., is connected to a sensor, other
D791
control units can use the signal for their functions.
D790-1 D790-2 D795 The network consists of control units and segments. Segment is the
CAN-bus between control units.
D797-R 1 D797-O D797-F

2
000035
D794 D793
1. Segment
2. CAN-bus drivetrain
11.6.1 CAN bus

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

Redundant CAN-bus, description
Redundant CAN-bus means that each control unit has two
D791-4 D791-3 D791-2 D791-1 connections for communication. The CAN-bus is connected in series
CAN R CAN L CAN R CAN L CAN R CAN L CAN R CAN L
between the control units. This means that the CAN-bus can handle
loss of a segment. If several segments fail, then one or some control
units lose contact with the network and work independently, often with
limited capacity to perform their task.
D790-1 D790-2 D795
CAN R CAN L CAN R CAN L
Signals can be checked with diagnostic menu.
003170
CAN L CAN R CAN L CAN R CAN L CAN R
D797-R D797-O D797-F

Principle illustration redundant CAN-bus
11.6.3 CAN-bus drivetrain

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

003171
D794 D793
Principle illustration CAN-bus drivetrain

11 Common electrics – RMI (Remote Machine Interface) 11:21
11.6.5 RMI (Remote Machine Interface)

RMI (Remote Machine Interface), description
Remote Machine Interface is a tool for listening to the machine at a

distance. RMI consists of a control unit which is connected to the
machine, antenna for communication and GPS-antenna ( ) for
positioning.
007443
RMI interface (A911) records communication on the CAN bus and
sends the information to a central RMI server. In the event of a fault
RMI-interface (A911) the control unit in the machine can send information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.
From the RMI server, data from the machine can be analysed and
processed for reading off different values. For example, when it is
time for a service or if there are error codes stored in the machine.
There is a GPS-antenna available as an option, making it

possible to read off the machine's position.
010504
Control unit CAN-gateway RMI (D795-2) sends certain information

from the machine's CAN-bus to RMI-interface (A911) which sends
Control unit CAN-gateway RMI (D795-2)
it on via the RMI-server.
NOTE
RMI only sends data from the machine, but no data can be sent to
the machine. RMI cannot be used to control the machine.
11.6.6 Kalmar CAN Customer Gateway

Kalmar CAN Customer Gateway
Kalmar CAN Customer Gateway is an interface to be able to connect

external equipment to save machine data.
Control unit Kalmar CAN Customer Gateway (D795-2) translates

the communication on the machine's CAN-bus to RS232 and CAN
for connection to external equipment according to a pre-determined
010504
protocol.
Control unit Kalmar CAN Customer Gateway (D795-2)
NOTE
Kalmar CAN Customer Gateway only sends data from the machine,
data cannot be sent to the machine. Kalmar CAN Customer
Gateway cannot be used to control the machine.
The following are examples of data available to customers via Kalmar

CAN Customer Gateway:
• Operating hours
• Temperature values
• Fuel consumption
• Current speed
• Current weight of load
• Operating time to next service
• Number of lifted containers different counters for different sizes
• Position of twistlocks (locked/open)
• Boom position

11:22

D:1
D Error codes
D Error codes
Error codes
See Workshop manual DRF400-450, section D Error codes.

D:2

E:1
E Diagrams
E Diagrams
Diagrams
See Workshop manual DRF 400-450, section E Diagrams.

