Manual de Manutenção DCF 80

Empty container handler 8-10
tonnes
Publ. no UDCF03.03GB
Maintenance Manual in original MAINTENANCE MANUAL
DCF 80-100
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DCF 80-100
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:7
Machine card.............................................................................................. A:8
Function descriptions ................................................................................. A:8
About the documentation .............................................................................. A:11
The documentation's parts ....................................................................... A:11
Ordering of documentation....................................................................... A:11
Feedback ...................................................................................................... A:12
Form for copying ...................................................................................... A:12
Maintenance Manual DCF 80-100 UDCF03.03GB

A:2
UDCF03.03GB Maintenance Manual DCF 80-100

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

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

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

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

without prior notification. The information in the manual is valid at the
time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Use only 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
5 Steering Technical description, description of the machine's functions with schematic
6 Suspension drawings and explanatory texts for the included components.
Work instructions for preventive maintenance.
7 Load handling
Work instructions for checking and adjusting.
8 Control system
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 are indicated by either section and group numbers, e.g.

"see section 4 Brakes, group 4.3.9 Wheel brakes" or with the section
and page number, e.g. "see Fuel level sensor, description page 4:24"
where 4:24 denotes section 4 Brakes, 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

Product alternatives
The information in the manual is divided in modules. For product
000264
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.
Symbol indicating optional equipment
Special equipment is not described in the manual. If you're uncertain
about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:8.
Product alternatives
Product alternatives are such options that exclude certain standard
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:7. The machine card is supplied together with the spare
parts catalogue and should be stored in the cab as an aid to service
personnel.
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.
The function descriptions use symbols to illustrate components such as

valves, sensors, etc.

4:10 4 Bromsar – Parkeringsbromssystem
4.5 Parkeringsbromssy stem

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

ackumulatorladdnings - och prioriteringsventil styr tryck till
ackumulatorerna som lagrar trycket. Parkeringsbromsenhe ten lossas
med tryck frå n ackumulatorerna genom att parkeringsbromsventile n i
Ventilblock bromssystem trycks ä tter parkeringsbromsoket. Slutkontakt
parkeringsbroms ger signal s å att Indikeringslampa parkeringsbroms
tä nds nä r parkeringsbromsen ä r ansatt.
D
12 1
1
2 11
D790-1 D790-2
8 D797-1 2
3 D
7 D 8
4 10
C 7
Pa GHB 3
6 C
ACK M P HB
T
P 9
5
6
5 4
014645
P
1. Str ömst ä llare parkeringsbroms (S107) 7. Brytkontakt parkeringsbroms (S200)
2. Reglerenhet hytt (D790 -1) 8. Ackumulatorer
3. Reglerenhet ram (D797 –1) 9. Ventilblock bromssystem
4. Magnetventil parkeringsbroms (Y642) 10. Parkeringsbromsok
5. Hydrauloljepump broms och styrning 11. Reglerenhet KIT (D790 -2)
014684
6. Ventilblock ackumulatorladdnings - och 12. Indikeringslampa parkeringsbroms

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

Symbol explanation function descriptions
Symbol explanation function descriptions

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

A Foreword – About the documentation A:11
About the documentation

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

A:12 A Foreword – Feedback
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To: Cargotec Sweden AB

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

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

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

B:1
B Safety
Contents B Safety
Safety..................................................................................................................B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic system, depressurising............................................................... B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under the machine ....................................................................... B:8
Lifting heavy components .......................................................................... B:9
Vibrations ................................................................................................... B:9
Noise ........................................................................................................ B:10
Solvents ................................................................................................... B:10
Fire and explosion risks............................................................................ B:11
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electrical system and electric motors ....................................................... B:16
Rotating components and tools................................................................ B:16
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:17
Welding .................................................................................................... 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 Operator's Manual, Maintenance
Manual and Workshop 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 system, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• Clothing, etc., page B:8
• Several mechanics on the same machine, page B:8
• Working under the machine, page B:8
• Lifting heavy components, page B:9
• Vibrations, page B:9
• Noise, page B:10
• Solvents, page B:10
• Fire and explosion risks, page B:11
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electrical system and electric motors, page B:16
• Rotating components and tools, page B:16
• Tyres and rims, page B:17
• Lifting equipment, page B:17
• Welding, 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.
• Trolley and attachment in completely lowered position.
• Engine off.
• System voltage off (with battery disconnector).
018741

B Safety – Safety instructions B:5
Hydraulic system, depressurising

1 Machine in service position, see Service position, page B:4.
2 Depressurise the hydraulic system.
Turn on the system voltage and turn the start key to position I.
Repeatedly activate the load handling functions.
3 Turn the start key to position 0 and switch off the system voltage.
009798
4 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
005648
5 Depressurise the attachment.

Open relief valve top lift.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to fine filter hydraulic oil.
Check that relief valve attachment is closed before the
009961
engine is started.
The figure above shows open valve.

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

Fuel system
The following safety instructions shall be followed for work when
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces
and may ignite.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel can be corrosive to the eyes
and skin, as well as mucous membranes in the throat.
CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.
IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised
for this work.

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

moving parts.
Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.
Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.
Risks
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 the drive wheels on both sides of the truck at the
same time if the drive wheels on both sides are raised.
Working under the machine

Working under the frame
A raised vehicle may not, for any reason, be supported or lifted in
parts that belong to the wheel suspension or steering. Do not support
under mudguards or tanks either. Always support under the frame or
drive 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 that withstand the load and 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.
If lifting must be performed without lifting device:

• Lift near the body.
• Keep your back vertical. Raise and lower with your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.
Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.
Safety actions
• Use heavy gloves to protect against the cold and transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.

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

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

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

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.
• Always have a fire extinguisher close at hand.

Fluid or gas under pressure

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

a hard surface. Gas may flow out from damaged valves.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
• Cooling system.
Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than the
manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall first be drained of pressure and
then punctured before being discarded (to avoid risk of explosion).
Carefully drill a hole with 3 mm diameter after draining the pressure.
• Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
• First open the cooling system's cap for the filling point, to release
the high pressure. Be careful. Hot steam and coolant may jet out.
Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting 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.
• For example, 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 can be found in some paints, fillers, adhesives and
foam plastics.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates may be released in the form of vapour, dust (or may
be found in aerosol) when cutting, grinding, or welding. May cause
irritation of mucous membranes with asthma-like symptoms as well as
impaired lung function. Even brief exposure to high levels may give
problems with permanent oversensitivity.
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.
Electrical system and electric motors

Safety actions
Always turn off the battery disconnector when working on the electrical
system and electric motors.
Always block the machine's wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines
Risks
Rotating components, e.g., fans or shafts, can cause severe injuries
if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in
the machine.

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

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

Welding
DANGER
Contact Cargotec Support before welding on the
machine.
CAUTION
In today's machines there are a lot of electronics.
All control units must be unplugged and the electric
power must be turned off with the battery disconnector
prior to all welding on the machine.
Powerful welding currents may otherwise short-circuit
the electronics, destroy expensive equipment, and
may cause an explosion or fire.

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
• Steering spindle
• Hub
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Valve block, lift cylinder
• Tilt cylinder
• Twistlock, lifting hook
• Control breaker (for hydraulic function)
• Emergency switch
• Cab
• Hydraulic cylinder, cab tilt
• Frame
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units

Non-ionised radiation
WARNING
Extra equipment such as two-way radio, remote
controlled door opener, etc. may emit non-ionising
radiation. This type of equipment transmits on the
frequency band 100 - 500 MHz.
Danger of disturbances on active medical products
(e.g. a pacemaker).
Do not use a two-way radio, remote controlled door
opener, etc. when persons with active implanted
medical products are in the cab.
NOTE
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.

B Safety – Environment B:21
Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.
Still there are no environmentally safe chemicals, e.g., oils and
coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well-planned recycling of the machine is the starting point for finishing
the life cycle and making use of materials for re-use in new products.
According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.
Environmentally hazardous waste
Components such as batteries, oils and other chemicals, and other
materials that may constitute environmentally hazardous waste, must
be handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids
Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.
Air conditioning system
The refrigerant in the air conditioning unit for the cab contributes to
the greenhouse effect if it escapes into the open air. Special training
is required for all service work on the air conditioning unit. Many
countries also require certification by an authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Working in a contaminated area
The machine shall be equipped for work within a contaminated area
(polluted environment or health-hazardous area) before starting the
work. Also, special local instructions apply for handling and service
work on such a machine.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and electrical wiring. Some
models have cast lead counterweights.
If the machine is equipped with air conditioning, refrigerant of the type
R134a and an amount between 1-3 kg is used.

B:22

C:1
Contents C Preventive maintenance

Preventive maintenance ...................................................................................C:3
Preventive maintenance, general ................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:5
Service schedule............................................................................................. C:7
Washing ........................................................................................................ C:14
Lubrication 500 hours ................................................................................... C:14
Lubrication 1000 hours ................................................................................. C:19
Checking for cracks ..................................................................................... C:23

C:2

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

service organisation authorised by Cargotec.
CAUTION
Service intervals shall be followed.
This is to maintain the machine's safety and to fulfil
warranty and service agreements!
Use spare parts and fluids approved by Cargotec to
fulfil the warranty.
Preventive maintenance, work instructions

1 For a new machine it is very important to check-tighten the wheel
nuts during the first work week until they are seated properly. This
should be performed at an interval of 4–5 operating hours (up to
approx. 40–50 operating hours).
2 For a new machine, the checking action must be performed 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
Operat- Operating
ing time Actions time 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 must be performed after 50h
operating time. The checks are performed to increase operational
reliability.
1 Engine Reference
Bolted joints, mountings, suspension devices, hose
clamps, wear and chafing of hoses, cable harnesses,
etc.
Sealing check oil, coolant, exhaust system
Fuel prefilter, draining condensation Section 1 Engine, group 1.2.3 Fuel prefilter
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, check Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Engine oil and oil filter, change Section 1 Engine, group 1.8 Lubrication system
Oil pressure
Valve clearance. (Applies to TAD760VE)
NOTE
Performed by service shop authorised by Volvo Penta.
2 Transmission
Leakage check
Oil level, check Section 2 Transmission, group 2.6 Lubrication system
Transmission oil filter, changing Section 2 Transmission, group 2.6 Lubrication system
3 Driveline/Axle
Mounting propeller shaft, check-tightening Section 3 Driveline/Axle, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Driveline/Axle, group 3.3 Drive axle
4 Brakes
Leakage check
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check Section 4 Brakes, group, 4.5.4 Parking brake unit
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Suspension, group 6.3 Tyres and rims
Wheel nuts, check-tightening Section 6 Suspension, group 6.3 Tyres and rims
7 Load handling
Hose connections, check-tightening
Bolted joints, check-tightening
Mast wheel and slide plates, function check
Slide plates and support rollers, function check
Sensors Check that all sensors are undamaged and free of grease.
Attachment Check for damage

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

Service schedule
Service must be performed every 500 operating hours. The actions are
divided into 500 h, 1000 h and 2000 h 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 Section B Safety
leakage traces 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, page
C:14
Lubrication 1000 hours L L Lubrication 1000 hours, page
C:19
Checking for cracks C* C* * Check every 1000h or Checking for cracks , page
every year. C:23
1 Engine (engine alternative Volvo TAD760VE)
Bolted joints, attachments,
C C C
mountings, etc.
Fuel tank C C Clean, as needed.
Fuel prefilter * Incl. draining of Section 1 Engine, group 1.2.3
condensation water. Fuel prefilter
Which must be performed
C* C / R* C / R* every 50 hours.
Change filter earlier if
error code is displayed.


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Fuel filter Change filter earlier if Section 1 Engine, group 1.2.4
R R
error code is displayed. Fuel filter
Injectors C
Valve clearance First check after 50 h, NOTE
then every 2000 h.
C* Performed by service shop
After engine replacement
authorised by Volvo Penta.
or engine overhaul
check/adjust after 250 h.
Turbo C
Air filter main cartridge Check of indicator, Section 1 Engine, group 1.6.1
C/R C/R C/R change when indicated, Air cleaning system
or every 12 months.
Air filter safety cartridge Changed every other
C C/R C/R time main cartridge is
changed.
Exhaust system Sealing check. Section 1 Engine, group 1.6.3
C C C
Exhaust system
Intercooler pipe Sealing check. Section 1 Engine, group 1.6.4
C
Intercooler
Radiator External check and
cleaning.
C C C NOTE
Do not use high
pressure wash.
Drive belt Change as required, or Section 1 Engine, group 1.7.5

C C C/R every 36 months / every Cooling fan
8000 h.
Coolant C C C / R* Level check. Section 1 Engine, group 1.7.7
* Change after 5000 h or Coolant
once every two years.
For volume and quality,
see section F Technical
data.
Coolant, freezing point C C C For volume and quality,
data.
Engine oil For volume and quality, Section 1 Engine, group 1.8
R R R see section F Technical Lubrication system
data.
Engine oil filter R R R At every oil change.
Lubrication and cooling Sealing check.
C C C
system
1 Engine (engine alternative Cummins QSB6.7)
Exhaust system C C C Sealing check. Section 1 Engine, group 1.6.3
Exhaust system
Charge air hoses C C C Sealing check. Section 1 Engine, group 1.6.4
Intercooler


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Engine oil R R R For volume and quality, Section 1 Engine, group 1.8
see section F Technical Lubrication system
data.
Engine oil filter R R R At every oil change
Fuel tank C C Clean if necessary. Section 1 Engine, group 1.2.1
Fuel tank
Fuel prefilter C C/R C/R Incl. draining of Section 1 Engine, group 1.2.3
condensation water. Fuel prefilter
Shall be done every 50
hours.
Change filter earlier if
error code is displayed.
Fuel filter R R Change filter earlier if Section 1 Engine, group 1.2.4
error code is displayed. Fuel filter
Air filter main cartridge C/R C/R C/R Checking indicators, Section 1 Engine, group 1.6.1
change when indicated. Air cleaning system
Air filter safety cartridge C C/R C/R Changed every other
time main cartridge is
changed.
Radiator C C C External check and Section 1 Engine, group 1.7.4
cleaning. Radiator and expansion tank
NOTE
Do not use high
pressure wash.
Drive belts C/R C/R C/R Change when needed. Section 1 Engine, group 1.7.5
Cooling fan
Drive belt tensioner C/R C/R * Check every 1000h or
every year.
Change when needed.
Fan hub C C * Check every 1000h or
every year.
Coolant, level C C C Level check. Section 1 Engine, group 1.7.7
The coolant should be Coolant
changed after 2000h
and the cooling system
checked/cleaned during
the change.
data.
Coolant, freezing point C C C
Coolant quality, checking C C Check after 1000h or
every year.
Bolted joints, attachments, C C C
mountings, etc.
Valve clearance C Valve clearance Section 1 Engine, group 1.5.4
checked/adjusted after Valve mechanism
5000h / every 4th year.
Vibration damper, rubber C Check every 2000h or Section 1 Engine, group 1.5.6
every other year. Crank mechanism


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
2 Transmission
Breather filter C C Clean if necessary Section 2 Transmission, group
2.2 Torque converter
Transmission oil filter R R The transmission oil Section 2 Transmission, group
should be changed 2.6 Lubrication system
every 1,000 hours or 1
time/year.
data.
Transmission oil R R For volume and quality,
data.
Transmission, calibration C C Calibration of the Section 2 Transmission,
transmission is group 2.8 Control system
recommended every transmission
1000 hours.
3 Driveline/Axle
Propeller shaft C C C Bolted joints and Section 3 Driveline/Axle,
universal joint. group 3.2 Propeller shaft
Drive axle C C Section 3 Driveline/Axle,
group 3.3 Drive axle
Drive axle oil R R For volume and quality, Section 3 Driveline/Axle,
see section F Technical group 3.3 Drive axle
data.
Mounting drive axle C C Section 3 Driveline/Axle,
group 3.3 Drive axle
Differential, breather nipple C C Clean if necessary.
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, Section 4 Brakes, group 4.5.4
change when needed. Parking brake unit
Oil brake system R For volume and quality, Section 4 Brakes, group
see section F Technical 4.8.14 Oil for brake system
data.
5 Steering
Link arms C/L C/L C/L Check the bearings. Lubrication 500 hours, page
C:14
Sensor steering wheel angle C C C Section 5 Steering, group
mini-wheel/joystick control 5.2.12 Sensor steering wheel
angle
6 Suspension
Steering axle suspension C C Section 6 Suspension, group
6.2.1 Steering axle cradle


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Wheel spindle, check C C Section 6 Suspension, group
6.2.2 Wheel spindle
Wheel hub steering axle, C Check bearing pre-load. Section 6 Suspension, group
check 6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and Section 6 Suspension, group
pressure, change as 6.3 Tyres and rims
needed.
Wheel nuts C C Check-tightening. Section 6 Suspension, group
6.3 Tyres and rims
Rim C* * Checking for cracks, Section 6 Suspension, group
every 2,000 hours and 6.3.2 Rim
in connection with tyre
changes.
7 Load handling
Slide plates spreader beam C C Check wear, change as Section 7 Load handling,
needed. group 7.5.4 Spreader beam
Lifting chains C C C Check damage, tension Section 7 Load handling,
chain when needed. group 7.2.9 Mast
Mast suspension C C Checking the wear. Section 7 Load handling,
group 7.2.9 Mast
Slide plates mast C C C Check wear, adjust when Section 7 Load handling,
needed. group 7.2.9 Mast
Slide plates in trolley C C Check wear, adjust when Section 7 Load handling,
needed. group 7.2.11 Trolley
Attachment C C Check for damage.
Slide plates spreader beam C C Check wear, change as Section 7 Load handling,
needed. group 7.5.4 Spreader beam
Tilt cylinder C C C Section 7 Load handling,
group 7.7.7 Tilt cylinder
Twistlocks C/R Check for cracks every Section 7 Load handling,
other year or every 4000 group 7.9.1 Twistlocks
operating hours.
Replace every 10,000
operating hours.
Reset time counter
for twistlocks after
replacement.
Lifting hooks / Lock lugs C/R Check for cracks every Section 7 Load handling,
other year or every 4000 group 7.9.2 Lifting hook
h.
Replacement every 10
000 h. Reset the hour
counter for lifting hook
after replacement.
8 Control system
Service indicator, reset C C C Section 8 Control system,
group 8.2.4 Service indicator
Instruments and controls C C C Checking function.


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
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, cab
environment, at latest and accessories, group 9.4.1
every 500 h. Fresh air filter
Condenser C C C Clean when needed. Section 9 Frame, body, cab
and accessories, group 9.4.8
Condenser
NOTE
Do not use high
pressure wash.
Moisture filter C/R C/R C/R Check, change if Section 9 Frame, body, cab
indicator is grey. and accessories, group 9.4.9
Moisture filter
Windscreen wipers C C C Incl. washing, top up
when needed.
Lighting and audible signals C C C
Roof window C C Check damage, change Section 9 Frame, body, cab,
when needed. and accessories, group 9.9.3
Roof window
Cab frame C C Check rust damage,
deformation or cracks.
Doors C C C Section 9 Frame, body, cab
and accessories, Group 9.10.2
Doors
Cab undercarriage C C Check mountings, Section 9 Frame, body, cab
isolators and bolted and accessories, group 9.10.3
joints. Cab undercarriage
Frame C C Check occurrence of
any deformation and rust
damage as well as cracks
in welded joints.
Counterweights C Check that the
counterweights are
positioned properly and
that the mounts and
welding seams are intact
and free of visible cracks.
Check tightening torque
of bolted joints.
Central lubrication C C C Section 9 Frame, body, cab

and accessories, group 9.14
Central lubrication
Paint/coatings C C Check the machine's
painted surfaces
for stone chips and
scratches.


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Safety decals C C C Check that safety decals See Operator's manual DCF
are legible, securely 80–100, section 3 Overview,
fastened, and not group 3.2 Signs
damaged. Clean dirty
decals and replace
decals as needed.
Cooler hydraulic oil C C External check and
cleaning.
NOTE
Do not use high
pressure wash.
Breather filter hydraulic oil C/R R R Change when indicated. Section 10 Common
tank hydraulics, group 10.6.6
Breather filter hydraulic oil
tank
Hydraulic oil filter R R Section 10 Common
hydraulics, group 10.6.7
Hydraulic oil filter
Hydraulic oil R For volume and quality, Section 10 Common
see section F Technical hydraulics, group 10.6.8
data. Hydraulic oil
Fine filter hydraulic oil R R R Section 10 Common
hydraulics, group 10.6.9
Fine filter hydraulic oil
11 Common electrics
Fuses C C C Check that fuses are Section 11 Common electrics,
intact, change if needed. group 11.2.2 Fuses
Batteries C C C Section 11 Common electrics,
group 11.3.1 Start battery
Battery cable C C C Section 11 Common electrics,
group 11.3.1 Start battery
Position sensors C C C Should be free from
grease and dirt, clean as
needed.
• Sensor hydraulic
pressure lift cylinder
• Mast position sensor
• Spreading
• Twistlocks
• Contact
• Cab tilt


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Test-run Test-run the machine and check:
• Instruments
• Brakes
• Gearshifting
• All load handling functions
• Steering
• Any noise
After test-run Check the following after test-run:
• Sealing (no leakage)
• Fluid levels
Washing
CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,
battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.
Lubrication 500 hours

1 Machine in service position.
2 Clean the area around each grease cup before greasing.
3 Lubricate all lubrication points on the machine with lubricating
grease, see section F Technical data.
Also do a visual check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Points lubricated by the central lubrication are
indicated by *.

7
6
9
10 10
4 4
5 5
9
2-3 6 2-3
018742
1 1
Overview, lubrication points, 500 hours
Pos. Lubrication points Reference

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

Wheel hub
4 Lift the right steering wheel with a jack (40 ton) so that wheel
bearing and wheel spindle are unloaded, do not lift so high that
the wheel hangs freely.
5 Lube the wheel hub until grease is forced out by 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
Work carefully to avoid damaging the seal.
009125
Lubrication point wheel hub
Wheel spindle
6 Grease the wheel spindle's upper and lower bearings.
1 NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.
NOTE
On machines with central lubrication, check that lubrication
reaches all relevant lubrication points, see section 9 Frame, body,
cab, and accessories, group 9.14 Central lubrication.
2
009126
Lubrication points wheel spindle

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

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

1. Inner bearing
2. Outer bearing

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

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

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

018743
2
1. Hinge, door
2. Hinge, cover lid

Mast
1 17 Start the machine and raise the mast to facilitate access to

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

Lubrication 1000 hours

1 Lower carriage and engage full spreading.
2 Turn off the engine and turn off the main electric power.
3 Clean the area around each grease cup before greasing.
4 Lubricate the machine's lubrication points with Lubricating grease
as shown on the diagrams below, see section F Technical data.
Also do a visual check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Points lubricated by the central lubrication are
indicated by *.
4-8
1 1
2
018744
Overview, lubrication points, 1000 hours
Pos. Lubrication points Reference

Lubrication 500 hours Lubrication 500 hours, page C:14
1 Universal joints (2 psc) Universal joint, page C:20
2 Trolley, mast (4 pcs)* Trolley, page C:20
3 Locking cylinders (2 pcs)* Side lift attachment with twistlock, page C:21
5 Contact pins (2 pcs)*
6 Spreading cylinders (4 pcs)*
7 Side shift cylinder (x 4)
8 Electric connectors (not shown on diagram) Electric connectors, page C:23

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

1. Mast wheel

Side lift attachment with twistlock

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

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

Side lift attachment with lifting hook

13 Lubricate the lock lugs' shafts (position 1) with lubricating grease.
Check that the sensors are undamaged and free from grease.
1 5
4
4
009376
Lubrication points for side lift attachment with lifting hook
14 Grease the locking cylinders' mounts (position 2) with lubricating
grease.
15 Grease the side shift cylinders' mounts (position 3) with lubricating
grease.
16 Grease the spreading cylinders' mounts (position 4) with lubricating
grease.
17 Lubricate the contact pins (position 5). Check that the sensors are
undamaged and free from grease.

18
On machines with central lubrication, check the grease levels in
the pump units on the frame and attachment.
Top up with lubricating grease if the grease levels in the reservoirs
are below the middle.
Filling takes place through the grease nipples on the pump units.
NOTE
If grease has penetrated out from the safety valve, it means there
is a stop in the system, this means that no points are greased,
see section 9 Frame, body, cab, and accessories, group 9.14
Central lubrication.
Electric connectors
19 Grease electric connectors with electric connector grease. Check
that damp does not enter the connectors.
Pump unit central lubrication, example illustration

1. Filling point
2. Safety valve
Checking for cracks
DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
mast and attachment.
DANGER
Welds in areas of high stress concentration must be
checked in accordance with recommended intervals.
The interval is calculated according to the machine
being used for normal handling and on a level, smooth
ground surface. For other handling or, e. g., rough
surface, the interval should be shortened.
If the welds show signs of cracking, take the machine
out of operation as soon as possible and contact
Cargotec Support.
1 Turn off the engine and turn off the system voltage.
2 Clean every weld carefully before inspection.
3 Check for damage and cracks in the areas with high stress
concentration, see Check points, page C:25. Check the whole
length of every weld.
In the event of uncertainty about welds, test them with magnetic
powder and penetrating fluid if necessary as follows:
a. The magnetic particle method is used to determine if there's a
crack or not, and where it is. See Magnetic particle method,
page C:24.

b. Confirmed cracks are investigated further with penetrating

fluid. See Checking cracks with penetrating fluid, page C:24.
Magnetic particle method
1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic particle and the following equipment:
• Equipment: Yoke Tiede
• Method:
005375
a Alternating current AC
b Contrast colour
Rim
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid
1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
005376
any remaining cleaning fluid evaporate.

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

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

Check points
1 Check the following welds particularly carefully:
7
8
018745
1 9
Check points, overview
Pos. Check point Reference

1 Steering axle mounts Steering axle mounts, page C:26
2 Tilt cylinder and tilt cylinder mount. Tilt cylinder and tilt cylinder mount., page C:26
3 Mast Mast, page C:27
4 Mounting of frame beam to back piece Mounting of frame beam to back piece, page C:27
5 Drive axle mount Drive axle mount, page C:28
6 Mast mount Mast mount, page C:29
7 Side lift attachment Side lift attachment, page C:29
8 Twistlocks
8 Trolley Trolley, page C:30
9 Lift cylinder bracket Lift cylinder bracket, page C:30

Steering axle mounts

2 Check the steering axle mounts in the frame and the steering axle
a. Steering axle mounts in the frame.
b. Steering axle mounts in the steering axle cradle.
a Tilt cylinder and tilt cylinder mount.

3 Check the attachment lugs on the tilt cylinder.
009664
4 Check the tilt cylinder's mounting in the mast.

009662
5 Check the tilt cylinder's mounting in the frame.

018746

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

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

Drive axle mount

9 Check the drive axle mount in frame.
015528

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

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

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

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

0:1
0 Complete machine
Contents 0 Complete machine

Complete machine............................................................................................. 0:3
Complete machine, description ..................................................................0:3

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Complete machine, description
The Kalmar DCF80-100 is a machine with mast for handling empty
containers. The machine has a lift capacity of up to 8–10 tonnes
depending on version.
The engine is a straight six-cylinder, four-stroke, turbocharged

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

it has three gears in each direction. The engine's power is transmitted
using a torque converter.
The power transmission consists of propeller shaft and a rigid drive axle
with differential and hub reduction. The machine has front-wheel drive.
The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the disc
brake type and acts on the drive axle's input shaft.
7
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 nuts and clamps. The drive
6 axle has twin wheels, the steering axle has single wheels.
Load handling consists of components and functions for handling

loads. Loads are lifted with a side lift attachment secured to a trolley
that is fitted on a mast. Load handling is divided into the functions
lifting/lowering, tilt, side shift, spreading, levelling and load carrying.
Lifting/lowering is the function for lifting and lowering the trolley. Side
shift is moving the side lift attachment laterally along the trolley.
Spreading is adjusting the width between Twistlock or Lifting hooks on
the side lift attachment. Tilt is for angling the load in the longitudinal
018747
direction of the truck using the mast. Levelling is for angling the side
1 2 3 4
lift attachment in the lateral direction of the truck. Load carrying is the
1. Steering axle locking of the load to the side lift attachment.
2. Engine The control system includes functions to warn the operator of
3. Frame dangerous situations and faults. The control system has diagnostic
options that facilitate troubleshooting.
4. Drive axle
5. Mast The frame supports the machine. The engine, transmission, drive axle,
and steering axle are installed in the frame. On the sides of the frame
6. Side lift attachment
are tanks for fuel and hydraulic oil. The cab is located on the rear
7. Cab section of the frame. As an option, the cab can be tilted.
The hydraulic system is supplied by four hydraulic oil pumps, the

pumps are assembled into two pump banks which are fitted on the
transmission's power take-off. Three variable pumps supply load
handling, steering and other hydraulic functions. A fixed pump supplies
the brake system's brake and cooling circuit over an accumulator
charging valve. The hydraulic oil tank is fitted on the right-hand side of
the machine. The hydraulic oil filters are return filters that are fitted in
the hydraulic oil tank.

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

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

1:1
1 Engine
Contents 1 Engine
1 Engine................................................................................................................. 1:3
1.2 Fuel system....................................................................................................1:10
1.2.1 Fuel tank ...................................................................................................1:12
1.2.3 Fuel prefilter ..............................................................................................1:13
1.2.4 Fuel filter ...................................................................................................1:16
1.5 Engine's mechanical parts .............................................................................1:17
1.5.4 Valve mechanism ......................................................................................1:17
1.5.6 Crank mechanism .....................................................................................1:21
1.6 Air intake and exhaust outlet..........................................................................1:22
1.6.1 Air cleaning system ...................................................................................1:22
1.6.3 Exhaust system .........................................................................................1:25
1.6.4 Intercooler .................................................................................................1:26
1.7 Cooling system ..............................................................................................1:28
1.7.4 Radiator and expansion tank ....................................................................1:28
1.7.5 Cooling fan ................................................................................................1:29
1.7.7 Coolant ......................................................................................................1:33
1.8 Lubrication system .........................................................................................1:40
1.9 Control system engine ...................................................................................1:44
1.10 Ignition/heating...............................................................................................1:45
1.11 Start/stop........................................................................................................1:46

1:2

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

standards. The following engine alternatives are available:
• Volvo TAD760VE
• Cummings QSB6.7
Engine alternative Volvo TAD760VE,

function description
Volvo TAD760VE is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.
˚C
0 . bar
P I
rpm
II kph
III
8 <˚ 1
2 5 12
D790-1 D790-2 D795
D793 D794 D797-R

13 3 11
H2O
6 9
M SENSORS 10
4
004726
7
1. Ignition key lock (S150) 8. Accelerator pedal (B690)
2. Control unit, cab (D790-1) 9. Make-contact (closing switch) coolant level (B759)
3. Control unit, engine (D794) 10. Sensor fuel level (B757)
4. Preheating coil (E800) 11. Control unit frame rear (D797-R)
5. Control unit KIT (D790-2) 12. Control unit, KID (D795)
6. Starter motor (M654) 13. Control unit, transmission (D793)
7. Electric components engine

1:4 1 Engine – Engine
Engine alternative Cummins QSB6.7,

The Cummins QSB6.7 is a straight, 6-cylinder, 4-stroke, turbocharged

low-emission diesel engine with common rail injection, air-to-air
intercooler and electronically controlled fuel injection.
°C
. bar
0 rpm
P I kph
II
III
1
8 <°
D D
D D
3 9 2
D794 D790-1 D790-2
D797-1 D795
12 13
D
D D
D
D H2O
4 SENSORS
10 11
7
M 5
015050
6
1. Ignition key lock (S150) 8. Accelerator pedal (B690)

2. Control unit KIT (D790-2) 9. Control unit, cab (D790-1)
3. Control unit, engine (D794) 10. Make-contact (closing switch) coolant level (B759)
4. Preheating coil (E800) 11. Sensor fuel level (B757)
5. Starter relay 12. Frame control unit (D797-1)
6. Starter motor (M654) 13. Control unit, KID (D795)
7. Engine sensor

Engine alternative Volvo TAD760VE,

component location
7 8 9
6
5 10
4
3
11
12
13
14
15
16
17
18
018928
19
21 20
Left-hand side (in machine's travel direction)
1. Sensor coolant temperature 12. Sensor fuel pressure (fuel distribution pipe)
2. Solenoid valve EGR 13. Water pump
3. Oil dipstick, engine oil 14. Sensor oil pressure
4. Filling point engine oil 15. Oil filter
5. Crankcase ventilation 16. Sensor fuel pressure
6. Turbo 17. Fuel filter
7. Sensor boost pressure and temperature 18. Solenoid valve proportional valve high-pressure pump
8. Injector and preheating (6 pcs.) fuel (MPROP)
9. Connection cab heating 19. Oil plug
10. Alternator 20. Electrical connection, Control unit, engine (D794)
11. Fuel pump 21. Sensor camshaft speed

1 2
018927
6 5 4
Right-hand side (in machine's travel direction)
1. Thermostat housing 4. Oil plug
2. Preheating of air after intercooler 5. Drain point coolant
3. Starter motor 6. Sensor crankshaft rpm

0
P I
4
2 II 3 5
III
12
10
11 8
9
018946
Electric components machine
1. Accelerator pedal (B690) 7. Control unit, Volvo engine (D794)
2. Ignition key lock (S150) 8. Control unit, transmission (D793)
3. KIT cab control unit (D790-2) 9. Fuel tank
4. Control unit, KID (D795) 10. Sensor fuel level (B757)
5. Control unit, cab (D790-1) 11. Frame control unit (D797-1)
6. Control unit, Cummins engine (D794) 12. Frame option control unit (D797-2)

Engine alternative Cummins QSB6.7,

component location
3
1 2
5
6
018941
8
9
Engine alternative Cummins QSB6.7, left-hand side (in machine's direction of travel)
1. Filling point engine oil 6. Connections cab heat
2. Dipstick, engine 7. Coolant inlet
3. Outlet exhaust system 8. Oil filter
4. Outlet coolant to radiator 9. Starter motor
5. Alternator

11
10
8
3
4
5
018942
7 6
Engine alternative Cummins QSB6.7, right-hand side (in machine's direction of travel)
1. Turbo air inlet 7. Control unit, engine (D794)
2. Air outlet turbo 8. Vibration damper (rubber)
3. Crankcase ventilation 9. Fan drive
4. Fuel filter 10. Water pump
5. Draining the engine oil 11. Drive belt tensioner
6. Air intake

1:10 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
prefilter with water trap and fuel filter are on the engine. The water trap
is equipped with electrical indication, an event menu appears on the
display when the water trap must be emptied of water.
For position of components see:

• Engine alternative Volvo TAD760VE, component location, page
1:5
• Engine alternative Cummins QSB6.7, component location, page
1:8
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 can be corrosive to the eyes
and skin, as well as mucous membranes in the throat.

1 Engine – Fuel system 1:11
Fuel system, bleeding (engine alternative Volvo)
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 complete when resistance is felt 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.
014097
1. Hand pump
Fuel system, bleeding air (engine alternative

Cummins QSB6.7)
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

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

1:12 1 Engine – Fuel tank
1.2.1 Fuel tank
Fuel tank, cleaning
NOTE

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

1 Engine – Fuel prefilter 1:13
1.2.3 Fuel prefilter
Fuel prefilter, draining condensation water

(engine alternative Volvo TAD760VE)
NOTE
The water trap must be drained of water every 50th operating
hour.
NOTE

2 Open the drain cock (position 1) and drain fuel/water.
3 Remove the water reservoir (position 2) from the filter cartridge by
turning clockwise.
4 Clean the reservoir and refit it on the filter cartridge.
5 Close the drain cock and bleed the system, see Fuel system,
bleeding (engine alternative Volvo), page 1:11.
1
007348
1. Drain cock
2. Water reservoir

1:14 1 Engine – Fuel prefilter
Fuel prefilter, draining the condensation water

(engine alternative Cummins QSB6.7)
NOTE
NOTE
The water trap must be drained of water as necessary or at least
every 50 operating hours.

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

hand. Bleed the fuel system, see Fuel system, bleeding air (engine
alternative Cummins QSB6.7), page 1:11.
5 Wipe off the fuel pre-filter and remove the collection container.
015539
Drain cock fuel prefilter

1 Engine – Fuel prefilter 1:15
Fuel prefilter, changing (engine alternative Volvo

TAD760VE)
NOTE

2 Disconnect the wiring from the sensor for water-in-fuel.
3 Remove the water reservoir and drain it of any water.
4 Remove the filter cartridge.
5 Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush oil onto the gasket.
6 Assemble the filter cartridge with the water reservoir and install
1 them on the filter bracket.
7 Connect the wiring to the water trap's sensor.
8 Bleed the fuel system, see Fuel system, bleeding (engine
alternative Volvo), page 1:11.
007349
1. Fuel prefilter
Fuel prefilter, changing (engine alternative Cummins

QSB6.7)
NOTE

2 Open the drain cock and drain any water.
4 Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush a small amount of oil onto the gasket.
5 Screw the filter cartridge onto the filter bracket.
6 Bleed the fuel system. Fuel system, bleeding air (engine
alternative Cummins QSB6.7), page 1:11.
015540
Fuel prefilter

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

TAD760VE)
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.

2 Remove the fuel filter.
3 Clean the filter's contact face on the filter bracket
4 Moisten the O-ring on the new filter with fuel.
5 Fit the new filter on the engine according to the instructions on
the filter.
6 Bleed the fuel system, see Fuel system, bleeding (engine
alternative Volvo), page 1:11.
006434
Fuel filter, changing (engine alternative Cummins

QSB6.7)
NOTE

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

Screw on the fuel filter until it makes contact with the contact
surface, then tighten a further 3/4 turn.
6 When needed, bleed the fuel system, see Fuel system, bleeding
015529
air (engine alternative Cummins QSB6.7), page 1:11.

Fuel filter 7 Start the engine and check sealing.

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

1.5.4 Valve mechanism
Valves, checking/adjusting (engine alternative

Cummins QSB6.7 )
NOTE
Coolant temperature must be below 60 °C.
Removing
2 Disconnect the system voltage with the battery disconnector.
3 Carefully clean all attachments, mountings and joints with
compressed air to remove all loose particles.
4 Release the injectors' drain hose from the rear section of the
rocker cover.
5 Remove the screws that attach the drain hose to the rocker cover.
008025
6 Remove mounting screws and insulators from the valve cover.
NOTE
It might be necessary to bend the ventilation hose carefully to pry
it from the valve cover.
7 Remove the valve cover.
NOTE
Do not remove the valve cover gasket on engines where the
gasket is fitted in a groove on the valve cover; these gaskets
008026
can be re-used. If the gasket is removed from the valve cover, it

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

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

for installing a new gasket:
1. First press the corners of the gasket down into the groove on
the valve cover.
2. Then push the rest of the gasket down into the valve cover.
008029 10 Check to see if the rubber insulators are cracked. Replace the
insulators if they are cracked or damaged.
008028
Adjusting
11 Use special tool, part number 3824591 to rotate the crankshaft
until cylinder no. 1 is located in the top dead centre (T.D.C.).
The top dead centre (T.D.C.) can be determined by the following
method:
008030
NOTE
The indicator for the top dead centre (T.D.C.) is on the vibration
damper/crankshaft speed indicator.
1. Rotate the vibration damper/crankshaft speed indicator ring

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

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

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

MIN MAX
Inlet valves 0.152 mm 0.381 mm
Outlet valves 0.381 mm 0.762 mm
NOTE
Valve clearance checks are usually performed as a part of
troubleshooting, and adjustments are not normally necessary
008033
during inspection as long as the valve clearance lies between

the values listed above.
NOTE
The valve clearance is correct when the feeler gauge can be
moved forward and back with only a slight resistance.
14 Measure the valve clearance by placing a feeler gauge, with a

2 thickness corresponding to the valve clearance to be adjusted,
between the top side of the push rod and the seat of the valve
lifter. If the valve clearance does not correspond, loosen the lock
nut and adjust the valve clearance to the correct value.
1
Valve clearance
Inlet valves 0.254 mm
Outlet valves 0.508 mm
Tighten the lock nut and check the measurement of the valve
clearance again. Torque tighten to 24 Nm.
008034
15 Use special tool, part number 3824591, and rotate the crankshaft
360 degrees.
Follow the same steps and specifications as above and measure
the clearance for the following valves:
(E=exhaust valves, I=intake valves)
Cylinders 2E, 3I, 4E, 5I, 6I and 6E.
008030

1:20 1 Engine – Valve mechanism
Installing
16 Reinstall the valve cover.
Reinstall the insulators and mounting screws.
Tighten the screws to a tightening torque of 24 Nm.
008026
17 Lubricate the O-ring on drain hose connection with clean engine oil.
18 Fit the injectors' drain hose on the rocker cover. Tighten the screws
to a tightening torque of 10 Nm.
19 Close the battery disconnector.
008035

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

alternative Cummins QSB6.7)
1 Check that the index lines (A) on the vibration damper hub (B) and
the outer section (C) are in line with each other. If the position
between the lines deviates more than 1.59 mm, replace the
vibration damper.
2 3
008036
2 Check the rubber part for signs of wear. If any rubber pieces are
missing or if the surface of the rubber is more than 3.18 mm below
the metal surface, replace the vibration damper.
3 Check that the damper ring cannot move longitudinally in relation to
the hub. Replace the vibration damper if it can move longitudinally.
For position of vibration damper, see Engine alternative Cummins
QSB6.7, component location, page 1:8.
008037

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

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

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

Air filter, changing
2 Clean the outside of the air filter housing.
3 Remove the cap from the air filter housing.
2
3
1
008040
1. Dust reservoir
2. Air cleaner
3. Indicator air filter

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

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

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

1:24 1 Engine – Air cleaning system
10 Reset the indicator.

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

2 Check the exhaust system's sealing and other wear.
3 Check that the exhaust system suspension is intact.
2 3
018947
1. End-pipe
2. Silencer
3. Exhaust pipe

1:26 1 Engine – Intercooler
1.6.4 Intercooler
Intercooler, checking
2 Raise the hood.
3 Clean the intercooler with compressed air.
1
NOTE
Do not use high pressure wash.
4 Check that the intercooler suspension is intact.

2 5 Check the sealing integrity and check that the intercooler's hoses
and clamps are in good condition.
6 Close the hood.
4
018923
1. Intercooler
2. Radiator
3. Fuel cooler
4. Transmission oil cooler
Charge-air pipe, checking

2 Check charge air pipes/hoses with regard to leaks, holes, cracks
or loose connections and other external damage. Tighten hose
clamps if necessary.
If the pipes/hoses are damaged or if connections leak, the boost
pressure will be too low and engine power is reduced. Damaged
charge air pipes/hoses can also result in engine damage.
NOTE
If there is oil in the intercooler hoses, very carefully clean the
intercooler and all pipes and hoses in the intercooler system on
the inside before the engine is started.
3 Check that there is no oil in the charge air hoses/pipes. If they

018748
are contaminated by oil on the inside, this indicates leakage at

the turbo's shaft seal. In which case, replace the turbocharger
assembly.

1 Engine – Intercooler 1:27
Charge-air pipe, check (engine alternative Cummins

QSB6.7 )
2 Check the charge-air pipes, hose connections, and the condition
of the clamps for visible cracks and external damage. If the pipes
are damaged or if connections leak, the boost pressure will be too
007962
low and engine power is reduced.
3 Check that there is no oil in the charge-air pipes. If the pipes have
Charge air pipe, principle illustration oil on the inside, this indicates leakage at the turbo's turbine shaft
seal. In which case, replace the turbocharger assembly.
NOTE
If there is oil in the intercooler hoses, very carefully clean the
intercooler and all pipes and hoses in the intercooler system on
the inside before the engine is started.

1:28 1 Engine – Cooling system
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.

1:5
1:8
1.7.4 Radiator and expansion tank
Radiator, external cleaning

2 Clean the radiator with compressed air.
1 NOTE
Do not use high pressure wash.
3 Check that the cooling flanges are whole.
4
018923
1. Intercooler
2. Radiator
3. Fuel cooler
4. Transmission oil cooler

1 Engine – Cooling fan 1:29
1.7.5 Cooling fan

Drive belt, check (engine alternative Volvo)
Check after operating when the belt is warm.
2 Raise the hood.
3 It should be possible to press down the drive belt approx. 3-4 mm
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, changing (engine alternative Volvo
TAD760VE), page 1:30, .
Check that the belt does not have any intersecting cracks.
Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
NOTE
The belt tensioner is automatic.
IMPORTANT
Always change a drive belt that looks to be worn or
008011
has cracks.
4 Close the hood.
Drive belt, check (engine alternative Cummins QSB

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

Transverse cracks are acceptable, longitudinal cracks that are
008011
intersected by transverse cracks are not acceptable.