E:2

F:1
F Technical data
Contents F Technical data

Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Lift capacity and dimensions............................................................................F:6
Oils and lubricants, recommendation...............................................................F:9
Tightening torques, recommendations...........................................................F:11
Tightening torque, ORFS connections ...........................................................F:12
Tightening torque, connections for air conditioning unit.................................F:13
Unit explanations ...........................................................................................F:14
Conversion SI-units........................................................................................F:15
Conversion table, length ................................................................................F:16
Conversion table, area...................................................................................F:16
Conversion table, volume ..............................................................................F:16
Conversion table, weight................................................................................F:16
Conversion table, pressure ............................................................................F:17

F:2

F Technical data – Technical data F:3
F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.
1 Engine Volvo TAD1360VE

Power acc. to ISO 3046 (net power) 256 kW between 1500-1900 rpm
Torque ISO 3046 1745 Nm at 1200 rpm
Max. rpm 2,000 rpm
Number of cylinders 6 cylinders
Alternator, power 2240 W (28 V / 80 A)
System voltage, voltage capacity 24 V (2x12 V / 150 Ah)
2. Transmission ZF 5WG261
No. of gears, forward - reverse 5 – 3
3. Driveline/Axle Kessler
Drive axle, type Kessler D102
4. Brakes
Footbrake system - wheels affected Wet Disc Brake - drive wheel
Parking brake system - wheels affected Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels DRF420 DRF400/450 DRF450

Dimension, front and rear 18.00x25/36 18.00x25/40 18.00x33/36
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air filled. Spare and replacement tyres must be of a brand approved by Cargotec.
9. Cab Spirit Delta with Volvo TAD1360VE

Equivalent sound pressure level LpAZ 72 dB(A)
in cab according to EN12053 with
measurement uncertainty σR = 2.5 dB.
Measuring value with standard engine.
Whole-body vibration in accordance 0.5 m/s2
with EN13059 with measurement
uncertainty k = 0.3 x measured value.
9.6 Lighting system

Control lights 1.2 W2x4.6d
Interior lighting 10 S8.5

F:4 F Technical data – Technical data
9.6 Lighting system

Rear lights 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Rear lights, brake lights & direction indicators - Replace complete
LED
Running lights 5 W2.1x9.5d
- Replace complete
Running lights LED
Headlights (during high, low beam) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work light bulb 70 PK22s (H3)
35 D1S Xenon tube. Cartridge and
Work light, Xenon ballast are replaced complete.
- Replace complete
Work lighting LED
Rotating beacon 70 PK22s (H1)
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
1.2 Engine, fuel system

Fuel tank, volume 550 l
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1–D,
ASTM D 975 No 2–D.
AdBluetank, volume 20 l
Quality AdBlue, according to ISO standard 22241.
1.7 Engine, cooling system
Coolant volume 48 l
Coolant filling Volvo Penta Coolant VCS, ready-mixed
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, only use coolant of
the same type that was used before.
1.8 Engine, lubrication system

Oil volume incl. filter 36 l
Oil type, quality See Oils and lubricants, recommendation, page F:9.

2.6 Transmission, lubrication 5WG261

system
Oil volume 58 l
3.3 Driveline/Axle, drive axle Kessler D102

Differential, oil volume 65 l
Hub reduction, oil volume 2x12 l
4 Brakes
Oil tank brake system, volume 140 l
7 Load handling Spreading motor Rotation motor

Planetary gear hydraulic motor, attachment 2.3 l 2.45 l
Disc brake hydraulic motor, attachment - 0.6 l

Refrigerant, volume 2000 g
Refrigerant air conditioning (cooling plant) R134a
Lubricant air conditioning Zexel PAG-oil
Windshield wiper fluid, volume 5 l
Hydraulic oil tank, volume 600 l
Hydraulic oil system, volume 940 l (total, including tank)

Lift capacity and dimensions

Capacity (ton)
A B
**
* **
* *
H 5 * **
H 4 *
*
005113
(1 ) (1 )
1865 1865
3815 3815
6315 6315
A Container 86 B Container 96
Container 86 Container 96 Lift height top lift