It should be possible to press down the belts approx. 3-4 mm
between the belt pulleys.
NOTE
The belt tensioner is automatic.
5 Close the hood.

1:30 1 Engine – Cooling fan
Drive belt, changing (engine alternative Volvo

TAD760VE)
2 Loosen the belt tensioner and lock it with a drift.
1
007314
Volvo TAD760VE
1. Drift
3 Remove the belt from the coolant pump first.

4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves and is tensioned correctly.
1
007969
Volvo TAD760VE
1. Coolant pump

1 Engine – Cooling fan 1:31
Drive belt, changing (engine alternative Cummins

QSB6.7)
2 Raise the hood.
3 Lift up the belt tensioner to remove the drive belt.
NOTE
The belt tensioner is tensioned in the direction that the spring is
bent over the tensioner arm. To reduce the tension in the belt,
rotate the belt tensioner in order to tighten the spring more firmly.
CAUTION
008013
Do not use too much force when unloading the belt
tensioner. Continued winding can cause the tensioner
arm to break.
4 Lift up the belt tensioner and fit the drive belt. If it is difficult to fit
the drive belt (the belt seems too short), first place the belt in the
grooved belt pulley. Then continue to hold up the belt tensioner
and pry the belt over the coolant pump's belt pulley.
Loosen the belt tensioner and check that the belt is sitting correctly
in the grooves and is correctly tensioned.
5 Close the hood.
Drive belt tensioner, check (engine alternative

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

1:32 1 Engine – Cooling fan
5 Remove the drive belt.

6 Check that the lower tension lever stop is in contact with the lower
stop lug for the tension lever on the belt tensioner housing.
If these two are not in contact with each other, the drive belt
tensioner must be replaced.
008016 7 Check the drive belt tensioner for signs of wear and damage
between the tension wheel and the radius of the tension lever.
If there are signs that these two surfaces are rubbing against
each other, then the centre bearing is worn out and the drive belt
tensioner must be replaced.
008017
8 A worn drive belt tensioner that is slack or a drive belt that

"wanders" off the pulleys indicates that the pulleys are not in
alignment.
This can be measured with a straight edge and a clinometer.
NOTE
The pulleys may not be more than 3 degrees out of alignment.
9 Install the drive belt.

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

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

1 Engine – Coolant 1:33
1.7.7 Coolant
Coolant level, check
WARNING
The cooling system is pressurised. Steam or hot
coolant may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
Coolant should be filled in the system's expansion tank (position A).

The fluid level should be visible in the sight glass (position C) on the
expansion tank.
A
NOTE
Open very carefully as hot coolant may jet up.
If the coolant level becomes too low, the warning light for low coolant
level (position 40) lights up on the instrument panel.
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
B
C
018642
A. Position for coolant reservoir (expansion tank)

B. Filling point
C. Level marking, MIN and MAX

2 Raise the hood.
3 If needed, top up (position B) with ready-mixed recommended
coolant. For volume and quality, see section F Technical data.

1:34 1 Engine – Coolant
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
4 Close the hood.
Coolant quality, check (engine alternative Cummins

QSB6.7 )
WARNING
up.

2 Raise the hood.
A 3 Check the coolant's quality with test equipment for coolant,
"Quick-Check Coolant Quality Test Strips".
IMPORTANT
Only use testing equipment that is appropriate for the
type of coolant used in the machine. Coolant type
differs depending on engine alternative.
4 Change the coolant if the test equipment indicates poor coolant

B quality, see Coolant, changing (engine alternative Cummins
C QSB6.7), page 1:38.
5 Close the hood.
018642

B. Filling point

Coolant, changing (engine alternative Volvo)

Radiator performance is reduced due to deposits in the radiator and
in the engine's radiator ducts. Clean the system in conjunction with
changing the coolant.
WARNING
up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid contact with skin, use
protective goggles and protective gloves. In the event
of contact with skin, wash the skin.
IMPORTANT
Machines with ECC or AC are equipped with a
combined heating and cooling unit, which can lead to
frost erosion if the machine runs without coolant.
Risk of freezing and damage to the heating and cooling
unit!
The electrical connection to the AC compressor must
be disconnected, when cleaning the radiator with water
or agent without antifreeze properties.
NOTE
Read safety instructions for coolant before starting work, see
section B Safety.
NOTE
The filler cap must be screwed off before draining.

Draining
2 Open the filler cap on the expansion tank carefully until a slight
resistance is felt and allow any overpressure to be vented away.
A The filler cap has a position for venting out overpressure without
the risk of the cap loosening. The position feels like a small notch
when turning the cap.
WARNING
B warm. Wait until the coolant has cooled before topping
C up.
3 When the overpressure has been vented away, remove the filler
cap from the cooling system's expansion tank.
4 Position a receptacle under the drain points on the radiator and
engine. For cooling system volume, see section F Technical data.
018642

B. Filling point
5 Open all drain points. Drain the coolant from the radiator and
engine block with drain hose.
6 Check that all coolant drains.
NOTE
The deposits that may be inside the cock/plug must be cleaned
out; otherwise there is a risk that coolant may remain and cause
freezing damage.
Allow the drain cocks or plugs to remain open and ensure that the
heating knob is set to full heat during cleaning.
007394
7 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the water flowing out is clear.
8 If there still are impurities after flushing for some time, cleaning
Drain point Volvo TAD760VE engine with coolant can be performed. Otherwise continue with Filling
point, page 1:37.

Cleaning with coolant

1 Fill the cooling system, see Filling point, page 1:37. Only use the
recommended coolant, see section F Technical data.
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. Check that the water valve in the cab is fully open
during cleaning.
4 If there still are impurities after flushing for some time, cleaning with
a radiator cleaner can be performed, contact Cargotec Service.
NOTE
Use only cleaning agent approved by the engine manufacturer.
Follow the instructions on the packaging carefully.
Filling point
1 When the cooling system is completely free from impurities, close
the drain points.
CAUTION
2 Stop the engine after about one hour and check the coolant level,
top up if needed.

Coolant, changing (engine alternative Cummins

QSB6.7)
NOTE
Read safety instructions for coolant before starting work, see
section B Safety.

2 Raise the hood.
3 Remove the cap on the expansion tank.
4 Place a container under the radiator and engine. (The cooling
system holds approx. 40 l.)
5 Drain the cooling system.
Open the drain cock on the lower part of the radiator. Collect the
coolant in the container.
014698
6 Open the drainage on the engine.

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

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

tank. For volume and quality, see section F Technical data.
A
CAUTION
9 Turn on the system voltage and start the engine.

B
10 Set the cab heat to max.
C
11 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system.
12 Check the level in the expansion tank, fill if necessary.
13 Close the hood.
14 Check the coolant level again after 10 operating hours.
018642

B. Filling point

1:40 1 Engine – Lubrication system
1.8 Lubrication system

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

1:5
1:8
Oil and oil filters, changing (engine alternative

Volvo TAD760VE)
NOTE
Read safety instructions for oil before starting work, see section
B Safety.
1 Run the engine until warm.

3 Remove the drain plug from the engine and drain the engine of oil.
4 When the oil has run out fit the oil plug with a new gasket. Tighten
to a tightening torque of max. 79 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
007317
5 Remove the oil filter with the filter tool.

6 Check that the contact face on the filter bracket is clean and that
no gasket remains from the old filter.
7 Brush a little oil on the new filter's rubber gasket.
8 Spin on the filter by hand until the rubber gasket just touches the
contact surface on the filter bracket.
Then turn another full turn, not more.
9 Fill with engine oil to the correct level. For volume and quality,
see section F Technical data.
NOTE
Do not fill over MAX-level.
10 Start the engine and let it idle. Check that the oil pressure is
normal.
11 Switch off the engine and check the oil level, see Oil level, check,
006435
page 1:42, as well as the sealing integrity. Top up with oil as

required.

1 Engine – Lubrication system 1:41
Oil and oil filters, changing (engine alternative

Cummins QSB6.7)
NOTE
B Safety.
1 Run the engine until warm.

3 Raise the hood.
4 Remove the drain plug from the engine and drain the engine of oil.
5 Remove the oil filter with the filter tool.
6 Brush a little oil on the new filter's rubber gasket.
7 Check that the contact face on the filter bracket is clean and that
no gasket remains from the old filter.
8 Spin on the filter by hand until the rubber gasket just touches the
contact surface on the filter bracket.
Then turn another full turn, not more.
9 When the oil has drained install the oil plug with a new gasket.
Torque tighten to max. 80 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
015537
10 Fill engine oil. For volume and quality, see section F Technical
Oil filter data.
11 Start the engine, let it idle. Check that the oil pressure is normal.
12 Switch off the engine and check the oil level, see Oil level, check
(engine alternative Cummins QSB6.7), page 1:43. Top up as
needed.
13 Close the hood.

1:42 1 Engine – Lubrication system
Oil level, check
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The engine's oil filling pipe and oil dipstick are located under the hood.
2 Check the oil level when the engine has been warmed up. Wipe
A B off the dipstick before checking.
The oil dipstick has two markings, MAX and MIN, between which
the oil level should be.
NOTE
On certain machines the dipstick is long. Wear gloves.
3 Top up with new engine oil as required. For volume and quality,
4 Fill – wait 5 minutes – check on the dipstick.
NOTE
Work carefully when filling to prevent other fluids or particles from
contaminating the oil, which means risk of engine damage.
015095
Machine with Volvo TAD760VE

A. Oil dipstick, engine oil
B. Filling point

1 Engine – Lubrication system 1:43
Oil level, check (engine alternative Cummins

QSB6.7)
NOTE
Safety.
Engine oil, general

The engine oil filling pipe (position B) and dipstick (position A) are
under the service hatch in front of the cab.
B A
2 Check the oil level when the engine has been warmed up. The
oil dipstick has two markings, MAX and MIN, between which the
oil level should be.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
3 Fill engine oil (position B) if required (for volume and grade, see
section F Technical data).
4 Fill - wait awhile - check on the oil dipstick.
NOTE
018848
Work carefully when filling to prevent other fluids or particles from

Machine with Cummins QSB6.7
contaminating the oil, which means risk of engine damage.
A. Oil dipstick, engine oil
B. Filling point

1:44 1 Engine – Control system engine
1.9 Control system engine

Control system engine, description
The engine is controlled by a control 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 for 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 on the engine are detected by the control

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

1 Engine – Ignition/heating 1:45
1.10 Ignition/heating
Ignition/glowing, description (engine alternative
Volvo)
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).
For position of components, see Engine alternative Volvo TAD760VE,

component location, page 1:5
Ignition/heating, description (engine alternative

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

component location, page 1:8.

1:46 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). The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, frame (D797-1). Engine shutdown is controlled by the Control unit,
engine (D794) that cuts off the fuel supply to the engine.
Start lock-out is available as an option, where a code has to be

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

This means that the engine turns off automatically after 3-30 minutes
(depending on customer setting) if the machine is at a standstill and
idling.
For position of components, see Engine alternative Volvo TAD760VE,

component location, page 1:5 or Engine alternative Cummins QSB6.7,
component location, page 1:8.

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 three

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

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

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

2:4 2 Transmission – Transmission
2
F
R
<° 1
5 4
6 3 21
D790-1 D790-2 D795
18 D797-F
20
D794 UDS
D793
7
13 Pa
°C
11 12 14 15 16 19
Pa °C
9
17
10
8
018750
1. Multi-function lever (S162) 12. Sensor oil pressure transmission (B765)
2. Shifting program selector on Control unit KIT (D790-2) 13. Sensor turbine speed (B751)
3. Control unit KIT (D790-2) 14. Sensor oil temperature (B766)
4. Accelerator pedal (B690) 15. Oil pump transmission
5. Declutch pedal (S220-1) 16. Oil filter transmission
6. Control unit, cab (D790-1) 17. Transmission oil cooler
7. Control unit, transmission (D793) 18. Make-contact (closing switch) declutch (S220-2)
8. Solenoid valve clutch reverse (Y631) 19. Frame control unit (D797-1)
9. Solenoid valve clutch 1st gear (Y6067-1) 20. Control unit, KID (D795)
10. Solenoid valve clutch 2nd gear (Y6069) 21. Control unit, engine (D794)
11. Solenoid valve clutch forward (Y630)

2 Transmission – Transmission 2:5
Transmission, component location
7
3
8 6
5
10
4
2
1
15
16 11
17
12
19
018751
13
18 14
1. Valve block transmission control 11. Sensor, drum rpm (B752)
2. Connection cooler (out from transmission) 12. Sensor engine speed and oil temperature (B758/766)
3. Oil pump transmission 13. Sensor oil pressure
4. Transmission oil cooler 14. Oil filter transmission
5. Inlet radiator 15. Connection cooler (from cooler to sump)
6. Thermostat 16. Temperature monitor torque converter (S221)
7. Outlet radiator 17. Sensor turbine speed (B751)
8. Power take-off 18. Sensor output shaft speed (B758)
9. Cooling unit 19. Output shaft
10. Breather filter transmission

2:6 2 Transmission – Transmission
1 2 3 4 5
11
10
018752
8 7
1. Accelerator pedal (B690) 7. Fuse transmission (F58-1:5)
2. Control unit KIT (D790-2) 8. Control unit, transmission (D793)
3. Control unit, KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. Make-contact (closing switch) declutch (S220-2)
5. Control unit, cab (D790-1) 11. Frame control unit (D797-1)
6. Diagnostic socket drivetrain

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 location,

page 2:5.
Breather filter, cleaning

2 Disconnect the breather filter from the transmission.
3 Clean the breather filter from dirt.
4 Refit the breather filter.
1. Breather filter, on top of torque converter.

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 pressurising of clutch discs for each of the gears. The
discs connect the input shaft with the main shaft or tubular shaft,
depending on which gear has been selected. Shifting takes place
without disengaging the transmission from the engine.
Clutches for FORWARD and REVERSE are controlled electrically,

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

page 2:5.

2 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 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 transmission, changing
NOTE
B Safety.
NOTE
Do not over-fill the transmission!
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 oil filter.
Lubricate the O-ring on the new oil filter with transmission oil.
Tighten to contact and then another two-thirds of a turn.
7 When the transmission oil has drained, fit the drain plug.
NOTE
018789
B
A
018644

A. Oil dipstick, transmission
B. Filling point
A B 8 Remove the transmission dipstick and fill new transmission oil

through the dipstick's hole to the marking for low level on the
dipstick.
For volume and quality, see section F Technical data.
9 Switch on the main current and start the engine and allow the
engine to idle for at least two minutes.
10 Check that the drain plug for transmission oil seals tightly.
018849

2 Transmission – Lubrication system 2:11
11 Warm up the transmission so that the oil temperature is approx.

60-65 ºC on the display. Use operating menu oil temperature to
check the transmission oil temperature.
a 12 Check the oil level. Fill to the MAX mark for oil level.
13 Calibrate the transmission, see Transmission, calibration, page
000356
b 2:14.
Operating menu oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature
Oil level, check
NOTE
B Safety.
The transmission's oil filling pipe and oil dipstick are located under
the hood.
B
A
018644

A. Oil dipstick, transmission
B. Filling point
A B 1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 82-93°C on the
display). The oil dipstick has two markings, MAX and MIN, the oil
level should be at MAX.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
2 Top up the transmission oil as required. For volume and quality,

see section F F Technical data).
3 Fill - wait awhile - check on the oil dipstick.
NOTE
018849
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.

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

two modes with reduced functionality to protect the transmission,
Limp-home and Shut-down.
Mode Limp-Home
For certain malfunctions, the control unit activates "Limp-Home". In
this mode the transmission is shifted to neutral position. To be able to
continue operation, travel direction must be selected again with the
gear selector.
In this mode the operator can use the transmission's two first gears in
each direction. If the malfunction occurs in a higher gear, the operator
has to downshift manually to first or second gear to continue.
Mode Shut-Down
For serious malfunctions, the control unit activates "Shut-Down". In
this mode the transmission is locked in neutral, no solenoid valves
are activated.
Machine assumes neutral position

The machine is equipped with 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 driver's
seat as the warning for released parking brake in order 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.
In which case, it is not possible to select any travel direction.
In an emergency the machine can be operated by bypassing the safety

system, for more information see section 8 Control and monitoring
system, group 8.2.2 Bypassing.
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and
rolling over!
Only use bypassing in emergency situations!
1 Release the load.

2 Activate switch for bypassing.
3 Select travel direction.
4 Drive the machine to service. Speed is limited to 10 km/h.

2:14 2 Transmission – Control system transmission
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 position 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 is activated (Service,

Diagnostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION DRIVE-TRAIN with Enter.
5 Scroll with the arrow keys (1 and 2) and select DRIVE-TRAIN,
SCALE STEERING menu 4.
DRIVE-TRAIN RETURN
000062
6 Check that the oil temperature is at least 61 °C.

If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.
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, apply full throttle for 10 seconds and
then run the engine at idling speed.
D. Repeat steps B and C until the oil is hot.
Towards the end of heating the engine speed may decrease
because the oil out from the transmission is too hot. If this occurs,
leave the gear in neutral position and maintain the engine speed at
1200 rpm for 20 seconds.
When the temperature is correct MODE is changed from 0 to 1.

2 Transmission – Control system transmission 2:15
7 Select DRIVE-TRAIN, menu 3.

GEARBOX TUNING
Description: Calibration of transmission clutches.
PHASE: Indicates current phase in the calibration.

0. Pre-filling of clutch.
1. Calibration of clutch.
4. Calibration complete.
5. Calibration incorrect.
6. Calibration paused.
CLUT- Indicates which clutch shall be calibrated.
CH: F. Clutch forward.
R. Clutch reverse.
1. Clutch gear 1.
2. Clutch gear 2.
3. Clutch gear 3.
4. Clutch gear 4.
AC- Indicates action from mechanics (in the event
TION: of a fault).
0. No action (normal condition if no
malfunction).
1. Increase throttle application.
2. Reduce throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (depress the brake if the
machine starts to move).
6. Heat the transmission, see step 4.
7. No action; the engine is controlled via
Control unit, transmission.
8. Keep the accelerator pedal in its current
position.
9. Check error codes.
10. Apply the parking brake.
SUB- Internal value for sub-phase 1 or 0.
PH:
STA- Calibration status.
TUS: 0. Calibration not in progress.
3. Calibration in progress.
8 Check that the gear selector is in neutral position.

9 Start calibration by pressing Enter.

2:16 2 Transmission – Control system transmission
10 Calibration starts (takes approx. 15 minutes) and engine speed

is raised to approx. 770 rpm.
The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.
11 When the engine speed decreases to idling and PHASE = 4 then

calibration is complete.
12 Switch 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.
005193
Propeller shaft, checking

• After 50h:
Check-tighten the retaining bolts at the mountings for the drive axle
and transmission to 98 Nm (oiled screw).
• After 500h:
Clean.
Check clearance in universal joints.
• After 1000h:
Grease universal joints with universal grease EP2.
Check-tighten the retaining bolts at the mountings for the drive axle
and transmission to 98 Nm (oiled screw).
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.
1 1. Hub reduction
2 3 4 2. Wheel brake
5 6 4 3. Drive shaft (internal)
3 2 1 4. Mounting drive axle
5. Drive axle housing
6. Differential (internal)
7. Drain point drive axle oil hub reduction
10
004336
9 8. Filling point and level check drive axle oil hub reduction
8 7
9. Filling point and level check drive axle oil differential
10. Drain point drive axle oil differential
Drive axle, checking

1 Check the drive axle's attachment to the frame so that there is no
corrosion on structural elements (e.g., attaching bolts).
2 Check-tighten the drive axle's attaching bolts to 1380 Nm (oiled
screw).
3 Check-tighten the wheel nuts to 650 Nm (oiled bolt).
4 Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
5 Check that drive axle seals tight.
6 Check the oil level in drive axle and the hub reductions.
008046
Attaching bolts drive axle

3:6 3 Driveline/Axle – Drive axle
Drive axle oil, changing
NOTE
Safety.
1 Position the machine so that the hub reductions' drain plugs at the
wheels are in the lowest position.
This applies to both drive wheels.
1 2
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (raise the machine under
the mast) and rotate the wheel into the correct position. Lower
the machine.
015100
3 Position a receptacle by each hub. Position a piece of sheet metal

or similar in the wheel rim to lead oil into the receptacle.
Wheel hub, drive axle
4 Remove the drain plugs for the hubs (position 1) on both sides.
1. Drain plug hub Also remove the level and filling plugs for the hubs (position 2) to
facilitate draining.
2. Level and filling plug hub
Both sides shall be drained separately.
5 Position a receptacle under the differential and remove the drain
1 2 plug (position 3). Also remove the level and filling plug for the
differential (position 2) to facilitate draining.
6 Clean the drive axle's breather while the oil is draining.
7 Install the drain plugs on the hubs and the differential.
004337
3 NOTE
Differential drive axle Check that the seals are intact, clean and in the correct position.
1. Bleeding the drive axle (inside frame)
2. Level and filling plug differential
3. Drain plug differential
8 Fill oil in the hubs until the oil level is flush with the filling and level
holes (position 2). For volume and quality, see section F Technical
data.
1 2
NOTE
The oil is very viscous, fill the oil slowly. Check the level in stages
so that the oil has time to settle.
9 Install the hubs' level and filler plugs.