Model H4 H5
Row 1 Row 2 Row 3 Row 1 Row 2 Row 3
(mm) (mm)
DRF400-60C5 38*/40 25** 10** 37**/40* 25* 10* 14900 18100
DRF420-60S5 41*/42 25* 11* 40*/42 25* 11* 15100 18100
DRF450-60S5 43*/45 27* 13* 42*/45 27* 13* 15100 18100
DRF450-60S5M 42*/45 30* 15* 42*/45 30* 15* 15100 18100
DRF450-60S5X 43*/45 35* 18* 42*/45 35* 18* 15200 18200
DRF450-60C5X 42*/45 32** 14** 41**/44*/45 32* 14* 15000 18200
DRF420-65S5 41*/42 28* 14* 40*/42 28* 14* 15100 18100
DRF420-65S6 39**/41*/42 28* 14* 40*/42 28** 14** 16200 19250
DRF450-65S5 43*/45 31* 16* 42*/45 31* 16* 15100 18100
DRF450-65S6 42**/44*/45 31* 16* 43*/45 31** 16** 16200 19250
DRF450-65S5X 45* 36*/38* 21* 43*/45 37*/38 21* 15200 18200
DRF450-65C5X 42*/45 33**/34* 16** 41**/44*/45 34* 16* 15000 18200
DRF450-65S6X 42**/45* 35*/38 21* 43*/45 34**/36*/38 21** 16300 19350
DRF450-70S5 45* 34* 18* 45* 34* 18* 15100 18100
DRF450-70S5X 45* 39*/41 23* 45* 40*/41 23* 15100 18100
DRF450-
45* 39*/41 23*/(31*) 45* 40*/41 23*/(31*) 15100 18200
70S5XS
DRF450-
45* 36**/38* 20**/(27**) 43**/45* 37*/38 20*/(27*) 14900 18200
70C5XS
DRF450-
45* 43*/45 26*/(34*) 45 45* 26*/(34*) 15200 18400
75S5XS
DRF450-
45* 40**/42*/43 24**/(32**) 45** 41*/43 24/(32*) 15000 18400
75C5XS
( ) = Support jacks down

Dimensions (mm)
A 1
A 2
H 3
R 1
R 3 100 V L
003191
100
Operating width Turning radius Main dimensions

Service
Model Ground weight
A1-20" A2-40" R1-20" R3-40" B V L H3 clear- Tyres (kg)
ance
6055- 18.00x-
DRF400-60C5 11200 13600 8100 9400 4150 11200 4500 250 72700
12185 25/40
6055- 18.00x-
DRF420-60S5 11200 13600 8100 9400 4150 11200 4500 250 64500
12185 25/36
6055- 18.00x-
DRF450-60S5 11200 13600 8100 9400 4150 11200 4500 250 66400
12185 25/40
6055- 18.00x-
DRF450-60SM 11200 13600 8100 9400 4150 11200 4500 250 69400
12185 25/40
6055- 18.00x-
DRF450-60S5X 11200 13600 8100 9400 4150 11200 4600 300 76500
12185 33/36
6055- 18.00x-
DRF450-60C5X 11200 13600 8100 9400 4150 11200 4600 300 81100
12185 33/36
6055- 18.00x-
DRF420-65S5 11600 13600 8500 9400 4150 11700 4500 250 66500
12185 25/36
6055- 18.00x-
DRF420-65S6 11900 13900 8500 9450 4150 12000 4500 250 67700
12185 25/36
6055- 18.00x-
DRF450-65S5 11600 13600 8500 9400 4150 11700 4500 250 69000
12185 25/40
6055- 18.00x-
DRF450-65S6 11900 13900 8500 9450 4150 12000 4500 250 69800
12185 25/40
6055- 18.00x-
DRF450-65S5X 11600 13600 8500 9400 4150 11700 4600 300 76300
12185 33/36
6055- 18.00x-
DRF450-65C5X 11600 13600 8500 9400 4150 11700 4600 300 80500
1258 33/36
6055- 18.00x-
DRF450-65S6X 11900 13900 8500 9450 4150 12000 4600 300 77200
12185 33/36
6055- 18.00x-
DRF450-70S5 12000 13600 8900 9400 4050 12200 4500 250 69400
12185 33/36
6055- 18.00x-
DRF450-70S5X 12100 13600 9000 9400 4150 12200 4700 300 77800
12185 33/36
DRF450- 6055- 18.00x-
12100 13600 9000 9400 4150 12200 4700 300 79300
70S5XS 12185 33/36
DRF450- 6055- 18.00x-
12100 13600 9000 9400 4150 12200 4700 300 84200
70C5XS 12185 33/36