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

3 Driveline/Axle – Drive axle 3:7
10 Fill oil in the differential until the oil level is flush with the filler and
1 2 level hole.
11 Install the level and filler plug on the differential.
NOTE
Check that the seal is intact, clean and in the correct position.
004337
3
12 Remove the receptacle.
Differential drive axle
13 Turn on the system voltage and test drive the machine.
1. Bleeding the drive axle (inside frame)
14 Check the oil level in the drive axle after a short test-run.
2. Level and filling plug differential
3. Drain plug differential

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................................................................................4:6
4.3.4 Accumulator ................................................................................................4:8
4.3.9 Wheel brake ................................................................................................4:9
4.5 Parking brake system ....................................................................................4:10
4.5.4 Parking brake unit .....................................................................................4:12
4.8 Temperature control, cleaning and oil brake system......................................4:14
4.8.12 Oil filter, brake system ...............................................................................4:15

4:2

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

• Power-assisted brake system, function description, page 4:5
• Parking brake system, function description, page 4:10
• Temperature control, cleaning and oil brake system, function
description, page 4:14

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

4.1.1 Brake pedal
Brake pedal, checking and adjustment

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 moves smoothly.
Stop screw for adjusting clearance between brake

pedal and brake valve. (The illustration shows a loose
brake pedal.)
4 Lubricate the pedal hinge 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 power assisted brake system consists of a hydraulic oil tank,
hydraulic oil pump, valve block, accumulator, brake valve, pressure
sensors, brake cylinder and wheel brake units.
Hydraulic oil pump, brakes and steering, pumps oil (from the tank).
Valve block, accumulator charging valve and priority valve, controls the
pressure to the steering, the accumulators or cooling circuit for the
brakes and the hydraulic oil. The brake valve directs pressure from the
accumulators to the brake cylinders. The brake cylinders compress the
discs in the brake units that brake the machine. Make-contact (closing
switch) brake pressure emits a signal so that the brake light is switched
on when the brake cylinders are pressurised.
When the accumulators are charged the valve block for the accumulator
charging valve and priority valve controls hydraulic oil through the
hydraulic oil's cooling circuit, see section 10 Common hydraulics, group
10.6 Temperature control, cleaning and hydraulic oil.
12 D790-2 5
B
P
T
D 10 D797-1
8 C
Pa
11
C 9 D D
4 Pa
3
C ACC
7
B
P
6
2
1
019019
B
1. Oil pump brake system 8. Make-contact (closing switch) brake light (S216)
2. Oil filter, brake system 9. Break contact (opening switch) (S204)
3. Accumulator charging valve 10. Frame control unit (D797-1)
4. Accumulators 11. Brake lights (H411L & H411R)
5. Brake valve 12. Control unit KIT (D790-2), Warning lamp, brake
pressure
6. Brake cylinder
7. Wheel brakes

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

location
4
1 2
5 6
3 8
9
12
019020
11 10
1. Brake lights (H411L and H411R) 7. Break contact (opening switch) (S204)
2. Control unit KIT (D790-2), Warning lamp, brake 8. Distribution block drive axle
pressure
9. Make-contact (closing switch) brake light (S216)
3. Brake valve
10. Oil filter, brake system
4. Frame control unit (D797-1)
11. Oil pump brake system
5. Wheel brake
12. Accumulators
6. Accumulator charging valve
4.3.1 Oil pump brake system

Hydraulic oil pump, checking
NOTE
Safety.
Checking the pump pressure

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

4 Brakes – Oil pump brake system 4:7
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

pump pressure on the accumulator charging valve.
5 Start the engine and let it idle.
008048
Measuring outlet 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. 0.10–0.15 MPa at
max. engine rpm.
008049
10 Remove the pressure gauge and fit the protective cap on the
Close the accumulator charging valve pressure check connection.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
Checking accumulator charging
CAUTION
Accumulator charging has two pressure limits that are
dependent on each other. Both the upper pressure and
the lower pressure must be within the specified limits.
Reduced brake performance.
The machine must not be operated with incorrect
brake pressures.

4:8 4 Brakes – Accumulator
13 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

accumulator pressure on the accumulator charging valve.
008050
Measuring outlet accumulator pressure
NOTE
the lock ring.
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 should switch to charging at 15.5±0.5 MPa.
The pressure level depends on the setting of the boost pressure's
008049
upper limit in step 6.

Close the accumulator charging valve 18 Depressurise the hydraulic system, see section B Safety.
20 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
NOTE
the lock ring.
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 lamp for low brake pressure is activated earlier, one
of the brake system's accumulators is probably defective and
these should therefore be checked further.

4 Brakes – Wheel brake 4:9
4.3.9 Wheel brake
Wheel brakes, bleeding
NOTE
Safety.
Brake cylinder
2 Place a box wrench on the breather nipple and connect a
transparent hose to the breather nipple.
Direct the other end of the hose down into a receptacle.
3 Start the machine and press down on the brake pedal; keep the
pedal pressed down.
4 Open the breather nipple and let the oil run out of the nipple until it
is free from air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is long.
For this reason allow at least two litres of oil pass through the
breather nipple during bleeding to ensure that no air pockets
Breather nipple brake cylinder, top side of drive axle remain in the system.
at the wheel hub's inner short side (left side).
5 Close the breather nipple.
6 Move the wrench and the hose and collection container and repeat
steps 2-5 on the other side.
Cooling circuit
NOTE
Cooling circuit ventilation is vital for the correct cooling of the
discs.

2 Position a receptacle under the drive axle at the inside of the
wheel. Position a piece of sheet metal or similar by the breather
nipple to lead oil down into the receptacle.
3 Start the engine and allow the engine to idle. Wait until the brake
accumulators are fully charged and the accumulating charging
valve has switched to brake cooling.
4 Loosen the breather nipple (do not remove it) and allow the oil to
run out until it is free from air bubbles.
5 Move the receptacle and the sheet metal to the other wheel.
Repeat steps 1-4 on the other wheel.
Breather nipple cooling circuit, top side of drive axle

at the wheel hub's inner short side (left side).

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

Parking brake system, function description
The parking brake consists of hydraulic oil tank, 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 means of the parking
brake valve in the accumulator charging valve pressurising the parking
brake caliper. Make-contact (closing switch) parking brake emits a
signal so that Indicator light parking brake is switched on when the
parking brake is applied.
D
12
5
6 11
D790-1 D790-2
C D797-1
7
D
D
4
8
Pa 10 9
C ACC
3
H
P
T
2
019021
B
1. Oil pump brake system 7. Frame control unit (D797-1)
2. Oil filter, brake system 8. Solenoid valve, parking brake (Y642)
3. Accumulator charging valve 9. Parking 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

4 Brakes – Parking brake system 4:11
Parking brake system, component location
1 4
2 5 6
12
019022
11 10 9 8
1. Control unit, cab (D790-1) 7. Break-contact parking brake (S200)

2. Control unit KIT (D790-2) 8. Parking brake disc
3. Switch parking brake (S107) 9. Parking brake caliper
4. Frame control unit (D797-1) 10. Oil filter, brake system
5. Accumulator charging valve 11. Oil pump brake system
6. Solenoid valve parking brake 12. Accumulators

4:12 4 Brakes – Parking brake unit
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.
The parking brake is applied by spring force and is released with
accumulator pressure that is controlled electrically by a solenoid
valve.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.
6 Remove the cover from the brake caliper.
Check that there is no oil inside the cover.
7 Loosen the lock nut.

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

12 Check the function of the parking brake.

4 Brakes – Parking brake unit 4:13
4.5.4.2 Parking brake pads
Brake pads, replacement
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Machine in service position and wheels blocked, see section B

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

4 Loosen the adjusting screw so that the brake pads become loose.
5 Remove the split pin and loosen the nut on the attaching bolt
holding the parking brake caliper.
6 Pull out the attaching bolt so that the brake pads can be twisted
out and removed.
NOTE
The bolt does not have to be removed.
7 Remove the parking brake pads.

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

4:14 4 Brakes – Temperature control, cleaning and oil brake system
4.8 Temperature control, cleaning

and oil brake system
Temperature control, cleaning and oil brake
system, function description
The wheel brakes are cooled when the hydraulic oil is pumped through
the brake unit.
The temperature control system consists of hydraulic oil tank, oil pump
brake system, oil filter brake system, accumulator charging valve and
wheel brake units.
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 routes oil through the drive axle's brake units; it cools
the brakes and then routes the oil back to the tank.
If the temperature in the brake system becomes too high, the machine's
speed is limited to protect the brakes.
C C
4
P T
2 5
3
1
002611
1. Oil pump brake system 4. Wheel brake

2. Oil filter, brake system 5. Distribution block
3. Accumulator charging valve
Temperature control, cleaning and oil brake

system, control system
See Power-assisted brake system, component location, page 4:6.

4 Brakes – Oil filter, brake system 4:15
4.8.12 Oil filter, brake system
Oil filter brake system, changing
NOTE
B Safety.
IMPORTANT
The filter protects the brake system from contaminants.
It is very important that new contaminants 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.
NOTE
008051
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
the lock ring.
11 Start the engine and check that the filter holder does not leak.
12 Fit the cover plates over the transmission area.

4:16

5:1
5 Steering
Contents 5 Steering
5 Steering .............................................................................................................. 5:3
5.2 Power assisted system ....................................................................................5:4
5.2.6 Link arm ......................................................................................................5:8
5.2.12 Sensor steering wheel angle .......................................................................5:8

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 control and mini-wheel are available as options and mean

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

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 the
hydraulic oil pumps.
Steering consists of steering wheel, steering wheel shaft, steering

valve, hydraulic oil pump, priority valve, steering cylinder, link arms
and wheel spindles.
The steering wheel (via the steering wheel shaft) acts on the steering
valve which in turn directs oil pressure from the hydraulic oil pump to
the steering cylinder. The priority valve, located between the hydraulic
oil pump and the steering valve, gives priority to oil supply to the
steering valve ahead of 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.
2
PP P
C
CF LS
T
5
P
LS T L R
3
1
6
B
019024
1. Hydraulic oil pump 4. Steering wheel

2. Priority valve 5. Steering valve
3. Shuttle valve 6. Steering cylinder

5 Steering – Power assisted system 5:5
Joystick control/mini-wheel, function description
Joystick control or mini-wheel means that the machine is steered by

an electrical control in the left-hand armrest of the driver's seat. The
electrical control sends signals to the control system. The steering
cylinder is pressurised 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 steering control.
NOTE
The standard steering wheel always has priority over joystick
control or mini-wheel. Joystick control or mini-wheel are disabled
as soon as a steering wheel movement is made.

5:6 5 Steering – Power assisted system
Condition Reference value

Joystick control activated Voltage signal from switch mini-wheel/joystick control
Steering wheel No signal from sensor steering wheel angle
stationary
Speed Under 2 km/h (when activated)
Control switch Not activated
11
D D
2
13 3
D790-2 D790-1
12 D797-2
4
D 5 D
8
C PP
P
9 LS
P CF P
TP
6
LS
T
T LS B A
T
7 L R
10
019025
1. Hydraulic oil pump 7. Shuttle valve
2. Switch joystick or Switch mini-wheel 8. Priority valve
3. Control unit, cab (D790-1) 9. Steering valve
4. Frame control unit (D797-2) 10. Steering cylinder
5. Solenoid valve steering right (Y636-3) or Solenoid 11. Steering wheel
valve steering left (Y636-4) 12. Sensor steering wheel angle (B770)
6. Control valve for joystick control or mini-wheel 13. KIT cab control unit (D790-2)

5 Steering – Power assisted system 5:7
Power assisted system, component location
4 6
5 7
019026
1
Components hydraulics
1. Hydraulic oil pump for steering and load handling 5. Steering valve
2. Shuttle valve 6. Control valve, mini-wheel/joystick control
3. Priority valve 7. Steering axle with steering cylinder
4. Connection block return oil
2 3
5
4
019027
Electric components
1. Sensor steering wheel angle (B770) Joystick or mini-wheel (R825)
2. Control unit KIT (D790-2) 4. Control unit, cab (D790-1)
3. Switch activates joystick or mini-wheel (S113) 5. Frame option control unit (D797-2)

5:8 5 Steering – Link arm
5.2.6 Link arm
Link arm, checking

Check the link arms' guide bearings, axles and the bolts that lock the
link arms' axles.
007918
5.2.12 Sensor steering wheel angle

Sensor steering wheel angle, checking
(product option mini-wheel or joystick control)
1 Check that the joystick control and mini-wheel disconnect when
1 the steering wheel is turned.
2
002628
1. Indicator ring
2. Sensor steering wheel angle (B770)

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..............................................................................................6:6
6.2.3 Wheel hub ...................................................................................................6:6
6.3 Tyres and rims .................................................................................................6:8
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 journalled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journalled wheel hubs where
the wheels are mounted.
Suspension refers to:

• Steering axle cradle
• Wheel spindle
• Wheel hub
Suspension, component location

1 2 3 4 5 6
008047
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. Spindle bolt / bearing
6.2.1 Steering axle cradle
Steering axle cradle, checking

1 Machine in service position, see section B Safety, with transverse
wheels.
2 Check that the bushings in the suspension are intact.
008078

6 Suspension – Steering axle cradle 6:5
3 Measure the distance between the frame and the steering axle
cradle. Note the measurement.
4 Lift the machine under the rear counterweight.
NOTE
Do not lift under the steering axle.
5 Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
6 Calculate the difference between the two measurements. The
difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.
007842
The figure shows front mounting

6:6 6 Suspension – Wheel spindle
6.2.2 Wheel spindle

Wheel spindle bearing, checking
1 Machine in service position, see section B Safety, with transverse
wheels.
2 Measure dimension A with a feeler gauge. Note the measurement.
3 Lift the machine under the rear counterweight.
4 Re-measure measurement A.
5 Calculate the difference between the two measurements. The
difference must be max. 0.25 mm.
If the difference is greater, shimming must be repeated, see
Workshop manual.
A 008079
6.2.3 Wheel hub
Wheel hub, checking

1 Clean the hub covers on the control wheels.
2 Remove the hub cover.
3 Wipe off grease from hub cap and hub nut. Handle it as
environmentally hazardous waste.
008080
4 Bend up the lock washer's tabs, remove the lock nut, and the lock
washer.

6 Suspension – Wheel hub 6:7
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 a torque of 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
Work carefully to avoid damaging the seal.

6:8 6 Suspension – Tyres and rims
6.3 Tyres and rims

Tyres and rims, safety
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Wheels (tyre + rim) must only be handled pressurised
after inspection and approval, as well as inflated to
full pressure, by certified personnel.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air must always be released through the valve. If
this is not possible - loosen the valve in the rim are
release the air. If this does not work, break off, cut or
saw off the valve pipe. 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. 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 is not permitted to mix rim components between
rims. The parts are adapted during manufacture.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.

6 Suspension – Tyres and rims 6:9
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.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other
approved instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,
pieces of wood, metal filings, etc.
Check if the tyre wear is abnormal, this may be
indicative of mechanical problems. Take action
immediately to repair any defects and change damaged
tyres.
Tyre and rim system, description

The tyres are the points of contact between the machine and the
ground, and the tyres 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 6:8.
DANGER
inflating! Lock ring and lock lugs may release and
The air must always be released through the valve. If
this is not possible - loosen the valve in the rim are
release the air. If this does not work, break off, cut or
saw off the valve pipe. 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. Damaged tyres may explode.
Do not exceed prescribed air pressure! When
changing tyre or rim version, another air pressure may
apply, contact Cargotec.

1 Check the rims.

1 2 3
• 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.
008081
1. Lock ring
2. Rim bead seat taper
3. Rim
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:
• 650 Nm oiled screw.
018762

Tyre and rim system, removing and fitting (drive

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

a) Unscrewing the valve and releasing the air.
014571
b) If this does not work, undo the valve in the rim and release the air.
NOTE
Only applies to tubeless tyres.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572

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

Tyre and rim system, removing and fitting

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

a) Unscrewing the valve and releasing the air.
014571
b) If this does not work, undo the valve in the rim and release the air.
NOTE
Only applies to tubeless tyres.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572

d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that the
wheel is positioned safely for lifting in the lifting equipment.
5 Remove the wheel nuts.
6 Remove the wheel and position it safely so that it does not fall or
move.
005124
Installing
7 Fit the wheel.
8 Fit the wheel nuts. Tighten the wheel nuts crosswise successively
with increasing torque to 650 Nm (oiled screw).
9 Inflate the tyre, see Tyres, inflating, page 6:15.
10 Lower the machine and remove the jack.
11 Test-run the machine and check that the wheels are secure.
12 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.

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. It is not permitted
to mix rim components between rims. The parts are
adapted during manufacture.
If the tyre pressure has been below 300 kPa then the
tyre must be removed and both tyre and rim examined
with regard to damage.
Never install rim components by striking with a
hammer while inflating. Never strike fully or partly
018762
inflated tyres or rim sets.

Never inflate tyres before all parts are in place.
Wheels shall be inflated on the machine or in a
Examples: The figure shows inflation of drive wheel. protective device, designed and dimensioned so that
it can handle or dissipate a shock wave from a tyre
explosion as well as catch the ejected parts.
Do not exceed the prescribed tyre pressure. The tyre
pressure must be checked when the tyre is at ambient
temperature. The pressure increases due to heat while
driving. 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 wheel rim parts are fitted 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 Check that all wheel rim parts are in the correct position when the
tyre pressure is 30 kPa.
5 Inflate the tyre to prescribed pressure, see section F 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 minimise risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and
size. Over-dimensioned tyres may not be used.
It is not permitted to mix rim components between
rims. The parts are adapted during manufacture. If a
part is damaged then all rim parts must be replaced.
1 Dismantle the rim, see Tyre, change, page 6:16.

2 Carefully clean the outside of the rim edge with a steel brush.
005375
3 Measure wear after the lock ring.

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

6 Suspension – Rim 6:17
1 4 Check that the lock ring (position 1) and rim flange (position 2) are
2 3 intact and in the correct position. Replace damaged parts.
004873
1. Lock ring
2. Rim flange
3. Rim bead seat taper
5 Check the lock ring's elasticity before assembly.

Check that the ends overlap each other by 25-50 mm when the
ring is not mounted on the rim.
015739
25-50 mm
5-20 mm 6 After assembly, the distance between the lock ring's ends should
be 5-20 mm.
015741
7 Check that the distance between the lock ring groove and the
circlip is max. 2.5 mm.
015740
Max 2.5 mm
8 Check for damage in the areas with high stress concentration.

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

6:18 6 Suspension – Rim
Magnetic particle method

1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic particle and the following equipment:
• Equipment: Yoke Tiede
• Method:
005375
a Alternating current AC
b Contrast colour
Rim
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid
1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
005376
any remaining cleaning fluid evaporate.

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

1 2
6 Visually inspect the area.
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 ...................................................................................................7:6
7.2.8 Sensor hydraulic pressure lift cylinder.........................................................7:7
7.2.9 Mast ............................................................................................................7:8
7.2.10 Mast position sensor .................................................................................7:10
7.2.11 Trolley........................................................................................................ 7:11
7.4 Side shift ........................................................................................................7:13
7.5 Spreading.......................................................................................................7:15
7.5.4 Spreader beam .........................................................................................7:19
7.7 Tilt ..................................................................................................................7:22
7.7.2 Servo filter .................................................................................................7:23
7.7.7 Tilt cylinder ................................................................................................7:23
7.7.8 Mast ..........................................................................................................7:24
7.8 Levelling.........................................................................................................7:25
7.9 Load carrier....................................................................................................7:28
7.9.1 Twistlocks ..................................................................................................7:28
7.9.2 Lifting hook ................................................................................................7:36
7.10 Other functions...............................................................................................7:46
7.10.1 Container counter......................................................................................7:46
7.10.2 Speed reduction ........................................................................................7:46

7:2

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The function load handling refers to, e.g. lifting/lowering, side shift, tilt
and securing a load. Load handling also includes help functions to
handle loads, e.g. container counter.
Load handling is divided into different sub-functions.
• Lifting/lowering
• Side shift
• Spreading
• Tilt
• Levelling
• Load carrier (side lift attachment with twistlock locking)
• Other
018626
- Container counter
Load handling is primarily controlled with the control levers while
Lifting/lowering
certain functions have separate switches.
Certain sub-functions (e.g. Load carrier) can in turn be divided into
different technical solutions. In these cases, the sub-function is broken
down into further sub-functions.
Many functions change depending on the options with which the
machine is equipped. In these cases the basic function is described
first, then there is a description of how the different options affect the
basic function.
014022
Side shift
018627
Tilt
014023
Spreading
014021
Levelling

7:4 7 Load handling – Lifting/lowering
7.2 Lifting/lowering
Lifting/lowering, function description
Damping
Lifting/lowering means that the mast's components are raised and

lowered so that the attachment is raised and lowered. The machine is
equipped with a duplex lift mast. During lifting, the inner mast is raised
with the lift cylinders. The chain, which is secured in the carriage (and
in the outer mast) runs over the chain wheel at the top of the inner mast,
and by these means also lifts the carriage at the same time as the inner
mast. The lift cylinders are pressurised by Control valve lift and tilt.
During lifting, an extra hydraulic pump is connected (assuming that the

conditions for quick lift have been met) in order to increase the speed
of the lifting movement.
The lifting/lowering function is controlled by electric servo. Electric

servo means that the control levers are electrical and send voltage
signals to the control system to control the lifting/lowering function.
018626
Damping
Damping means that the speed of functions is reduced automatically
close to the upper end position. This entails that mechanical parts are
exposed to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When

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

7 Load handling – Lifting/lowering 7:5

Twistlocks Locked or unlocked, not intermediate position
Contact Mast down: no contact
Height limitation Bypassed or lift height lower than the height limitation.
2 4
D790-1 D794
D797-1
3
17
1b 1a 19
5
LS
18
14 P
A2
11 B2
12 P PS
6
10 19
C
P EF
7
LS
9
16 C C
019030
13 15 8
1. Control lever 10. Pressure reducer
a Control lever lifting/lowering (R8071) 11. Accumulator
b Control lever (S815-P1) 12. Servo filter
2. Control unit, cab (D790-1) 13. Quick-lift pump
3. Frame control unit (D797-1) 14. Solenoid valve quick lift (Y6062-2)
4. Control unit, engine (D794) 15. Hydraulic oil pump
5. Solenoid valve lifting (Y6005) and lowering (Y6004) 16. Pressure limiting valve
6. Control valve lift and tilt 17. Position sensor mast (B7211-2)
7. Shuttle valve 18. Hydraulic pressure sensor lift cylinder (B768-1)
8. Main pump 19. Lift cylinders
9. Priority valve

7:6 7 Load handling – Servo filter
Lifting/lowering, component location
1 2 3 4 5 6 7
11
10
019031
1. Pressure reducer 7. Hydraulic pressure sensor lift cylinder (B768-1)
2. Accumulator servo circuit 8. Hydraulic oil pumps
3. Test outlet servo circuit 9. Servo filter
4. Lift cylinder 10. Control valve lift and tilt
5. Position sensor mast (B7211-2) 11. Side lift attachment
6. Mast
7.2.2 Servo filter
Servo filter, change
NOTE
B Safety.

2 Depressurise the hydraulic and brake systems, see section B
Safety.
3 Turn the start key to position 0 and switch 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.
009161

7 Load handling – Sensor hydraulic pressure lift cylinder 7:7
8 Check that the O-ring on the filter holder is intact and in place.
9 Fit the filter and filter holder.
10 Check the oil level in the hydraulic oil tank when all of the hydraulic
pistons are in retracted position. The oil should be at the top of the
sight glass. Top up as needed, for grade see section F Technical
data.
NOTE
The hydraulic oil level is checked when all of the hydraulic pistons
are in retracted position.
7.2.8 Sensor hydraulic pressure lift cylinder
Sensor hydraulic pressure lift cylinder, checking

2 Wipe the sensor clean with a cloth or similar.
3 Check the sealing and that the sensor and the sensor's connector
is securely fastened.
009188

7:8 7 Load handling – Mast
7.2.9 Mast
Mast suspension, checking

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

1 Raise and secure the trolley.
WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.

3 Visually check that the frame's mounting points and welding
seams are intact.
4 Also check that the mast's mounting points and welding seams are
intact. Check both inside and outside.
5 Make a marking on the mast.
6 Remove the load from the mast mountings in an appropriate
manner.
7 Make a new marking on the mast. Measure the distance between
the markings. The measurement should be max. 1 mm.
8 If the difference is greater, the bearings in the mast mountings
must be replaced, see Workshop manual.
009673

7 Load handling – Mast 7:9
Slide plates, checking

2 Check that the slide surfaces in the mast and trolley have a normal
appearance and do not show signs of damage or unevenness.
3 Check the clearance in the mast and between the trolley and mast.
4 When a noticeable clearance arises, which corresponds to a
minimum clearance of 2 mm, the clearance must be reduced by
using adjustment shims, see Workshop manual. If less than 5 mm
wear limit remains on the slide plates they must be replaced.
NOTE
Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
Lifting chains, checking and adjusting

With the aim of increasing safety, the lifting chains should be checked
regularly according to the following:
The chains must be thoroughly cleaned over their entire length. The
check is performed without a load on the side lift attachment.
Wear checking
1 The chain must not have extended more than 3%. Measure the
length of the 25 links that first (and most often) travel over the
chain wheel during lifting. This is where the extension is greatest.
Compare with the value in the table. If the 3% limit is exceeded
the chains must be replaced.
2 P-measurement = the distance between 2 pins
Measurement over 25 links

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

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

7:10 7 Load handling – Mast position sensor
10 Check that there is 10-20 mm of space between carriage and the

mast. Adjust the position by tensioning or loosening the chains
equally on the adjustment nut in the carriage.
NOTE
If the chain is slack when the carriage is in its lowest position,
the chain must be tightened.
009153
Inspection hole, distance between carriage and mast.
11 Adjust the chains so that the carriage is lifted evenly in the mast.
3 • Loosen the locking washers (position 1) and remove the lower

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

2 Wipe the sensors clean with a rag or similar item.
3 Check that they are secured properly.
4 Check that the distance between sensor and inner mast (when it is
directly opposite the sensor) is 10±1 mm
014740

7 Load handling – Trolley 7:11
7.2.11 Trolley
Slide plates trolley, checking

1 Park the machine with attachment lowered as far down as possible
and spreaders in their narrowest position.
3 Clean the lower slide plates (position 2) and measure the
thickness.
1
NOTE
Slide plate thickness should be at least 10 mm.
4 Clean the upper slide plates (position 1) and measure the

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

adjusting
Slide plates trolley, checking

1 Park the machine with the attachment as far down as possible.
3 Check the clearance between the trolley's slide plates and the
attachment's main beam. The clearance can be checked by using
prybars.
NOTE

7:12 7 Load handling – Trolley
Slide plates trolley, adjusting

3 Unload applicable slide plate.
The slide plates can be unloaded by lifting the side lift attachment
in the outer edge or by using wedges to change the side lift
attachment's position in the lifting 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.
1 NOTE
8 Place the slide plate in the correct position.

Check the clearance between the side lift attachment and the
trolley. Clearance should be less than 1 mm with all slide plates
fitted.
Use a spacer plate to adjust the clearance.
NOTE
Generally, the upper slide plate is adjusted on the front of the
trolley and the lower slide plate on the rear of the trolley using
spacer plates.
1 NOTE
2 Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
NOTE
Check that the attaching bolts for all slide plates are tightened.
009190
9 Install the slide plate console.

The illustration shows slide plates and roller plates on 10 Install the slide plate guide bolt.
a trolley with mechanical levelling.
11 Check that the slide surface is clean and lubricate the slide surface
1. Slide plates and roller plates of the side lift attachment.
2. Retaining screws and guide screws for slide 12 Start the machine and check the side lift attachment function. Try
plates and roller plates to lift a container and then re-check the clearance of the side lift
attachment in the trolley.

7 Load handling – Side shift 7:13
7.4 Side shift

Side shift, function description
Side shift means moving the attachment sideways. Control valve
attachment pressurises the side shift cylinder that moves the
attachment's main beam 600 mm in relation to the trolley.
The side shift function is controlled by electric servo. Electric servo

means that the control levers are electrical and send voltage signals to
the control system to control the side shift function.
014022

1a 1b
2
D790-1
D797-1 D791-1
3 8
9 11
P1 A
4
T1 B
10
5
C
6
7
014024
1. Control lever 6. Shuttle valve

a Control lever side shift (R8073) 7. Hydraulic oil pump
b Control lever (S815-P3) 8. Control unit attachment (D791-1)
2. Control unit, cab (D790-1) 9. Solenoid valve, side shift left (Y6020) and right (Y6021)
3. Frame control unit (D797-1) 10. Control valve attachment
4. Solenoid valve, activation main pump (Y6062) 11. Side shift cylinder
5. Shuttle valve

7:14 7 Load handling – Side shift
Side shift, component location
2 3 5
4
019058
1. Side lift attachment 4. Solenoid valve, side shift right (Y6021)
2. Side shift cylinder 5. Solenoid valve, side shift left (Y6020)
3. Control valve attachment 6. Hydraulic oil pumps

7 Load handling – Spreading 7:15
7.5 Spreading
Spreading, function description
Damping
Spreading means changing the width between the twistlocks or lifting

hooks. The spreading distance is between 20 feet (side lift attachment
retracted) and 40 feet (side lift attachment maximum extension). A
30-foot stop is also available as an option.
Control valve attachment pressurises the spreading cylinders, which

actuate the spreader booms in and out.
The spreading function is controlled by electric servo. Electric servo

means that the control levers are electrical and send voltage signals to
the control system to control the spreading function. Inductive position
sensors indicate the position of the spreader booms.
Damping
014023
Damping means that the speed of functions is reduced automatically

close to end-positions. Four seconds after damping has been activated
the function is cancelled. This entails that mechanical parts are
exposed to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When

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

7:16 7 Load handling – Spreading

Twistlocks Unlocked or bypass activated
1b 1a 2
D790-1
D797-1 D791-1 8
3
9 10
C
P1
4 11
T1
A B A B
5 14 15
C
6 12 13
7
014025
1. a. Switch spreading 20'-40' (S1012) 9. Solenoid valve, spreading out right (Y6018R) and
spreading in right (Y6019R)
b. Control lever (S815-T1.1 and S815-T1.2)
10. Solenoid valve, spreading out left (Y6018L) and
2. Control unit, cab (D790-1) spreading in left (Y6019L)
3. Frame control unit (D797-1) 11. Control valve attachment
4. Solenoid valve, activation main pump (Y6062-1) 12. Spreading cylinder, right
5. Shuttle valve 13. Spreading cylinder, left
6. Shuttle valve 14. Sensor, end-position 20'-40' right (B769R)
7. Hydraulic oil pump 15. Sensor, end-position 20'-40' left (B769L)
8. Control unit attachment (D791-1)

7 Load handling – Spreading 7:17
30-foot stop, function description

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

Twistlocks / Lock lugs Unlocked or bypass activated
1
2b 2a 30-
35
3
D790-1
D791-1
4
30' 30'
014026
5 5 6 7 6 7
1. Switch stop at 30' (S1004) valve spreading in left (Y6019L) and Solenoid valve
spreading in right (Y6019R)
2. a. Switch spreading 20'-40' (S1012)
6. Sensor, end-position 30' left (B777L) and Sensor,
b. Control lever (S815-T1.1 and S815-T1.2) end-position 30' right (B777R)
3. Control unit, cab (D790-1) 7. Sensor, end-position 20'-40' left (B769L) and Sensor,
4. Control unit attachment (D791-1) end-position 20"-40" right (B769R)
5. Solenoid valve spreading out left (Y6018L) and
Solenoid valve spreading out right (Y6018R) or Solenoid

7:18 7 Load handling – Spreading
Automatic spreading 20-40 foot, function

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

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

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

Twistlocks Unlocked or bypass activated
Doors Closed
Parking brake Released
1a
1b
3 5
D790-1 D795
4 D791-1
10 9 7 6 8 6 7 9 10
014759
1. a. Switch spreading 20'-40' (S1012)
b. Control lever (S815-T1.1 and S815-T1.2)
2. Switch automatic spreading 20'-40' (S1012-2)
3. Control unit, cab (D790-1)
5. Control unit, KID (D795)
6. Solenoid valve spreading out (Y6018L & Y6018R)
7. Solenoid valve spreading in (Y6019L & Y6019R)
8. Buzzer automatic spreading (H9003)
9. Sensor end-position 20'-40' (B769L & B769R)
10. Sensor, end-position 30' (B777L & B777R)

7 Load handling – Spreader beam 7:19
Spreading, component location

4
1 5
3
10
9
8
7 8-10
019032
1. Spreader beam 7. Sensor damping 20' and 40' (B769L & B769R), 30'
2. Spreading cylinders stop, Sensor damping 30' (B777L & B777R)
3. Control valve attachment 8. Indicator plate 20'
4. Solenoid valve spreading in (Y6019L & Y6019R) 9. Indicator plate 30'
5. Solenoid valve spreading out (Y6018L & Y6018R) 10. Indicator plate 40'
6. Hydraulic oil pumps
7.5.4 Spreader beam

Spreader beam, description
The spreader beams are the part of the attachment that grips the
container. Two spreader beams run inside the main beam. The
spreader beams are slid in and out with hydraulic cylinders.
Twistlocks are fitted in the spreader beam, see 7.9.1 Twistlocks, page
7:28.
014737
Spreader beams

7:20 7 Load handling – Spreader beam
Slide plates spreader beam, checking

and spreading extended approx. 1000 mm.
1000 mm
013683
3 Check that the clearance between slide plates and main beam is
max max 5 mm both laterally and vertically. This is equivalent to
the dimensions X1–X2 = max 5 mm and Y1–Y2 = max 5 mm.
NOTE
If the measured clearance between slide plates and beams
is greater than 5 mm, the clearance must be adjusted using
Y2
Y1
adjustment shims.
Y2
Y1
X2
013690
X1
Left side
X2
013689
X1
Right side
4 For adjustment and replacement, see Workshop manual.
Slide plates, spreader beam for attachment with

levelling, checking and adjusting.
Slide plates spreader beam, checking


7 Load handling – Spreader beam 7:21
3 Check the clearance between slide plates and the attachment's

main beam as well as between slide plates and spreader beam.
The clearance can be checked by lifting the spreader beam in the
outer edge or by using prybars.
NOTE
Slide plates spreader beam, adjusting

1 3 Unload applicable slide plate.

The slide plates can be unloaded by lifting the spreader beam in
the outer edge or by using wedges to change the spreader beam's
position in 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.
2
NOTE
8 Place the slide plate in the correct position.

Check the clearance between spreader beam and slide plate.
Clearance should be less than 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.
NOTE
009189
Generally, the upper slide plate is adjusted on the front of the

1 spreader beam / main beam and the lower slide plate on the rear
The illustration shows the inner slide plates on the of the spreader beam / main beam using spacer plates.
side lift attachment's spreader beam.
1. Slide plates. NOTE
2. Retaining screws and guide screws for slide Do not use adjustment shims that are too thick. Inadequate
plates clearance increases wear on the slide plates.
NOTE
Check that the attaching bolts for all slide plates are tightened.
9 Install the slide plate console.

10 Install the slide plate guide bolt.
11 Check that the slide surface is clean and lubricate the slide surface
of the spreader beam.
12 Start the machine and check the spreading function. Try to lift a
container and then re-check the clearance of the spreader beams
in the attachment's main beam.

7:22 7 Load handling – Tilt
7.7 Tilt
Tilt, function description
Tilt means the angling of the mast in relation to the machine. Control
valve lift and tilt pressurises the tilt cylinders which angle the mast in
relation to the machine. Tilt is controlled with control lever, tilt.
The tilt function is controlled by electric servo. Electric servo means
that the control levers are electrical and send voltage signals to the
control system to control the tilt function.
018627

1b 1a 2
D790-1
13 14
D797-1
3
13 14
P A1
B1
T1
P PS 7
10
11
EF
C P 8
C
5
12
4 4
019033
1. Control lever 7. Control valve lift and tilt

a Control lever, tilt 8. Priority valve
b Control lever (S815-P2) 9. Pressure reducer
2. Control unit, cab (D790-1) 10. Accumulator
3. Frame control unit (D797-1) 11. Servo filter
4. Hydraulic oil pumps
12. Return filter
5. Pressure limiting valve
13. Load holding valve
6. Solenoid valve tilt in (Y6011) and Solenoid valve tilt
out (Y6010) 14. Tilt cylinders

7 Load handling – Servo filter 7:23
Tilt, component location
1 2 3 4
019034
1. Pressure reducer 6. Load holding valve
2. Accumulator servo circuit 7. Hydraulic oil pumps
3. Test outlet servo circuit 8. Servo filter
4. Mast 9. Control valve lift and tilt
5. Tilt cylinder
7.7.2 Servo filter
Servo filter, change

See Servo filter, change, page 7:6
7.7.7 Tilt cylinder
Tilt cylinder, checking

Check:
5 4
4 • visually that the frame's mounting points and welding seams are
intact.
• that the piston rod head is securely fastened to the tilt cylinder
(tightening torque 330 Nm).
• that the tilt cylinders are properly aligned, so that both cylinders
reach their end positions simultaneously.
015962
1 3 2
1. Tilt cylinder
2. Piston rod head
3. Screws
4. Locking washers, Nord Lock
5. Nuts

7:24 7 Load handling – Mast
7.7.8 Mast
Mast suspension, checking

See Mast suspension, checking, page 7:8.

7 Load handling – Levelling 7:25
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the twistlock mountings can spring
outwards and adjust the height of the twistlocks to the inclination of the
container being lifted. This means that the machine can handle loads
on uneven ground, up to ±3° levelling.
014021
Active levelling, function description
Active levelling means that the attachment is angled in the horizontal

direction. This means that the machine can handle loads on uneven
ground. Levelling is possible by means of the attachment being
suspended in the trolley with two hydraulic cylinders.
Active levelling means that the attachment's tilt can be controlled with
hydraulic function. The levelling angle is locked when it is not activated
by means of the connection to the levelling cylinders being blocked.
Active levelling means that inclination is controlled by pressurising the

hydraulic cylinders. The levelling function is controlled by electric servo.
Electric servo means that the control levers are electrical and send
009439
voltage signals to the control system to control the levelling function.

7:26 7 Load handling – Levelling

1b 1a
2 11
D790-1
+
D797-1 D791-1
3 8
9 11
C
P1 A
4
T1 B
10
5
C
6
7
009651
1. Control lever 6. Shuttle valve
a Levelling (R8075-1) 7. Hydraulic oil pump
b Control lever (S815-P3 and S815-P4) 8. Control unit attachment (D791-1)
2. Control unit, cab (D790-1) 9. Solenoid valve levelling right (Y6035) and levelling
3. Frame control unit (D797-1) left (Y6036)
4. Solenoid valve, activation main pump (Y6062-1) 10. Control valve
5. Shuttle valve 11. Levelling cylinders

7 Load handling – Levelling 7:27
Levelling, component location
4
5
2
3
019035
1. Side lift attachment 4. Solenoid valve levelling right (Y6035)
2. Levelling cylinder 5. Solenoid valve levelling left (Y6036)
3. Control valve attachment 6. Hydraulic oil pumps

7:28 7 Load handling – Load carrier
7.9 Load carrier

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

valve attachment pressurises two hydraulic cylinders, connected in
parallel, one on each side of the side lift attachment. Each hydraulic
cylinder acts on a linkage that turns a twistlock. Four position sensors,
two on each side of the side lift attachment, detect the position of the
linkage and indicate whether twistlocks are open or locked. Indicator
lights on the side lift attachment and in the cab, as well as a mechanical
indicator on the side lift attachment, show the status of the twistlocks.
A contact pin and a sensor at each twistlock indicate when the

attachment is in contact with the container. This is used to control
when twistlocks can be activated. One indicator light on the side lift
attachment and one in the cab indicate when the side lift attachment
has full contact. An event menu shows which twistlocks have contact
(1 - 2). To activate twistlocks, contact is required at both twistlocks.

7 Load handling – Twistlocks 7:29

Contact Full contact or bypass activated
2b
1 D1
2a
7 6
5
D790-1 D790-2 D795
D797-1 D791-1
4
8
17
13 16 3
P1 A
9 B
T1
15
14
10 16 3
17
D6
12 11
014028
1. Switch, lock twistlocks (S1003) 10. Shuttle valve
2. a. Switch, open twistlocks (S1002) 11. Shuttle valve
b. Control lever (S815-T2) 12. Hydraulic oil pump
3. Sensor contact left and right (B7203L and B7203R) 13. Solenoid valve open twistlocks (Y6039) and lock
twistlocks (Y6040)
14. Control valve
5. Control unit, KID (D795)
15. Over centre valve
6. Control unit KIT (D790-2)
16. Lock cylinders
7. Control unit, cab (D790-1)
17. Sensor unlocked twistlocks (B7204L and B7204R),
8. Frame control unit (D797-1) Sensor locked twistlocks (B7205LL and B7205RL)
9. Solenoid valve, activation main pump (Y6062-1)

7:30 7 Load handling – Twistlocks
Twistlocks, component location
1 3
4
5
11
10 6
7
019036
8

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

2 3 Lock and open the twistlocks, check that the indicator lights work,
both in cab and on attachment.
2 Clean the twistlocks from any dirt.
3 Under the rubber cover for twistlocks: check pin, link arm and lock
nut.
4 Clean the area around sensor contact.
5 Press in the contact pin so that the head is flush with the spreader
beam's underside. Check the distance to sensor contact, the
distance should be 5±1 mm. Adjust when needed.
014716
5 4
NOTE
1. Sensor contact The contact pin should move easily and spring back completely.
2. Sensor unlocked twistlock

3. Sensor locked twistlock
4. Lift pin
5. Contact pin
6 Put a crowbar between the lift pin (position 5) and the lift pin's
guide, check the clearance max. clearance: 1–1.5 mm. If
necessary, replace the wear washer (position 1) between
twistlocks and holder.
1
015527
1. Wear washer

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

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

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

Sensor contact, checking and adjusting

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

Sensor twistlocks, checking and adjusting

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

014720
2 1
Left side

7:36 7 Load handling – Lifting hook
7.9.2 Lifting hook

Lifting hook, function description
The container is secured to the side lift attachment with two fixed lifting
hooks that are positioned in the container's corner compartments (in
the side openings on the long side) and two movable lock lugs that are
positioned in the container's corner compartments (in the side openings
on the short side) that fix the side lift attachment to the container.
The lock lugs are controlled by Switch lock lug. A section in Control
valve attachment pressurises two hydraulic cylinders connected in
parallel, one in each spreader boom. Each hydraulic cylinder acts on
a linkage that turns a lock lug. Four position sensors, two in each
spreader boom, detect the position of the linkage and indicate whether
lock lugs are open or locked. Indicator lights on the side lift attachment
and in the cab show status for lock lugs.
Lock lugs are activated manually or automatically and can open if the
machine moves forward at a speed below 5 km/h. If the lock lugs
are not locked when the attachment is holding a load, the speed is
restricted on the machine's lifting/lowering, and the machine's speed
is limited to max 5 km/h.
Two detection sensors (one at each lifting hook), detect using

ultrasound at a distance (and inform the system) whether one or two
containers shall be lifted. There is a sensor that indicates contact
lower container and one that indicates contact upper container at each
lifting hook.
Two indicator lights on the side lift attachment and one in the cab
indicate when the side lift attachment has full contact. An event menu
shows which lifting hook has contact (1-2).
To activate the lock lugs, no contact is required at both lifting hooks, but
contact and correct locking are required so that the machine's hydraulic
functions and speed are not limited.
When handling double containers and automatic locking, contact is

required at all four contact sensors.

7 Load handling – Lifting hook 7:37

Contact Full contact or bypass activated
2b 1
2a
8 7
6
D790-1 D790-2 D795
D797-1 D791-1
5
9
4
14 17 3
P1 A
16 18
10 B
T1
15
11 17 3
D6 4
13 12
009653
1. Switch, lock lock lug (S1003) 10. Solenoid valve, activation main pump (Y6062-1)
2. a. Switch, open lock lug (S1002) 11. Shuttle valve
b. Control lever (S815-T2) 12. Shuttle valve
3. Sensor contact left, lower and upper and right, 13. Hydraulic oil pump
lower and upper (B7203LL, B7203LU-2, B7203RL and 14. Solenoid valve open lock lug (Y6039) and lock lock
B7203RU-2). lug (Y6040)
4. Sensor detecting upper container (B7203LU/RU) 15. Control valve
5. Control unit attachment (D791-1) 16. Pilot controlled non-return valve
6. Control unit, KID (D795) 17. Lock cylinders
7. Control unit KIT (D790-2) 18. Sensor unlocked lock lug (B7204L and B7204R).
8. Control unit, cab (D790-1) Sensor locked lock lug (B7205LL and B7205RL).
9. Frame control unit (D797-1)

Lifting hook, component location
1 3
4
5
6 7
12 11
10
9 13 9 8
8
7 14
019037
1. Control valve attachment 8. Sensor locked lock lug (B7205LL/RL)
2. Solenoid valve lock twistlocks (Y6039) 9. Lock cylinder lock lug
3. Solenoid valve open twistlocks (Y6040) 10. Sensor contact lower container (B7203LL/RL)
4. Over centre valve 11. Sensor detecting upper container (B7203LU/RU)
5. Hydraulic oil pumps 12. Contact pin
6. Sensor contact upper container (B7203LU-2/RU-2) 13. Lifting hook
7. Sensor unlocked lock lug (B7204L/R) 14. Lock lug

Lifting hook, checking
WARNING
Make sure that the engine is switched off when working
with lifting hooks and lock lugs.
Lock lugs can be locked automatically if all sensors for
contact are activated manually.
1 Clean the lifting hooks from dirt.