Operating width Turning radius Main dimensions

Service
Model Ground weight
A1-20" A2-40" R1-20" R3-40" B V L H3 clear- Tyres (kg)
ance
DRF450- 6055- 18.00x-
12500 13600 9400 9400 4150 12700 4750 300 82100
75S5XS 12185 33/36
DRF450- 6055- 18.00x-
12500 13600 9400 9400 4150 12700 4750 300 88100
75C5XS 12185 33/36

Oils and lubricants, recommendation

Cargotec's stated service intervals in the maintenance manual are
conditional on oil selection according to the following table. The
table states recommended viscosity for different oil types and grades
depending on outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
°C -40 -30 -20 -10 0 +10 +20 +30 +40

Oil type, quality F -40 -22 -4 +14 +32 +50 +68 +86 104
1.8 Engine, lubrication system
Volvo: VDS-3 SAE 15W40
SAE 5W30 (engine oil)
2.6 Transmission, lubrication system

API: CD/CE/CF-4/CF/CG-4/ CH-4/CI- SAE 10W, 10W/30, 10W/40
4/SF/SG/SH/SJ/SL
-25°C SAE 15W/30, 15W/40
ACEA: Categories A, B, E
SAE 20W/20, 20W/40
SAE 30
3.3 Driveline/Axle, drive axle

API GL-5 SAE 80W140
SAE 75W90
4 Brakes (UTTO-oil, Not1)

GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Oil planetary gear hydraulic motor, hypoid oil SAE 80W140
API GL-5
SAE 75W90
Disc brake hydraulic motor, See "10 Common
hydraulics" below
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
Note 1: The oil in the brake system must fulfil one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification

Grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for

all grease points except for lifting equipment and slide plates.
For lifting equipment, use a universal grease type EP according to

NLGI Grade 2 (EP2) with 3-5% Molybdenum disulfide intermix.
For slide plates, use lubricants approved by Cargotec. Order from

Cargotec Parts department. 0.65 kg cartridge for grease gun, part no.
923110.0360, and 5 kg can, part no. 923595.0003.
NOTE
Select grease grade according to relevant climate.
Electrical connector grease
Use electrical contact grease part no. 923836.0552.
Sealant silicone
Use silicone part no. 923107.0308.
Silicone adhesive
Use silicone adhesive part no. 923854.0100.
Coolant
Only use ready-mixed recommended coolant. Select mixture of the

coolant that is adapted for correct temperature.
CAUTION

Tightening torques, recommendations

The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tightening
torque should be reduced by approx. 5%.
For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque varies depending on surface

treatment. Certain combinations of bolts and nuts require lubrication
according to the following table.
State Screw Nut Lubrication

1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9

State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm

Quality 8.8 10.9 12.9

7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, ORFS connections

Pipe and hose coupling
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170

Goods coupling
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400
Tightening torque, connections for air

conditioning unit
O-ring coupling cooling coils
Hose diameter Thread Tightening torque

mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"
The above values should be considered guidelines and may vary

depending on installation.

Unit explanations
Unit Abbreviation
Newton metre Nm
Kilopond metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Meter m
Kilometre km

Conversion SI-units
SI-unit Conversion factor Non-SI Conversion factor SI
Torque
Nm x 10.2 = kg cm x 0.8664 = lb in
Nm x 0.74 = lbf ft x 1.36 = Nm
Nm x 0.102 = kg m x 7.22 = lb ft
Pressure (Pa = N/ m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table, length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1 mm = 0.001 m
Conversion table, area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table, weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table, pressure

Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735,56 Dry (mmHg) = 0.96784 atm

F:18

G:1
Contents G Terminology and index

Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:7

G:2

G Terminology and index – Terminology and index G:3

Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Attachment Part of the machine that grabs the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreader and levelling.
Axle distance Distance between drive axle and steering axle.
Bar Unit for measuring pressure.
Battery disconnector Cuts off current from battery.
Boom Lift beam can be moved vertically and longitudinally. Mounting for attachment.
Bottom lift attachment Vertically adjustable "lift legs" for load handling. Grabs the load from underneath.
Daily inspection The actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of the machine’s lift capacity.
Display "Window" showing digital information on steering wheel panel in cab.
Operating hours Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
ECC Electric Climate Control. Climate control unit with thermostat-controlled cooling,
dehumidification, and heating.
EGR Exhaust Gas Recirculation. Exhaust gas cleaning function, where some of the exhaust
gases are led back into the intake manifold to reduce NOx emissions from the engine.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) of a pump.
Hanging load Lifted load.
FMI Fault Message Identifier.
Main fuse Located by battery. Cuts the power to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transmit power to different functions.
Indicator Manual "sensor", e.g., shows that a filter is clogged and needs to be replaced.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorized trained person.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to
regulations.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.

G:4 G Terminology and index – Terminology
Term Description
Control valve Valves that can be used to control something, e.g., release pressure and thus lower
a boom or a fork.
Machine model Machine type. Indicated, for example: DRF 400-450. See also type designation.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
OP Overload Protection. Overload system to warn in case of overloading of machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant mesh.
Product alternatives One of several alternatives is selected for a machine, e.g., engine alternative.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current's amplitude. In everyday language, a stepless valve, as
opposed to an Off/On valve. On, e.g., the transmission's valve housing.
Reachstacker Machine with special lift boom and top lift attachment for containers.
Serial number Unique machine designation. Available on machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small user movement results in a big machine movement, e.g. power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of attachment.
Levelling Attachment is tilted, for example, if load stands on uneven ground.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Widening of attachment.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
Steering axle Wheel axle with steering.
Buzzer Audible alarm to catch the operator’s attention.
Option Optional equipment for machine.
Tilting Load is tilted forward or backward.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Four lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
UTTO-oil Universal Tractor Transmission Oil.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.
Wet brakes Brake discs in oil-bath.
Valve slide Moving part in the valve. Decides the oil's path.

G Terminology and index – Terminology G:5
Term Description
Rotation yoke Rotating unit on attachment, rotates attachment in relation to lift boom.
Overload system A warning system, LLMC (Longitudinal Load Moment Control). The system is used for
stationary load handling, in order to not jeopardize the machine forward stability. LLMC
is not intended to control lateral (side) stability or stability when operating.