2 Check the thickness of the lifting hooks, as illustrated. Minimum
thickness should be 46 mm.
3 Replace the lifting hook if required.
mm
46
n.
Mi
014019
Lifting hook thickness
Lifting hook, checking for cracks
DANGER
Twistlocks and lifting hooks should be checked in
accordance with recommended intervals. The interval
is calculated according to the machine being used
for normal handling and on a level, smooth ground
surface. For other handling or, e.g., rough surface, the
interval should be shortened.
If there are signs of cracking, the machine must be
immediately taken out of operation and Cargotec
Service contacted.
WARNING

DANGER
Material fatigue, reduced strength.
Fatal danger!
Replace a lifting hook that shows signs of cracks or
other external damage, or a lifting hook with more
than 10 000 operating hours.
1 Remove the lifting hooks from the attachment.
NOTE
Lifting hooks are heavy, be careful when removing.
2 Check for cracks within the marked area on the lifting hooks
without causing damage.
3 If the lifting hooks show signs of cracking, they must be replaced
with new ones.
014722
4 Install approved lifting hooks.
Area for checking for cracks on lifting hooks

NOTE
Use new bolt and new lock nut.

Lock lug, checking
WARNING
DANGER
Wear results in reduced strength.
Fatal danger!
Replace lock lugs that show signs of wear, cracks or
exterior damage.
1 Check that the lock lugs:

• are intact and do not show signs of abnormal wear.
• do not fit loosely against the shaft or lock cylinder.
• connect to and secure the container correctly when lifting.
2 Adjust or replace lock lugs if necessary.
3
009643
1. Clevis pin
2. Lock lug
3. Mounting lock cylinder

Sensor contact, checking and adjusting
A 1 Check the sensors for contact and adjust if necessary. Check the
left and right-hand sides in the same way.
2 Measurement (A) over the contact pin on the upper container
should with unactuated contact pin be approx. 39 mm.
3 When measurement (A) decreases to 22 mm, the light (B1) for
contact with the upper container should be illuminated.
B
014724
B 1
A C
B 2
009375
Lights on the side lift attachment
A Green light Lock lugs locked

B1 Orange light Contact (upper container)
B2 Orange light Contact (lower container)
C Red light Lock lugs released
4 Adjusting:
Secure the contact pin in an appropriate way so that the
measurement (A) is 22 mm. Then move the sensor along the oval
mounting hole and screw it in at exactly the position it has when
lamp (B1) illuminates.
5 Measurement (B) over the contact pin on the lower container
should with unactuated contact pin be approx. 30 mm.
6 When measurement (B) decreases to 18 mm, the light (B2) for
contact with the lower container should be illuminated.
7 Adjusting:
Secure the contact pin in an appropriate way so that the
measurement (B) is 18 mm. Then move the sensor along the oval
mounting hole and screw it in at exactly the position it has when
lamp (B2) illuminates.

Inductive sensor, checking and adjusting

A number of inductive sensors control the side lift attachment's different
1 functions.
The sensors are PNP - positive/negative/positive. The last P means

that the sensor sends out a positive signal when it is activated, which
takes place when a magnetic object comes closer than 8 mm from
the tip of the sensor.
The sensor is equipped with an LED that can be used to check the
sensor's function.
1. The gap between sensor tip and the magnetic activator should be
set to 51 mm. At a distance greater than 8 mm, the positive 24 V
signal stops, i.e. the sensor is deactivated.
5±1 mm
2. When the sensor is activated, the yellow LED should be illuminated.
3. Check that the sensor is clean and free of grease, and that it does
not show signs of damage. (Grease can activate the sensor).
009655
2
1. Yellow LED, sensor activated
2. Magnetic activator

Sensor detecting upper container, checking

The sensors for detecting upper containers use ultrasound to detect if
there is one or two containers to be handled. The sensors are activated
when the attachment is 30-50 cm from the container and event menu
contact is illuminated on the display.
1 Drive the machine forward toward the two containers and check
1 that the event menu contact on the display lights up no later than
when the attachment is 30 cm from the container.
2 If the event menu contact for the upper container does not
illuminate:
• Determine, by using a piece of cardboard or similar item,
which of the sensors has not been activated.
• Clean the sensor.
• Check that the sensor and wiring are undamaged.
014035
3 Repeat the check according to item 1 above. If the event menu

contact still is not illuminated, replace the sensor.
1. Sensor detecting upper container
Indicator light, checking
B 1
A C
B 2
009375
Lights on the side lift attachment
A Green light Lock lugs locked

B1 Orange light Contact (upper container)
B2 Orange light Contact (lower container)
C Red light Lock lugs released
1 Check that the contact pins at the corner boxes can move freely
in and out. A pin that binds in the inner position indicates contact
even if the side lift attachment is not fully in contact with the
container.
Lubricate the pins if required.
2 Check that the indicator light attachment upper container (B1) is
illuminated when the side lift attachment is in contact with the
upper container.
3 Check that the indicator light (B2) is illuminated when the lifting
hooks are engaged.
4 Check that the indicator light (B2) switches off after lifting.
5 Lift an empty container enough that indicator light contact (B2)
switches off.
6 The inductive sensors for contact should be adjusted so that they
emit a signal when the contact pins are pressed in, see Sensor
contact, checking and adjusting , page 7:42.

Sensor lock lugs, checking and adjusting

1 Check that the sensors are free of damage and dirt.
sensor for unlocked lock lugs is illuminated.
1
3 Check that indicator light lock lug open is illuminated.
2 4 Insert the lifting hooks into the container and lock the lock lugs.
5 Check that the LED on the sensor for locked lock lugs is
illuminated.
009377
6 Check that the indicator light locked lock lugs is illuminated.
3
7 Check that lock lugs lock correctly, adjust the lock cylinders as
required.
Right side
1. Sensor detecting upper container
(B7203LU/RU)
2. Sensor unlocked lock lug (B7204R/L)
3. Sensor locked lock lug (B7205LL/RL), lower

7:46 7 Load handling – Other functions
7.10 Other functions

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

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

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

4
D795
D791-1
3 D
D
1 2
1. Sensor contact left and right (B7203L and B7203R) 004297

2. Sensor locked twistlock left and right (B7205LL and 4. Control unit, KID (D795)
B7205RL)
7.10.2 Speed reduction

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

8:1
8 Control system
Contents 8 Control system

8 Control system .................................................................................................. 8:3
8.2 Monitoring ........................................................................................................8:6
8.2.2 Bypass ........................................................................................................8:6
8.2.3 Speed limitation...........................................................................................8:6
8.2.4 Service indicator..........................................................................................8:7
8.3 Error codes ......................................................................................................8:8
8.4 Diagnostics ....................................................................................................8:10
8.4.1 CAN/POWER ............................................................................................8:13
8.4.2 LIGHTS .....................................................................................................8:14
8.4.3 CAB ...........................................................................................................8:15
8.4.4 CLIMATE ...................................................................................................8:15
8.4.5 HYD...........................................................................................................8:16
8.4.6 ENGINE ....................................................................................................8:17
8.4.7 TRANSM ...................................................................................................8:19
8.4.8 ELSERV ....................................................................................................8:20
8.4.9 ATTACH ....................................................................................................8:21
8.4.10 OLS ...........................................................................................................8:23
8.4.11 EXTRA ......................................................................................................8:23
8.5 Settings ..........................................................................................................8:27

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.
Diagnostics comprise a 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 controlling
B C D
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. Function keys (KIT)

B. Warning and indicator lights
C. Display (KID)
D. Alarm indicator
Function keys
Function keys
The function keys (A) are used to navigate in the menu system. They
are also used to enter values in the system, change light contrast in the
keys/indicator panel, and to acknowledge a warning.
• Function key 1: Scroll anticlockwise in menu system as well as
enter value 1.
000055
• 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
when the machine is started. This menu is shown until another menu is
1 2
selected or an event-controlled menu is shown (e.g., in case of error
U code type "WARNING" and "STOP"). Scroll to other menus (see list
below) with function keys 1 (arrow left) and 2 (arrow right).
For overview of operating menus see, section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments.
The following operating menus are available to aid the operator:

• Engine and transmission operating menu
• Operating menu engine
• Operating menu transmission and hydraulics
014252 • Operating menu electrical system
• Service menu
• Operating menu heating and air conditioning
Examples of available operating menus
• Operating menu service interval
• Operating menu statistics
• Operating menu container counter
• Operating menu load handling
• 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.
For overview of the event menus see, section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments.
Warnings are described in connection with each function. The following

event menus are available:
• Event menu start interlock
• Contact side lift attachment, twistlock
• Locked/unlocked twistlock
• Contact side lift attachment, hooks with lock lugs
• Open door
• Automatic spreading
Service menu
Service menu
The service menu is the gateway to the machine's diagnostic system.
Different parts of the Service menus are made available by pressing
"Enter" and entering different codes. The different service menus are:
• Error codes, description, page 8:8
000056
• Diagnostic test, general, page 8:10

• Setup, general, page 8:27

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

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

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

preset value by limiting gear position and engine speed.

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

Service indicator, resetting

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

4 Reset the service indicator 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 or minus key.
STORED XXXXh
004908
PRESENT XXXXh

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

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

manual.
Error code indication
Error code indication
53 54 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:

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

8 Control system – Error codes 8:9
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). When
the error code has been acknowledged the display returns to
previously selected menu. If the error code is active, it is stored in
003817
the error code list under operating menu for service.
If the error code is active it is repeated to remind the operator of
Example of automatic display figure the error status, stop every 3rd minute, warnings every 5th minute.
• In the error code list under operating menu for service.

Active error codes are stored in the error code list. Navigate to the
operating menu for service. Show the error code list by pressing in
function key Enter for two seconds. Navigate in the error code list
with function key arrow right and arrow left. Exit the error code list
by pressing function key Reset (R).
001998
Example of display in error code list NOTE

If error code isn’t included in the error code list, it may be due to
the following:
– condition for error detection no longer exists, e.g., control
lever is released or engine is off.
– loose connection/poor contact.

8:10 8 Control system – Diagnostics
8.4 Diagnostics
Diagnostic test, general
The machine has built-in functions for troubleshooting called diagnostic
DIAGNOSIS test. The diagnostic test consists of several menus that are shown in
CAN/POWER LIGHTS CAB the display. The menus are grouped for faster access.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH The following pages show compilations of the diagnostic menus. The
005263
OLS EXTRA workshop manual has a more detailed description of each diagnostic
menu.
The diagnostic test is divided into the following groups:

• CAN/POWER, menu overview, page 8:13
• LIGHTS, menu overview, page 8:14
• CAB, menu overview, page 8:15
• CLIMATE, menu overview, page 8:15
• HYD, menu overview, page 8:16
• ENGINE, menu overview (engine alternative Volvo TAD760VE),
page 8:17
ENGINE, menu overview (engine alternative Cummins QSB6.7),
page 8:18
• TRANSM, menu overview, page 8:19
• ELECTRIC SERVO, menu overview, page 8:20
• ATTACH, menu overview, page 8:21
• OLS, menu overview, page 8:23
• EXTRA
– EL-STEERING, menu overview, page 8:24
– MOVE-CAB, menu overview, page 8:25
– OPT, menu overview, page 8:26
– RMI, menu overview, page 8:26

8 Control system – Diagnostics 8:11
Diagnostic menu, description
1 The diagnostic tests are built up of menus. The menus are grouped
2 3 4
according to logical areas. With the diagnostic menus it is possible to
read off how the control unit interprets input signals as well as what
7 DIAG CAB 2(X) output signals are sent by the control unit.
FRONT WIPER
SWITCH (1-3) 2 Signal values (position 6) in the menu indicate measured values by
5 OUTPUT 11 6 the relevant control unit. The control units have internal voltmeters
005592
FEEDBACK 0 and ammeters that measure the signal on the connectors out to
components or in from components.
1. DIAG = Diagnostic menus
Output signals are control of solenoid valves, lights, relays, etc.
2. Menu group (CAB = cab functions)
3. Menu number Input signals are sensor signals, signals from controls and switches,
feedback control signals, etc.
4. Total number of menus in the loop. The
number of menus depends on how the machine The figure shows an example of a menu, here for diagnostics of
is equipped, which is why the number of menus windshield wiper. The table below indicates what you can read out
is indicated by (X) in this manual.
from the menu figure.
5. Variable
6. Signal value
7. Menu heading
Pos. Designation Description

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

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

To choose diagnostics, do the following:
1 Navigate to the service menu.
2 Press 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 ELSERV ATTACH arrow keys (1 and 2) to change menu.
005263
OLS EXTRA

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

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

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

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

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

797-2 FRAME (OPT) 797-2 FRAME (OPT) 791-1 ATTACHMENT(OPT)
POWER XX.XXV 24V SENSOR SUPPLY XY EME POWER XX.XXV
RED.POWER LE X RI X 5V REF X.XXV RED.POWER LE X RI X
EME STOP POWER X EME POWER 2 X
DIAG CAN/POWER 16(X) DIAG CAN/POWER 17(X)

791-1 ATTACHMENT (OPT) REDCAN STATUS CHECK
24V SENSOR SUPPLY XY PRESS ENTER
5V REF X.XXV
007104
SEGMENT ERROR X

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

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

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

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

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

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

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

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

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

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

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

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

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

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

HYDRAULIC OIL BRAKE COOLANT OIL HYDRAULIC PRESSURE
TEMP XXX TEMP XXX
FAN XY FAN XY LIFT CYLINDER XXX
SET OUTPUT +/- X SET OUTPUT +/- X TILT CYLINDER XXX
DIAG HYDRAULIC 4(X) DIAG HYDRAULIC 5(X) DIAG HYDRAULIC 6(X)

PRESSURE SWITCHES P-BRAKE CUT OFF HYDRAULIC
BRAKE PRESSURE X SWITCH X/Y PUMPS
BRAKE LIGHT PRESS. X FEEDBACK SWITCH X PUMP 2 XY
DECLUTCH PRESSURE X VALVE XY PUMP ATTACHMENT XY
DIAG HYDRAULIC 7(X) DIAG HYDRAULIC 8(X)

PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
EXTRA HYD PUMP PRESSURE TO ATTACHM.
VALVE XY VALVE XY
009156
SET OUTPUT +/- X SET OUTPUT +/- X

8 Control system – ENGINE 8:17
8.4.6 ENGINE
ENGINE, menu overview (engine alternative Volvo
TAD760VE)
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

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

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
015281
IND. SEVERITY XX

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

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

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

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

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

NOT USED
015041

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

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

OPERATING STATE OPERATING STATE DRUM SPEED XXXXHz
AUT/MAN MODE X SHIFT IN PROGRESS X OUTPUT SPEED XXXXHz
WARNING X FAULT X ENGINE SPEED XXXXHz
OPERATING MODE X OLD FAULT X TURBINE SPEED XXXXHz

OUTPUT STATUS FWD SUPPLY X FWD FEEDBACK XXXXmA
RSP DRIVE X X REV SUPPLY X REV FEEDBACK XXXXmA
2/4 VFS SELECTION X 2/4 SUPPLY X 2/4 FEEDBACK XXXXmA
1/3 VFS SELECTION X 1/3 SUPPLY X 1/3 FEEDBACK XXXXmA

PRESENT SENSOR INPUT PRESENT VALUE
PRESS FEED. XXXXohm AXLE RATIO XXXXX NOT USED
TRANSM.TEMP XXXXmV RADIUS XXXX
COOLER TEMP XXXXmV SPEED LIMITx10 XXXX
DIAG TRANSM. 13(14) DIAG TRANSM. 14(14)

ACT ERROR AREA XXX CONVERTER STATUS (Nm)
TYPE XXX TORQUE IMPELLER XXXXX
NUMBER OF OCCU. XXXXX TORQUE TURBINE XXXXX 006830
TIME AGO XXXXX

8:20 8 Control system – ELSERV
8.4.8 ELSERV
ELECTRIC SERVO, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG ELSERVO 1(X) DIAG ELSERVO 2(X) DIAG ELSERVO 3(X)

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS OUTPUT LIFT
P1 XX.XXV P4 XX.XXV REFERENCE XY
P2 XX.XXV P7 XX.XXV REQUIRED VALUE XXXmA
P3 XX.XXV P5 XX.XXV FEEDBACK XXXmA

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

NOT USED NOT USED NOT USED

NOT USED NOT USED NOT USED

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS REGENERATION STATUS
SPREADER IN X OUT X OPTION LOCKING X INPUT DAMPING X
PISTOL X LEVELLING LOCKING X OUTPUT LEFT XY
007105
UNLOCK TW X OUTPUT RIGHT XY

8 Control system – ATTACH 8:21
8.4.9 ATTACH
ATTACH, menu overview
For side lift attachment with hook locking
DIAGNOSIS DIAG ATTACHMENT 1(X) DIAG ATTACHMENT 2(X)

CAN/POWER LIGHTS CAB PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
CLIMATE HYD ENGINE P3 XX.XXV P5 XX.XXV
TRANSM ELSERV ATTACH P4 XX.XXV
OLS EXTRA P7 XX.XXV
DIAG ATTACHMENT 3(X) DIAG ATTACHMENT 4(X) DIAG ATTACHMENT 5(X)

PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
SPREADER IN X OUT X LOCK CONT X
AUTO 20/40 X PISTOL X UNLOCK CONT X
30/35 STOP X

LE RI ALIGNMENT LE RI LE RI
LOW SPEED 20/40 X X UPPER X X LOCKED CONT X X
30/35 STOP X X LOWER X X UNLOCKED CONT X X

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

OUTPUT SIDESHIFT RI OUTPUT LEVELLING CW OUTPUT LEVELLING CCW
REQUIRED VALUE XXX REQUIRED VALUE XXX REQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX FEEDBACK XXX

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

OUTPUT SPREADER LE IN OUTPUT SPREAD RI OUT OUTPUT SPREADER RI IN
REQUIRED VALUE XXX REQUIRED VALUE XXX REQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX FEEDBACK XXX

PRESENT OUTPUT SIGNAL PRESENT INPUT SIGNALS PRESENT OUTPUT SIGNAL
DETECT UPPER CONT. IND. UPPER
BUZZER AUTO 20-40 XY LE RI ALIGNMENT XY
009159
X X
ATTACH, menu overview

For side lift attachment with twistlock locking

8:22 8 Control system – ATTACH
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA

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

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

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

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

OUTPUT LEVELLING CW OUTPUT LEVELLING CCW NOT USED
REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX
FEEDBACK XXX FEEDBACK XXX

NOT USED OUTPUT SPREAD LE OUT OUTPUT SPREADER LE IN

OUTPUT SPREAD RI OUT OUTPUT SPREADER RI IN PRESENT OUTPUT SIGNAL
REQUIRED VALUE XXX REQUIRED VALUE XXX BUZZER AUTO 20-40 XY
009160

8 Control system – OLS 8:23
8.4.10 OLS
OLS, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAG OLS 1(X) DIAG OLS 2(X) DIAG OLS 3(X)

PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL VD VALUE XXXXXKg
PRESENT LOAD XXXXXKg
LIFT CYLINDER X.XXV BY-PASS X
TILT CYLINDER X.XXV MAST POS SENSOR X
DIAG OLS 4(X) DIAG OLS 5(X) DIAG OLS 6(X)

PRESENT INPUT SIGNAL OUTPUT ACT LIFT (HYD) OUTPUT ACT LOWER (HYD)
TILT ANGLE LIM X REFERENCE XY REFERENCE XY
HEIGHT LIM X REQUIRED VALUE XXX REQUIRED VALUE XXX
DIAG OLS 7(X)

PRESENT OUTPUT SIGNAL
TILT (HYD)
TILT ACTIVE XY
009162
8.4.11 EXTRA
8.4.11.1 VBFS
VBFS, menu overview

Not used.

8:24 8 Control system – EXTRA
8.4.11.2 EL-STEERING
EL-STEERING, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
DIAG STEERING 1(X) DIAG STEERING 2(X) DIAG STEERING 3(X)

PRESENT INPUT SIGNAL SWITCHES PRESENT INPUT SIGNAL
SIGNAL 1 P6 X.XXV ON/OFF X HORN X
SIGNAL 2 P7 X.XXV FORWARD X STEER.WHEEL CUT OFF X
LOGIC X.XXV REVERSE X
DIAG STEERING 4(X) DIAG STEERING 5(X)

OUTPUT STEERING LEFT OUTPUT STEERING RIGHT
009163
8.4.11.3 EXT-ATTACH
EXT-ATTACH, menu overview

Not used.
8.4.11.4 FREELIFT
FREELIFT, menu overview

Not used.

8 Control system – EXTRA 8:25
8.4.11.5 MOVE-CAB
MOVE-CAB, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
DIAG MOVE-CAB 1(X) DIAG MOVE-CAB 2(X) DIAG MOVE-CAB 3(X)

INPUT SWITCHES PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
UP/RIGHT X AUTO CABTILT X CAB UPPER POS X
DOWN/LEFT X LIFT HEIGHT POS X CAB LOWER POS X
OPEN DOORS X
DIAG MOVE-CAB 4(X) DIAG MOVE-CAB 5(X) DIAG MOVE-CAB 6(X)

PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL OUTPUT RIGHT
VALVE CAB UP XY ACTIVATE SLID-CAB XY REFERENCE XY
VALVE CAB DOWN XY REQUIRED VALUE XXX
FEEDBACK XXX
DIAG MOVE-CAB 7(X)

OUTPUT LEFT
REFERENCE XY
REQUIRED VALUE XXX
009164
FEEDBACK XXX

8:26 8 Control system – EXTRA
8.4.11.6 OPT
OPT, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
DIAG OPTION 1(X) DIAG OPTION 2(X) DIAG OPTION 3(X)

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

PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
D797-2 C1 P28 XY D791-1 C1 P14 XY
D797-2 C1 P42 XY D791-1 C1 P28 XY
009165
8.4.11.7 I/O
I/O, menu overview

Not used.
8.4.11.8 RMI
RMI, menu overview
DIAGNOSIS
CLIMATE HYD ENGINE
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
DIAG RMI 1(X) DIAG RMI 2(X) DIAG RMI 3(X)

MIU SW VER XXXX.XXXX SIGNAL QUALITY ERROR XX.XX.XX.XX
MIU TIME XX.XX.XX GSM XXX GPRS XXX ERR.VALID XX.XX.XX.XX
WLAN XXX RADIO XXX ACT ERR XX.XX.XX.XX
009166
SMS XXX: UNS.DATA XXX

8 Control system – Settings 8:27
8.5 Settings
Setup, general
Settings offer the option of adapting the properties of the functions
for each unique machine. Settings are entered via the menus in the
display. Settings options are divided into sections such as Initiations
and Calibrations
Initiation is performed before the machine is put into operation. This

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

functions. Certain functions require calibration in order to operate.