G:6

G Terminology and index – Index G:7
Index Engine . . . . . . . . . . . .
ENGINE . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 1:3
. . 8:18
Entertainment and communication . . . . . . . . . . 9:33
Environment . . . . . . . . . . . . . . . . . . . B:21
A Error codes . . . . . . . . . . . . . . . . . 8:10, D:1
Exhaust system . . . . . . . . . . . . . . . . . . 1:21
About the documentation . . . . . . . . . . . . . A:10 Extension . . . . . . . . . . . . . . . . . . . . . 7:10
About the maintenance manual . . . . . . . . . . . . A:3 EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:23
Accumulator . . . . . . . . . . . . . . . . . . . . 4:9
AdBluefilter . . . . . . . . . . . . . . . . . . . . 1:14
AdBluetank . . . . . . . . . . . . . . . . . . . . 1:11
Air cleaning system . . . . . . . . . . . . . . . . . 1:18 F
Air intake and exhaust outlet . . . . . . . . . . . . . 1:17 Feedback . . . . . . . . . . . . . . . . . . . . . A:11
Alternator . . . . . . . . . . . . . . . . . . . . 11:11 Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:16
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:21 Foreword . . . . . . . . . . . . . . . . . . . . . A:3
Axial piston pump with variable displacement . . . . . . 10:7 Frame . . . . . . . . . . . . . . . . . . . . . . . 9:42
Frame, body, cab and accessories . . . . . . . . . . 9:3
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:25
B Fuel filter . . . . . . . . . . . . . . . . . . . . . 1:11
Fuel pre-filter . . . . . . . . . . . . . . . . . . . . 1:9
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:9 Fuel system . . . . . . . . . . . . . . . . . . . . 1:8
Battery voltage (30) . . . . . . . . . . . . . . . . 11:13 Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:9
Body structure . . . . . . . . . . . . . . . . . . . 9:43 Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:4
BOOM . . . . . . . . . . . . . . . . . . . . . . 8:20
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:4
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3
Breather filter . . . . . . . . . . . . . . . . . . . 4:14 G
Breather filter hydraulic oil tank . . . . . . . . . . . 10:12 General safety information . . . . . . . . . . . . . . B:3
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:8 Glass/windows/mirrors . . . . . . . . . . . . . . . 9:34
C H
CAB . . . . . . . . . . . . . . . . . . . . . . . 8:16 Heating, ventilation and air conditioning . . . . . . . . 9:14
Cab interior . . . . . . . . . . . . . . . . . . . . 9:41 Height limitation . . . . . . . . . . . . . . . . . . 8:9
Cab structure and suspension . . . . . . . . . . . . 9:35 Hoses, pipes and valves . . . . . . . . . . . . . . . 10:9
CAN bus . . . . . . . . . . . . . . . . . . . . 11:20 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:17
CAN-bus drivetrain . . . . . . . . . . . . . . . . 11:20 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:14
CAN/POWER . . . . . . . . . . . . . . . . . . . 8:14 Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:12
Central lubrication . . . . . . . . . . . . . . . . . 9:44
CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:17
COMBI . . . . . . . . . . . . . . . . . . . . . . 8:23
Common electrics . . . . . . . . . . . . . . . . . 11:3
I
Common hydraulics . . . . . . . . . . . . . . . . . 10:3 Ignition voltage (15) . . . . . . . . . . . . . . . . 11:15
Communication. . . . . . . . . . . . . . . . . . 11:20 Ignition/heating . . . . . . . . . . . . . . . . . . . 1:33
Complete machine . . . . . . . . . . . . . . . . . 0:3 Intercooler . . . . . . . . . . . . . . . . . . . . . 1:21
Condenser . . . . . . . . . . . . . . . . . . . . . 9:25
Container counter. . . . . . . . . . . . . . . . . . 7:67
Control breaker voltage . . .
Control system . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
11:16
. 8:3
K
Control system engine. . . . . . . . . . . . . . . . 1:32 Kalmar CAN Customer Gateway . . . . . . . . . . 11:21
Control system transmission . . . . . . . . . . . . . 2:13
Control units . . . . . . . . . . . . . . . . . . . 11:17
Controls and instruments . . . . . . . . . . . . 4:4, 9:4 L
Coolant . . . . . . . . . . . . . . . . . . . . . . 1:25
Cooling fan . . . . . . . . . . . . . . . . . . . . 1:23 Levelling. . . . . . . . . . . . . . . . . . . . . . 7:37
Cooling system . . . . . . . . . . . . . . . . 1:23, 2:12 Lift boom . . . . . . . . . . . . . . . . . . . . . 7:12
Lift legs . . . . . . . . . . . . . . . . . . . . . . 7:50
Lift shoe . . . . . . . . . . . . . . . . . . . . . . 7:60
Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:4
D Lighting system. . . . . . . . . . . . . . . . . . . 9:28
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:12 LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:15
Diagrams . . . . . . . . . . . . . . . . . . . . . E:1 Load carrier . . . . . . . . . . . . . . . . . . . . 7:41
Distribution of electricity . . . . . . . . . . . . . . 11:12 Load centre limitation . . . . . . . . . . . . . . . . 8:9
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:35 Load handling . . . . . . . . . . . . . . . . . . . 7:3
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:5 Lubrication system . . . . . . . . . . . . . . . 1:29, 2:9
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3
M
E Main beam attachment . . . . . . . . . . . . . . . 7:17
Electric overload system . . . . . . . . . . . . . . . 8:7 Mechanical transmission. . . . . . . . . . . . . . . 2:8
Electrical distribution box . . . . . . . . . . . . . 11:17 Moisture filter . . . . . . . . . . . . . . . . . . . 9:25
Electrical protection . . . . . . . . . . . . . . . . . 11:4 Monitoring . . . . . . . . . . . . . . . . . . . . . 8:6