8:28

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

9 Frame, body, cab and accessories .................................................................. 9:3
9.1 Controls and instruments .................................................................................9:4
9.2 Safety and emergency equipment ...................................................................9:9
9.3 Seats..............................................................................................................9:10
9.4 Heating, ventilation and air conditioning ........................................................9:13
9.4.1 Fresh air filter ............................................................................................9:24
9.4.8 Condenser.................................................................................................9:25
9.4.9 Moisture filter.............................................................................................9:26
9.5 Wiper/washer system.....................................................................................9:27
9.6 Lighting system ..............................................................................................9:28
9.7 Signalling system ...........................................................................................9:30
9.8 Entertainment and communication ................................................................9:32
9.9 Glass/windows/mirrors...................................................................................9:33
9.9.3 Roof window..............................................................................................9:33
9.9.5 Rear view mirror ........................................................................................9:33
9.10 Cab structure and suspension .......................................................................9:34
9.10.2 Doors.........................................................................................................9:34
9.10.3 Cab undercarriage ....................................................................................9:35
9.10.4 Tiltable cab ................................................................................................9:35
9.11 Cab interior ....................................................................................................9:37
9.12 Frame.............................................................................................................9:38
9.13 Body structure................................................................................................9:39
9.14 Central lubrication ..........................................................................................9:40
9.15 Paint/coatings ................................................................................................9:42

9:2

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

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

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

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

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

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

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

Steering wheel panel
Steering wheel panel

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

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

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

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

Side lift attachment with twistlock locking
1 2 3 4
014669
1. Event menu contact twistlock

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

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

Safety and emergency equipment, description
A good working environment has safety and emergency equipment to
make the operator's work safe. The machine may be equipped with
the following equipment.
6, 7, 10
2
8
4
3
1
11 9
018772
5
1. Back-up alarm . 7. Buzzer in cab to indicate alarm or forgotten action,
e.g., if the operator leaves the cab without first applying
2. Revolving beacon.
the parking brake.
3. Horn.
8. External rear view mirrors.
4. Electrically powered loud horn .
Used to provide increased visibility for operating.
5. Fire extinguisher . 9. Blinking brake lights when reversing.
If the machine is supplied with a fire extinguisher, it should 10. Control breaker for hydraulics (servo circuits).
be of the type ABE in accordance with EN 3 part 1, 2,
4 and 5. With such a fire extinguisher, it is possible to Breaks all transmission of power and control signals to
extinguish fires in both solid organic materials and fluids. the hydraulics.
Adapted fire extinguishing equipment can be ordered
11. Buzzer automatic spreading (H9003) .
from Cargotec.
6. Seat belt.

9:10 9 Frame, body, cab and accessories – Seats
9.3 Seats
Seat, description (product alternative BE-GE
9200)
The function of the seat is to give the operator a good sitting position
1 2 and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
3 The seat has the following equipment:

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

Controls
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 Frame, body, cab and accessories – Seats 9:11
Seat, description (product alternative BE-GE 9200

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

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

Controls BE-GE 9200 used to activate buzzer if the operator leaves the seat without applying
the parking brake and shifts the transmission to neutral if the operator
1. Adjustable lower back (lumbar) support leaves the seat.
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

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

Isringhausen 6800)
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
The Isringhausen 6800 seat has the following equipment:

• head rest
• arm rest
• air suspension (with external compressor)
• air-adjusted 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
10. Adjustable lower back (lumbar) support
11. Arm rest

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

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

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

001839
• add fresh air to the cab

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

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

Air conditioning, function description (product

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

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

cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 ºC. The
system is operated with controls on the dashboard 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
001839
heating system.
Defroster nozzles The air conditioning adds the following functions to the heating and
ventilation unit:
• dehumidification of the air when it is humid
• cooling of the air when it is warm
As an option for the air conditioning there is automatic shut-off of

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

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

Heating, ventilation and air conditioning,

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

2 3
4
5
019039
7
1. Magnetic clutch compressor (M645) 5. Pressure switch (S246)

2. Compressor 6. Sight glass
3. Water valve (Y673) 7. Condenser
4. Moisture filter

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.
Air conditioning, checking/performance test
NOTE
The air conditioning does not work at temperatures below approx.
0 °C 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 °C, 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 °C. (Deviations
in the measurement result can occur if the performance test is
conducted when the ambient temperature is below approx. 18 °C).
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 °C,
the compressor cuts out via the thermostat or ECC and cuts in
again when the temperature has increased approx. 3-7 °C. (If the
compressor does not cut out, there is a risk of the evaporator icing
up and cooling performance decreasing.)
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air
conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.

Refrigerant amount, checking

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

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

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

Action in the event of leakage in the system

1 Turn off the air conditioning.
2 Check the cooling plant and pinpoint leaks. For this purpose, use
special leak detection equipment. If there still is refrigerant left,
the remaining refrigerant amount shall be evacuated and then
measured.
3 Rectify faults, seal leaks by replacing gaskets, hoses, etc.
4 Fill with the correct quantity of R134a refrigerant according to the
following points when all defects have been repaired.
5 The following work requires special filling equipment.
6 Connect the suction pressure gauge's blue hose to the service
valve on the compressor's suction side marked with S, SUC or
SUCTION.
7 Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.
8 Connect the hoses to the fluid reservoir.
9 Connect the yellow filler and vacuum hose to the nitrogen gas
cylinder. Open the cock on the cylinder and then the cock 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.) Close the cock on the pressure side and then the cock
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 will be blown out of the vacuum pump.
Then open the cock on the pressure side, vacuum-extract for at
least 30 minutes. Preferably longer.
14 First close both cocks 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 cock
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 cock 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 cock on the suction side and then the cock 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. In addition, 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. In normal
conditions, oil should neither be changed nor topped up. In the
event that incorrect oil volume is suspected, see 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.

9:24 9 Frame, body, cab and accessories – Fresh air filter
Pause heater, description
1
Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
An additional electric water pump pumps the coolant through the

heating system when the engine is switched off. The cab fan pumps
air into the cab. The pause heater switches off automatically when
the temperature in the cab is 6 °C below the set value on the air
conditioning unit. The pause heater is activated with Switch pause
heater when the ignition is switched on.
3 2
004909
1. Switch, pause heater (S199-1)

2. Control unit, cab KCU (D790-1)
3. Circulation pump pause 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 Frame, body, cab and accessories – Condenser 9:25
9.4.8 Condenser
Condenser, cleaning

2 Blow clean the condenser's cooler with compressed air.
014732
1. Condenser

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

3 Check the colour of the indicator on the moisture filter.
Blue indication = moisture filter ok.
Grey or pink indication = change moisture filter (see Moisture filter,
changing, page 9:26).
009183
Indicator moisture filter
Moisture filter, changing
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
IMPORTANT
Working on the air conditioning requires special
authorisation.
2 Drain the air conditioning of refrigerant R134a, with the intended

draining equipment.
3 Disconnect hoses and cabling from the moisture filter.
4 Disconnect the moisture filter pressure switch from the moisture
009183
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 good
B 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 bracket
E C 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 grooves are pressed into the bracket and work like drive
flanges. Counterhold the wiper arm when installing so that the torque
002214
A is not transmitted to the motor as it may be damaged (16–20 Nm
tightening torque).
A. Wiper motor front
The wipers turn off automatically 2 minutes after the operator has left
B. Wiper motor roof the cab. The wipers are activated automatically when the operator sits
C. Wiper motor rear in the set, selects a gear, or if the accelerator pedal is pressed down.
D. Washer motor and reservoir
E. Wiper, front

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

Lighting system, function description
The function of the lighting is to increase safety during operation and
load handling.
The lights are turned off automatically after 5 minutes of idling so that
the lights do not drain the batteries. Extra work lights are turned off after
2 minutes. The lighting is activated automatically when the operator
sits in the set, selects a gear, or if the accelerator pedal is depressed.
NOTE
It is important to use the correct bulb type for each area. See
section F Technical data.
1 2 3 5 4
9
10
13 11
6
D6 17
14 14
18
7 15
16 M
D790-1 D790-2
20 8 29 12 31
D797-1 D797-2 D791
19
Pa
009766
21 22 23 24 25 26 27 28 30 32 33
1. Switch work lights cab roof (S105-1) 20. Frame control unit (D797-1)
2. Switch work lighting attachment (S105-2) 21. Direction indicator (H422, H423, H426 & H427)
3. Switch, work lights on mast (S105-3) 22. Running lights (H416-1, H416-2, H417-1 & H417-2)
4. Switch, headlights (S100) 23. Driving lights low beams (E400L & E400R)
5. Switch, revolving beacon (S110) 24. Driving lights high beams (E402L-1 & E402R-1)
6. Door NC (normally closed) switch (S266-LE & S266-RI) 25. Tail lights (H412L & H412R)
7. Switch, courtesy lighting (S141) 26. Brake lights (H411L & H411R)
8. Control unit, cab (D790-1) 27. Mast work lights (E404L-1 & E404R-1)
9. Multi-function lever (S162) 28. Extra work lights mast (E404L-4 & E404R-4)
10. Lever direction indicator (S161) Extra work lights front wing (E404L-4 & E404R-4)
11. Switch interior lighting on Control unit KIT (D790-2)
29. Frame option control unit (D797-2)
12. Control unit KIT (D790-2)
30. Extra work lights mast (E404L-2 & E404R-2)
13. Relay work lights cab roof (K3017-1 and K3017-2)
Extra work lights front wing (E404L-2 & E404R-2)
14. Work lights cab roof (E406L-1 E406R-1, E406L-2 and
E406R-2) 31. Control unit attachment (D791)
15. Back-up lights (E405L & E405R) 32. Work lights Twistlock attachment (E404L-3 &
E404R-3)
16. Revolving beacon (H428)
Work lights Lifting hook attachment with lock lug (E404UL,
17. Interior lighting (E434-1) E404UR, E404LL and E404LR)
18. Courtesy lighting (E433) 33. Extra work lights Twistlock attachment (E404L-5
19. Make-contact (closing switch) brake light (S216) & E404R-5)

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

The function of the lighting is to increase safety during operation and
load handling.
NOTE
The following lighting is available:
1 4 5 6 6 7 9
3,8,10
30
12
29
28
27
26
019041
22, 23, 24, 25 21 19, 20 18 17 16 15 11, 13, 14
1. Mast work lights (E404L-1 & E404R-1) 17. Switches, see Controls and instruments, overview,
page 9:4
2. Auxiliary mast work lights (E404L-4 & E404R-4)
18. Switch, courtesy lighting (S141)
3. Relay, cab roof work lights (K3017-1 & K3017-2)
4. Multi-function lever (S162) 19. Frame option control unit (D797-2)
5. Control unit KIT (D790-2) 20. Frame control unit (D797-1)
6. Interior lighting (E434-1) 21. Make-contact (closing switch) brake light (S216)
7. Work lights cab roof (E406L-1 & E406R-1) 22. Direction indicators, front (H422 & H423)
8. Extra work lights cab roof (E406L-2 & E406R-2) 23. Running lights, front (H416-1 & H417-1)
9. Revolving beacon (H428) 24. Driving lights low beams (E400L & E400R)
10. Control unit, cab (D790-1) Driving lights high beams (E402L-1 & E402R-1)
11. Running lights, rear (H416-2 & H417-2) 25. Extra work lights front wing (E404L-4 & E404R-4)
12. Back-up lights, white (E405L & E405R) 26. Work lights lifting hook attachment (E404LL &
13. Tail lights, red (H412L & H412R) E404LR)
Brake lights (H411L & H411R) 27. Control unit attachment (D791-1)
14. Direction indicators, rear (H426 & H427) 28. Work lights twistlock attachment (E404L & E404R)
15. Door NC (normally closed) switch (S266-LE & 29. Extra work lights carriage (E404L & E404R)
S266-RI)
30. Work lights lifting hook attachment (E404UL &
16. Courtesy lighting (E433) E404UR)

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

Signalling 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
1 2 3 4
17 6
7
15
16
D6
13 18
14 M
8 19
D790-1 5 D790-2 D795
9
D797-1 D791-1
20
10 11 21
009767
12
1. Switch, revolving beacon (S110) 12. Reverse alarm (H965)

2. Switch hazard lights (Hazard) (S109) 13. Horn (H850)
3. Switch parking brake (S107) 14. Revolving beacon (H428)
4. Switch horn (S149-3) 15. Relay loud horn (K3016)
5. Control unit, cab (D790-1) 16. Loud horn (H850-1)
6. Multi-function lever (S162) 17. Make-contact (closing switch) operator-in-seat (S230)
7. Lever direction indicator (S161) 18. Buzzer, cab (H853)
8. Control unit KIT (D790-2) 19. Control unit, KID (D795)
9. Frame control unit (D797-1) 20. Control unit attachment (D791-1)
10. Direction indicator (H422, H423, H426 & H427) 21. Buzzer automatic spreading (H9003)
11. Back-up lights (E405L & E405R)
NOTE
On machines with side lift attachment, the sound signal can also
be activated with button open twistlock (S1002) on the hydraulic
functions panel or open twistlock on the joystick, providing that the
function for open twistlocks at contact is not active.

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

The machine has the following signalling systems:
1 2 3 4 5 6
018775
19 18 17 16 15 14 13 12 10,1 1 9 8 7
1. Control unit, KID (D795) 11. Control unit, cab (D790-1)
2. Buzzer, cab (H853) 12. Make-contact (closing switch) operator-in-seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switches, see Controls and instruments, overview,
5. Lever direction indicator (S161) page 9:4
6. Revolving beacon (H428) 15. Loud horn (H850-1)
7. Reverse alarm (H965) 16. Frame control unit (D797-1)
8. Back-up lights (E405L & E405R) 17. Direction indicators, front (H422 & H423)
9. Direction indicators, rear (H426 & H427) 18. Control unit attachment (D791-1)
10. Relay loud horn (K3016) 19. Buzzer automatic spreading (H9003)

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

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

documentation for each product.

9 Frame, body, cab and accessories – Glass/windows/mirrors 9:33
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component location
The windows are designed to both enclose the cab and provide the
C operator with a good view. Tempered glass windows are standard on
all trucks. Roof windows are a safety feature and are therefore always
D made of polycarbonate plastic.
The rear-view mirrors are of the type convex mirror. There is an interior
rear view mirror on all machines.
The machine has tinted windows in tempered glass.
The following panes may be of laminated glass:

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

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

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

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

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

Design and suspension, description
The cab has a flat floor with a bracket for the operator's seat. It is
suspended in the cab substructure via heavy-duty rubber insulators
located on the cab's underside. This is to minimise vibrations from
1 the frame to the cab. There is an insulator at four points, one in each
corner. Each insulator bracket has a rubber bushing and a bolt.
2
3
003206
4
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.2 Doors
Doors, description
The cab has two doors, the left is the operator's door and the right is
the emergency exit. The doors have:
• hand rail
• handle
• key lock
• opening window (emergency exit door )
There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be controlled with the diagnostics menu, see section 8
Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-CAB,
menu 1.
Doors, checking
2 Visually inspect the door's mounting points.
Lubricate the hinges of the doors if necessary.
3 Check the door's locking mechanism with regard to function and
wear.
006914

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

2 Check that the welding seams at the cab's mounting points are
intact and free of visible cracks.
3 Check that the isolators are intact. Replace any damaged isolator.
4 Check that bolted joints are tightened and that the brackets are
undamaged. Rectify as needed.
018895
The cab's mounting points with dampers.
9.10.4 Tiltable cab

Cab tilt, function description
WARNING
When entering under tilted cab.
Fatal danger!
Check that no one remains under or near a tilted cab.
Visibility is impaired!
NOTE
Only manoeuvre the cab while stationary!
Cab tilt simplifies visibility during load handling.
The cab is tilted up to obtain a more ergonomic work position. The

switch for Automatic/Manual cab tilt is used to select automatic or
manual cab tilt.
For automatic cab tilt, the cab is tilted automatically when the
attachment is at a preset lifting height. For manual cab tilt, the cab is
tilted with the switch for Manual tilt. In order for the cab to be tilted
automatically, the machine's speed must not exceed 5 km/h, the
operator's doors must be closed and the parking brake disengaged.
If the cab is not in the lowest position, i.e. tilted, the machine's speed is
limited to a maximum of 5 km/h.

9:36 9 Frame, body, cab and accessories – Tiltable cab
5
2 1 3 1
0
0 2
4 6
D790-1 D797-1
7
D797-2 12
8
9
12
B
T
A
TP
P LS LSPB
10
11
13
1
019043
1. Hydraulic oil pumps 7. Sensor cab up (B769-2) / cab down (B769-1)
2. Switch, automatic/manual cab tilt (S199-2) 8. Frame option control unit (D797-2)
3. Switch, manual cab tilt, cab up/down (S1010) 9. Solenoid valve cab up (Y6047) and cab down (Y6048)
4. Control unit, cab (D790-1) 10. Control valve, cab tilt
5. Sensor for cab tilt (B7211-1) on mast for automatic 11. Shuttle valve
cab tilt 12. Cab tilt cylinders
6. Frame control unit (D797-1) 13. Return filter
Tilt cassette, checking

2 Check:
• tilt cassette's mounting points and joints.
• tilt cylinders and tilt cylinder mounting points.
• function of the crush protection on the sides of the tilt cassette.
3 Rectify as needed.
019045
Tilt cassette

9 Frame, body, cab and accessories – Cab interior 9:37
9.11 Cab interior

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

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

9:38 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:
1
2
018776
3 4 5 6
1. Frame's rear section with counterweights 4. Bracket for front wings
2. Engine compartment with mountings for engine and 5. Cab mounting (4 points)
transmission
6. Steering axle mounts
3. Frame's front section with drive axle mounting

9 Frame, body, cab and accessories – Body structure 9:39
9.13 Body structure

Body, description
The body's function is a part of the frame. There are fenders to deflect
dirt, footsteps and handrail to facilitate access on the frame, engine
hood to deflect dirt and objects from the engine compartment and a
counterweight to balance the machine's lifting capacity.
2 1
018777
3
1. Counterweight
2. Hood, engine compartment
3. Wings

9:40 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

Example figure, components, central lubrication frequency and duration.
1. Pump unit
The central lubrication is supplied with voltage when the parking brake
2. Safety valve is released.
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 9:41
Central lubrication, checking
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling
the connections at the distribution block. A blocked hose remains
pressurised and the connection becomes firm.
NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2 Turn the start key to position I.

3 Operate the pump manually and check that the indicator pin moves
in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
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.
4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
Overview of central lubrication. Example figure.

1. Lubricant nipple, filling point, lubricating grease
2. Safety valve
3. Lubricant nipple, manual lubrication of the
system
4. Indicator pin
5. Switch, manual operation

9:42 9 Frame, body, cab and accessories – Paint/coatings
9.15 Paint/coatings
Paint/coatings, 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 ................................................................................10:8
10.6 Temperature control, cleaning and hydraulic oil.............................................10:9
10.6.6 Breather filter hydraulic oil tank ...............................................................10:12
10.6.7 Hydraulic oil filter .....................................................................................10:12
10.6.8 Hydraulic oil.............................................................................................10:13
10.6.9 Fine filter hydraulic oil..............................................................................10:15

10:2

10 Common hydraulics – Common hydraulics 10:3
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps the supply load handling, brakes and
steering with hydraulic pressure.
Pressure plate
On the machine there is a pressure plate with the most important
pressure information (stamped in). The pressure plate is located on the
left-hand side of the frame in front of the cab steps.
Pressure levels vary with the equipment and therefore they are unique
to each machine. When checking pressure, the pressures must
correspond with the pressure plate.
8
019049
7 6 5 4
1. Feed pressure control valve attachment 5. Max. pressure hydraulic oil pump 2
2. Max. brake pressure 6. Steering pressure
3. Gas pressure brake accumulators 7. Max. pressure hydraulic oil pump 1
4. Servo pressure lift and extension 8. Hydraulic oil pressure brake accumulators

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

Safety valves, component location
1 NOTE
The valves shall be closed during operation and are opened to
depressurise the machine.
2 019050
1. Relief valve attachment (figure shows closed

valve).
2. Accumulator drain valve with opening knob
and lock ring.