G:8 G Terminology and index – Terminology
O Signalling system . . . . . . . . . . . . . . . . . . 9:31

Sliding cab . . . . . . . . . . . . . . . . . . . . . 9:36
Oil filter, brake system . . . . . . . . . . . . . . . . 4:15 SLIDING-CAB . . . . . . . . . . . . . . . . . . . 8:24
Oil for brake system . . . . . . . . . . . . . . . . . 4:16 Speed limitation . . . . . . . . . . . . . . . . . . 8:8
Oil pump brake system . . . . . . . . . . . . . . . 4:7 Spreader beam . . . . . . . . . . . . . . . . . . . 7:26
OP . . . . . . . . . . . . . . . . . . . . . . . . 8:22 Spreading . . . . . . . . . . . . . . . . . . . . . 7:18
Other functions . . . . . . . . . . . . . . . . . . . 7:62 Spreading chains . . . . . . . . . . . . . . . . . . 7:23
Overload system . . . . . . . . . . . . . . . . . . 8:6 Spreading motor . . . . . . . . . . . . . . . . . . 7:22
Start battery . . . . . . . . . . . . . . . . . . . . 11:9
Start/stop . . . . . . . . . . . . . . . . . . . . . 1:34
P Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:46 Steering axle cradle . . . . . . . . . . . . . . . . . 6:4
Parking brake system . . . . . . . . . . . . . . . . 4:10 Support jacks . . . . . . . . . . . . . . . . . . . 7:62
Parking brake unit . . . . . . . . . . . . . . . . . 4:11 SUPPORT JACKS . . . . . . . . . . . . . . . . . 8:24
Power assisted system . . . . . . . . . . . . . . . 5:4 Suspension . . . . . . . . . . . . . . . . . . 6:3–6:4
Power-assisted brake system . . . . . . . . . . . . 4:5 Synchronised lift . . . . . . . . . . . . . . . . . . 7:68
Pressure reducer . . . . . . . . . . . . . . . . . . 7:9
Preventive maintenance . . . . . . . . . . . . . . . C:3
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:4 T
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6
Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Technical data . . . . . . . . . . . . . . . . . . . F:3
Temperature control, cleaning and hydraulic oil . . . . 10:10
R Temperature control, cleaning and oil brake system . . . 4:13
Radiator and expansion tank . . . . . . . . . . . . . 1:23 Terminology . . . . . . . . . . . . . . . . . . . . G:3
Reading instructions . . . . . . . . . . . . . . . . A:4 Terminology and index . . . . . . . . . . . . . . . G:3
Redundant CAN-bus . . . . . . . . . . . . . . . 11:20 Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:32
Redundant voltage feed of control units . . . . . . . 11:14 Torque converter/Clutch system . . . . . . . . . . . 2:7
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:16 TRANSM . . . . . . . . . . . . . . . . . . . . . 8:19
RMI . . . . . . . . . . . . . . . . . . . . . . . . 8:25 Transmission. . . . . . . . . . . . . . . . . . . . 2:3
RMI (Remote Machine Interface) . . . . . . . . . . 11:21 Twistlocks . . . . . . . . . . . . . . . . . . 7:41, 7:46
Rotation . . . . . . . . . . . . . . . . . . . . . . 7:28 Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:15
Rotation motor unit . . . . . . . . . . . . . . . . . 7:31 Tyres and rims . . . . . . . . . . . . . . . . . . . 6:7
S V
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 Vertically adjustable cab . . . . . . . . . . . . . . . 9:38
Safety and emergency equipment. . . . . . . . . . . 9:10 Voltage feed . . . . . . . . . . . . . . . . . . . 11:12
Safety instructions . . . . . . . . . . . . . . . . . B:4
Safety valves. . . . . . . . . . . . . . . . . . . . 10:4
Seats . . . . . . . . . . . . . . . . . . . . . . . 9:11 W
Sensor steering wheel reading . . . . . . . . . . . . 5:7
Service indicator . . . . . . . . . . . . . . . . . . 8:9 Weight indicator . . . . . . . . . . . . . . . . . . 7:63
Servo filter . . . . . . . . . . . . . . . . . . . . . 7:7 Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:6
Side shift . . . . . . . . . . . . . . . . . . . . . 7:14 Wheel spindle . . . . . . . . . . . . . . . . . . . 6:5
Side shift frame. . . . . . . . . . . . . . . . . . . 7:16 Wiper/washer system . . . . . . . . . . . . . . . . 9:27

G Terminology and index – Index G:9

last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

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Reachstackers 40-45 tonnes

9 Frame, body, cab and accessories

G Terminology and index

Maintenance Manual DRF 400-450 UDRF06.01GB

UDRF06.01GB Maintenance Manual DRF 400-450

The maintenance manual contains information about how the machine

Cargotec will not accept any responsibility for modifications performed

About the machine version

Cargotec reserves the right to change specifications and equipment

Duplication by any means such as copying, printing, etc., is prohibited.

Maintenance Manual DRF 400-450 UDRF06.01GB

Read operator's manual

Read the operator's manual

Read maintenance manual

refers to important information in the maintenance manual.

Read the maintenance manual

UDRF06.01GB Maintenance Manual DRF 400-450

Maintenance manual's content

For more information about function groups, see Function group

Maintenance Manual DRF 400-450 UDRF06.01GB

Function group structure

The maintenance manual and workshop manual contain different

References between sections in the same manual are indicated with

References are not given between Maintenance manual and Workshop

Product alternatives and optional equipment

Special equipment is not described in the manual. If you're uncertain

Product alternatives are such options that exclude certain standard

Equivalent information for different product alternatives is described

UDRF06.01GB Maintenance Manual DRF 400-450

Optional equipment are options that can be added to the standard

Information for optional equipment is described in separate sections

The machine card indicates of which drawings the machine consists,

The function descriptions describe the function in a logical flow from

Function descriptions use symbols to illustrate components such as

Maintenance Manual DRF 400-450 UDRF06.01GB

Example of function description

UDRF06.01GB Maintenance Manual DRF 400-450

Symbol explanation function descriptions

Maintenance Manual DRF 400-450 UDRF06.01GB

About the documentation

Always specify publication number when ordering.

For publication number, see the machine card.

UDRF06.01GB Maintenance Manual DRF 400-450

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

To: Cargotec Sweden AB

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

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

Maintenance Manual DRF 400-450 UDRF06.01GB

UDRF06.01GB Maintenance Manual DRF 400-450

Maintenance Manual DRF 400-450 UDRF06.01GB

UDRF06.01GB Maintenance Manual DRF 400-450

Cargotec has in this publication documented and warned for situations

A near accident is a warning!

Maintenance Manual DRF 400-450 UDRF06.01GB

Service position is used for service, maintenance and other situations

Service position means:

UDRF06.01GB Maintenance Manual DRF 400-450

Hydraulic and brake systems, depressurising

2 Depressurise the hydraulic system.

4 Depressurize the attachment.

The figure above shows closed valve.

Maintenance Manual DRF 400-450 UDRF06.01GB

5 Depressurise the brake system by opening the drain valve on the