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

Tanks and accumulators, component location
Tank
1 2 1 3 2 4 5 Tank
1. Cap for hydraulic oil filter
2. Filler plug hydraulic oil
3. Sight glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs hydraulic oil
018778
Accumulator
Accumulator
1 1. Accumulator
019051

10:6 10 Common hydraulics – Pumps
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from four pumps. Three of them
1 for working hydraulics/steering, and one for the brake system. The
pumps are assembled into two pump banks which are mounted to
the transmission's power take-off.
Hydraulic oil pump and quick-lift pump (position 1) supply the control
valve for lifting/lowering and tilt, as well as the attachment's control
valves. The quick-lift pump is engaged for lifting without load in order
to increase the lift speed.
The fixed brake oil pump (position 2) supplies the brake system's brake
2 and cooling circuit over an accumulator charging valve, see section 4
3 019052
Brakes
The main pump (position 3) supplies the steering as well as the

control valve for load handling. The priority valve ensures that there
1. Hydraulic oil pump and quick-lift pump for load is always pressure for steering, the residual flow goes to control valve
handling load handling.
2. Hydraulic oil pump for brake system, cooling
and filtration.
3. Main pump for steering and load handling

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,
18
D790-1 D790-2
LS
D797-1 D795 P
8 P
LS
C P
17
6 19
7 P
T
PS TP
5 1
P LS LSPB
EF PP
10 12 P
CF P
14 9 4 T LS
LS
11 T L R
20
2
16
C C
008091
13 15 3
1. Control valve lifting/lowering and tilt 11. Shuttle valve
2. Shuttle valve 12. Shuttle valve
3. Main pump 13. Quick-lift pump
4. Priority valve 14. Solenoid valve, activation quick-lift pump (Y6062)
5. Pressure reducer 15. Hydraulic oil pump
6. Servo pressure accumulator 16. Pressure limiting valve
7. Servo filter 17. Control valve attachment
8. Frame control unit (D797-1) 18. Control valve, cab tilt
9. Solenoid valve, activation main pump (Y6062-2) 19. Control valve, joystick control
10. Shuttle valve 20. Steering valve

10:8 10 Common hydraulics – Hoses, pipes and valves
10.5 Hoses, pipes and valves

Hoses, pipes and valves, component location
1 2
7
3
6
5
4
019053
1. Collection block unfiltered returns 5. Shuttle valve
2. Priority valve 6. Solenoid valve, activation main pump (Y6062-2)
3. Accumulator charging valve 7. Solenoid valve, activation quick-lift pump (Y6062)
4. Shuttle valve

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:9
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
The hydraulic system's oil is cooled and cleaned by means
of it circulating through coolers and filters. 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 for the brake system pumps oil (from the tank)
through the brake system's cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases the air flow through the cooler when the temperature
needs to be reduced. When the oil is cold, a bypass valve opens
and leads the oil directly to the tank so that resistance through the
cooler and filter does not become too great. The bypass valve closes
when the oil gets hot and then instead leads the oil through the cooler
and filter. The temperature sensor controls activation of the fan and
temperature display in the display.
Return oil from load handling and steering is filtered through the
hydraulic oil filter in the hydraulic oil tank.

10:10 10 Common hydraulics – Temperature control, cleaning and hydraulic oil
˚C
˚C
P
P
T
D D
EF PP
12 9
P D790-2
P CF D795
LS
T LS
T D797-1
L R
8
16
D D
10 M
P T
6
2 3 4 11
1 1 1 1
5
009638
˚C 7
1. Hydraulic oil pumps 7. Sensor hydraulic oil temperature (B776)

2. Brake oil filter 8. Frame control unit (D797-1)
3. Accumulator charging valve 9. Control unit, KID (D795)
4. Drive axle block 10. Cooling fan
5. Fine filter 11. Thermal bypass valve
6. Hydraulic oil cooler 12. Control unit KIT (D790-2)

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

component location
1 2
10
8
5
019054
1. Breather filter hydraulic oil tank 6. Bypass valve
2. Hydraulic oil filter 7. Sensor hydraulic oil temperature (B776)
3. Fine filter, hydraulic oil 8. Tank heater
4. Cooling fan 9. Hydraulic oil pumps
5. Cooler hydraulic oil 10. Hydraulic oil tank

10:12 10 Common hydraulics – Breather filter hydraulic oil tank
10.6.6 Breather filter hydraulic oil tank
Breather filter hydraulic oil tank, changing

2 Clean the area around the filter housing.
3 Remove the filter housing.
1 2 1 3 2 4
Press down and turn approx. 1/8 turn clockwise.
4 Replace the filter insert.
Handle the filter cartridge as environmentally hazardous waste.
5 Fit the filter housing.
Press down and turn approx. 1/8 turn anticlockwise.
6 Reset the filter indicator by pressing down the button in the middle
018782
on the glass centred on the filter cartridge.
1. Cover plate for hydraulic oil filter

2. Filling point hydraulic oil
10.6.7 Hydraulic oil filter
Hydraulic oil filter (return 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.
1 Turn off the engine and turn off the main electric power.
2 Lift up the filter unit and place it in the receptacle. Let the hydraulic
1 2 1 3 2 4 oil drain.
3 Separate the filter unit and remove the filter insert. Handle the filter
cartridge as environmentally hazardous waste. Note the position
of the parts.
018782


10 Common hydraulics – Hydraulic oil 10:13
4 Clean the filter holder's parts. Be especially thorough with the

magnetic rod.
5 Fit the new filters and assemble the filter units.
6 Install the filter units and the covers. Tighten the bolts crosswise.
7 Check the oil level, see Hydraulic oil, level check, page 10:13.
Magnetic rod
10.6.8 Hydraulic oil

Hydraulic oil, level check
NOTE
The oil level is checked with the mast lowered and the attachment
in the 20-foot position.
1 Machine in service position, section B Safety.

2 Check the oil level in the hydraulic oil tank. The oil level should be
in the centre of the sight glass. Fill oil as required. For oil grade,

10:14 10 Common hydraulics – Hydraulic oil
Hydraulic oil, changing
NOTE
Safety.
IMPORTANT

2 Remove the filler cap and pump out the hydraulic oil in a collection
container.
3 When the most oil possible has been pumped out. Place a
1 2 1 3 2 4 receptacle 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
018782
5 If the hydraulic oil filters are to be changed, change them before

filling the tank with oil, see Hydraulic oil filter (return filter),
changing, page 10:12.
6 Fill new hydraulic oil in the filler holes on the filter cover plates. This
filters the oil and protects the hydraulic system from contamination.
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic
cylinders fully retracted.

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

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

10:16

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electrical protection........................................................................................ 11:4
11.2.2 Fuses ........................................................................................................ 11:5
11.3 Batteries......................................................................................................... 11:8
11.3.1 Start battery............................................................................................... 11:8
11.4 Alternator ..................................................................................................... 11:10
11.5 Distribution of electricity ............................................................................... 11:11
11.5.1 Voltage feed ............................................................................................ 11:11
11.5.2 Electronic box.......................................................................................... 11:17
11.5.3 Control units ............................................................................................ 11:18
11.6 Communication ............................................................................................ 11:21
11.6.1 CAN bus .................................................................................................. 11:21
11.6.2 Redundant CAN bus ............................................................................... 11:21
11.6.3 CAN bus drivetrain .................................................................................. 11:21
11.6.5 RMI (Remote Machine Interface) ............................................................ 11:22

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 location
1. Control switch
1 2 2. Circuit fuses, electrical distribution box cab
3. Main fuses, electrical distribution box frame
4. Circuit fuses, electrical distribution box frame
5. Battery disconnector
3
018783
5
4

11 Common electrics – Fuses 11:5
11.2.2 Fuses
Fuses, description
The electrical system has three main circuits (30-, 15-, and
15E-voltage), see Distribution of electricity, description, page 11:11.
The main circuits are fused several times with main fuses and circuit
fuses.
Main fuses
Main fuses
1
2 IMPORTANT
3
4 Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
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.
018784
Main fuses
1. Electric power feed relay K315-1, electric
power to ignition voltage (15), (50 A)
2. Battery voltage (30) to cab, engine, and
transmission, (50 A)
3. Electric power feed relay K3009-1, power to
emergency stop switch voltage (15E), (50 A)
4. Ignition voltage (15) to control units on frame,
engine, cab and transmission, (50 A)
Terminal blocks on frame and carriage

The terminal blocks for the electrical system are located in the front
of the frame and the rear of the carriage. They are used when
removing/fitting the mast and carriage.
018785

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.
SUPPLY POWER
A1 10A KCU (KALMAR CAB UNIT)
E B2 5A KCU,START UP (KALMAR CAB UNIT)

X2044980 1
F58-4 15
C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
F 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
A
B
C
018786
Fuses on frame
A. 30-fuse (battery voltage), 51-1
B. 30-fuses (battery voltage), 58-1
C. 15-fuses (ignition voltage), 58-2
014278
D. 15E-fuses (control breaker voltage), 58-3

Circuit fuses electrical distribution box frame
Fuses in cab
E. 15-fuses (ignition voltage) and 30-fuses
(battery voltage), 58-4
F. 15-fuses (ignition voltage), 58-5

11 Common electrics – Fuses 11:7
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.

11:8 11 Common electrics – Batteries
11.3 Batteries
11.3.1 Start battery
Start battery, checking
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed
in the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
1 Check the battery voltage from the operating menu for electrical
system.
With the engine off, the battery voltage should be 23–25 V.
With engine at max. engine speed (2,000 rpm), the battery voltage
should be 27–29 V.
000354
Operating menu for electrical system 3 Check that the batteries are clean on the top to prevent leakage
currents between cells, which can cause reduced battery capacity.
Wipe clean with a cloth and clean warm water without detergent.
4 Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
5 Check the fluid level in the battery cells. Top up with battery water
if needed.
The electrolyte level should be 10 mm above the cells.
NOTE
Use only distilled water if topping up is necessary.

11 Common electrics – Start battery 11:9
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 must be checked with regard to bolted

joints, clamps, chafing risk and damage to the battery cables. Repair or
replace defective clamps and eliminate chafing risks. Change battery
cables that show signs of damage.
• Plus-cable between battery and battery disconnector.
• Plus-cable between battery disconnector and starter motor.
• Plus-cable between starter motor and alternator.
• Plus-cable between battery disconnector and main fuses.
• Plus-cable between starter motor and preheating relay.
• Plus-cable between preheating relay and preheating coil.
• Ground cable between battery and frame.
• Ground cable between engine and frame.

11:10 11 Common electrics – Alternator
11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. See section 1 Engine.

11 Common electrics – Distribution of electricity 11:11
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 illuminated
• Flashing hazard lights are activated
• Courtesy lighting is activated
• Start key in position I
Start-up
Start-up
The following takes place at start-up:
1. Start-up signal to Control unit cab (D790-1).
D791
Startup signal
D790-1 D790-2 D795

004755
D797-2 D797-1
(+)
Start-up signal is sent
2. Control unit cab (D790-1) initiates connection of redundant voltage

D791 feed. See Redundant voltage feed of control units, description,
page 11:13.
3. Control unit cab (D790-1) activates ignition voltage (15).
See Ignition voltage (15), description, page 11:14.
D790-1 D790-2 D795 4. Control unit cab (D790-1) establishes redundant CAN-bus.
See Redundant CAN bus, description, page 11:21.
5. Control unit cab (D790-1) activates CAN-bus drivetrain. See CAN
014675
bus drivetrain, description, page 11:21.

D797-1
6. Control unit cab (D790-1) activates control breaker voltage (15E).
Redundant CAN-bus communication See Emergency stop switch voltage (15E), description, page 11:15.

11:12 11 Common electrics – Voltage feed
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 and the hold circuit's run time for pause
heating has run out.
• Start key in position 1 and automatic engine shut-down has been
activated.
The following takes place when the system goes down in powerless
mode.
1. Cab control unit (D790-1) cuts off emergency stop switch voltage
(15E).
See Emergency stop switch voltage (15E), description, page 11:15.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:14.
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 11:21.
5. Cab control unit (D790-1) disconnects the redundant voltage feed.
See Redundant voltage feed of control units, description, page
11:13.
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 11:11.
• Starter motor
• Main relays (15-voltage)
• Control switch relays (15E-voltage)
• Engine
• Transmission

11 Common electrics – Voltage feed 11:13
11.5.1.2 Redundant voltage feed of control units
Redundant voltage feed of control units, description
A The redundant voltage feed only feeds the control units' control logic
D791 and buses, and is controlled completely by Control unit cab (D790-1).
The control units' outputs remain without power and are supplied with
Startup signal voltage first when ignition voltage is activated.
The redundant voltage feed for each control unit is independent of

D790-1 D790-2 D795 other control units. If a control unit is not working the voltage feed to
other control units is not affected.
When all control units have redundant voltage feed and bus
D797-2 communication, the system is ready to receive, process signals.
(+) D797-1
When redundant voltage feed is activated the following takes place.
B 1. Start-up signal is sent to Control unit cab (D790-1), see A in
D791 illustration.
2. A hold circuit is activated in Control unit cab (D790-1) which
activates the control unit's control logic.
D790-1 D790-2 D795 3. Control unit cab (D790-1) activates redundant voltage feed to the
other control units, see B in illustration.
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.
004767
D797-2 D797-1
(+)
A. Start-up signal is sent
B. All control units are supplied with voltage

11.5.1.3 Ignition voltage (15)
Ignition voltage (15), description

The ignition voltage feeds the power electronics.
Startup The ignition voltage is activated by:

2 • Start key in position I
• Flashing hazard lights (Hazard) activated
D790-1
When ignition voltage is activated the following takes place.
1
D1 D2
1. Battery disconnector in position 1. Voltage feed to Control unit
D795 cab (D790-1), ignition, switch flashing hazard lights, door switch
3 and interior lighting.
K1 2. Switch for start-up signal gives pulse to Control unit cab (D790-1).
D790-2
CAN bus communication is established (not drive-train).
- + 4
3. Start key in position I or flashing hazard lights activated.
D797-1
D3 4. Control unit cab (D790-1) feeds voltage to power relay ignition
(K315-1) and relay ignition key lock (K315-2) in electronic box
D4 D797-2 frame.
(+)
5. Ignition voltage supplies control units, relays, solenoid valves and
other electronics.
D5 D793 The drive-train's CAN-bus establishes communication.
K4
004769
D794
Power feed ignition circuit

D1. Diagnostic menu CAN/POWER 5

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

The emergency stop switch voltage feeds functions which require a
S250
control switch, e.g. working hydraulics.
D1
1 The control switch is activated with Switch control switch.
D790-1
D6 Condition for activating emergency stop switch voltage is that Switch,
2 4
control switch, is not pressed in.
D5 D3 D2 • Start key in position I
D797-2 • Ignition voltage (15)
K3009-1 K3009-2 (+)
• Switch, control switch not activated.
- + 5
When emergency stop switch voltage is activated the following takes
3 place.
D791
D5 D4 1. Ignition voltage is connected to Control unit cab (D790-1).
Y6010 2. Control unit cab (D790-1) activates Power relay K3009-1 in
K3002 electrical distribution box frame and emergency stop switch voltage
(15E) feeds the circuit until relay K3009-2 in electrical distribution
5 box frame.
D797-1 Y6011
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
that Power relay control breaker (K3009-2) is inactive.
D5 This verifies that the emergency stop switch is working.
Y6004
K3007 4. Control unit cab (D790-1) activates power relay control breaker
(K3009-2) in the electrical distribution box and the emergency stop
switch voltage supplies voltage to the control units (not drivetrain).
5
Y6005 5. When Switch control switch (S250) is pushed down, the emergency
stop switch voltage (15E) is cut off to Control unit cab (D790-1)
009170
and power is guided to relay K3002 and K3007, as well as Power

relay control switch K3009-1 and K3009-2. Power supply to the
control units is cut off and the functions cease.
Power feed, control breaker circuit
As extra safety the cab control unit (D790-1) also sends status
D1. Diagnostic menu CAN/POWER 7 for Switch, control breaker (S250) on the CAN bus. In this way
D2. Diagnostic menu CAN/POWER 6 functions are also cut off at signal level.

11.5.1.5 Voltage converter
Voltage converter, description
The voltage converter is located under a protective casing to the left

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

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

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

11 Common electrics – Electronic box 11:17
11.5.2 Electronic box

Electrical distribution box, component location
5 6
4 7
3
15
2
1 8
16
9 17
10 18
11 19
12
13
14
019055
1. Circuit fuses emergency stop switch voltage (15E) 11. Relay ignition K315-2
F58-3
12. Power relay ignition K315-1
2. Circuit fuses ignition voltage (15) F58-2
13. Power relay control switch K3009-1
3. Circuit fuses battery voltage (30) F58-1
14. Power relay control switch K3009-2
4. Diagnostic socket, engine, VODIA
15. Diagnostic socket machine
5. Diagnostic socket transmission
16. Circuit fuses cab battery voltage (30) and ignition
6. Main fuses voltage (15) F58-4
7. Control unit, transmission (D793) 17. Diagnostic socket CAN-Bus drivetrain
8. Connection block attachment 18. Circuit fuses cab ignition voltage (15) F58-5
9. Relay lift/lower K3007 19. Voltage converter
10. Relay tilt in/out K3002

11:18 11 Common electrics – Control units
11.5.3 Control units

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

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

light is physically controlled by voltage feed to the
4 control unit.
Lamp 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
Indicator lights control unit cab are supplied voltage.
Lamp 3 Long yellow single flashing light at communication with
Control unit KID (D795), which is a prerequisite for
trouble-shooting.
Short single flash yellow during 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.
Lamp 4 Red light in the event of active error.
1 Table Indicator lights control units on frame and attachment
2 Lamp 1 Green light when there is battery voltage to unit. The

light is physically controlled by voltage feed to the
3 control unit.
4 Lamp 2 Flashes green when one or more of the following
is missing: redundant voltage feed left, redundant
006766
voltage feed right or 15-voltage.

Indicator lights control units on frame and attachment. Green light when redundant voltage feed, left,
redundant voltage feed, right and 15-voltage are
supplied with voltage.
Lamp 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).
Lamp 4 Red light in the event of active error.

11 Common electrics – Control units 11:19
Control units, location

1 2 3
018788
7 6 5
1. Control unit, frame (D797-1) 5. Control unit, transmission (D793)
2. Control unit, KID (D795) 6. Control unit, Volvo engine (D794)
3. Control unit KIT (D790-2) 7. Control unit engine Cummins (D794)
4. Control unit, cab (D790-1) 8. Control unit attachment (D791-1)

11:20 11 Common electrics – Control units
1 2 3
019057
7 6 5
1. Control unit, frame (D797-1) 6. Control unit, Volvo engine (D794)
2. Control unit, KID (D795) 7. Control unit engine Cummins (D794)
3. Control unit KIT (D790-2) 8. Control unit attachment (D791-1)
4. Control unit, cab (D790-1) 9. Frame option control unit (D797-2)
5. Control unit, transmission (D793)

11 Common electrics – Communication 11:21
11.6 Communication
Communication, general
1 The machine's communication is handled by a so-called CAN bus

system. The CAN bus system consists of control units connected
together to form a network.
D791
The idea with the network is to share information. Signal values are
sent out by the control unit that, e.g., is connected to a sensor, other
control units can use the signal for their functions.
D790-1 D790-2 D795 The network consists of control units and segments. Segment is the
CAN-bus between control units.
D797-2 1 D797-1
(+)
2
004780
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 connections
D791 D790-1 D790-2 D795 for communication. The CAN-bus is connected in series between
CAN R CAN L CAN R CAN L CAN R CAN L
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
CAN L CAN R CAN L CAN R
capacity to perform their task.
004778
D797-2 D797-1
(+)
Signals can be checked with diagnostic menu.
Outline view, 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

11:22 11 Common electrics – RMI (Remote Machine Interface)
11.6.5 RMI (Remote Machine Interface)

RMI (Remote Machine Interface), description
Remote Machine Interface is a tool for monitoring 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.
As an option, there is a GPS antenna, making it possible to read

off the machine's position.
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.

D:1
D Error codes
D Error codes
Information is found in the Workshop
manual
See Workshop manual DCF 80–100, section D Error codes.

D:2

E:1
E Diagrams
E Diagrams
Information is found in the Workshop
manual
See Workshop manual DCF 80–100, section E Diagrams.

E:2

F:1
F Technical data
Contents F Technical data

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

F:2

F Technical data – Technical data F:3
F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.
1. Engine Volvo TAD760VE Cummings QSB6.7

Power acc. to ISO 3046 (net power) 180 kW at 2200 rpm 164 kW at 2200 rpm
Torque ISO 3046 1100 Nm at 1500 rpm 949 Nm at 1500 rpm
Max. rpm 2200 rpm
Number of cylinders 6 cylinders
Alternator, power 1920 W 2240 W
System voltage, voltage capacity 2x12 V – 135 Ah
2. Transmission Dana-Spicer Off Highway TE17

No. of gears, forward - reverse 3 – 3
3. Power transmission
Drive axle, type Kessler D81
Kessler D91
4. Brakes
Footbrake system - wheels affected Wet Disc Brake – drive wheel
Parking brake system - wheels affected Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels
Dimension, front and rear 12.00x24
14.00x24
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air filled. Spare and replacement tyres must be of a brand approved by Cargotec.
9. Cab Spirit Delta
Equivalent sound pressure level Volvo TAD760VE Cummings QSB6.7

in cab according to EN12053 with LpAZ 72 dB(A)
measurement uncertainty σR= 2.5 dB. LpAZ 65 dB(A)
Measuring value with standard engine.
Whole-body vibration in accordance 0.4 - 0.7 m/s2
with EN13059 with measurement
uncertainty k = 0.3 x measured value.

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

Light Rating (W) Socket
Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Running lights 5 W2.1x9.5d
Headlights (high and low beams) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work lights 70 PK22s (H3)
Work light, Xenon 35 D1S Xenon tubes. Insert and

ballast replaced complete.
Revolving beacon 70 PK22s (H3)
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
1.2 Engine, fuel system Volvo TAD760VE Cummings QSB6.7

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

Oil type, quality See Oils and lubricants, recommendation, page F:8.
Oil volume incl. filter 23 l 20 l

2.6 Transmission, lubrication Dana-Spicer Off Highway TE17

system
Oil type See Oils and lubricants, recommendation, page F:8.
Oil volume 37 l
Kessler D81
3.3 Driveline/Axle, drive axle Kessler D91
Oil grade See Oils and lubricants, recommendation, page F:8.
Oil volume, differential 42 l 54 l
Oil volume, hub reduction 2x4 l 2x4 l
7 Load handling

Refrigerant air conditioning R134a
Volume refrigerant Se sign for air conditioning
Lubricant air conditioning ZEXEL PAG-oil ZXL100
Washer fluid, volume 5 l
Hydraulic oil tank, volume 320 l
Hydraulic oil system, volume 450 l

Specifications for lifting capacity and

dimensions
β α
A2
100 100
H4
H5
B S
H3
R1
R2
H6
H8
H10
100
014020
100
L3 L2 A1
L
DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Lifting capacity
Classification [kg x 103] 8 9
Centre of gravity distance (L4 [mm]) 1220 1220
Number of containers, 8'6" container 5 6 7 8 5 6 7 8
Number of containers, 9'6" container 5 5 6 7 5 5 6 7
Dimensions
Truck length (L [mm]) 6900 6900
Truck width (W [mm]) 4050 4100
Height, base machine, Spirit Delta (H6 [mm]) 3940 4000
Seat height (H8 [mm]) 2800 2860
Distance drive axle - the attachment's front 1185 1185
section (L2 [mm])
Axle distance (L3 [mm]) 4550 4550
Track (front - rear) (T [mm]) 3270 – 2250 3270 – 2200
Turning radius, outer (R1 [mm]) 6750 7000
Slewing radius, inner (R2 [mm]) 1150 1500

DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Ground clearance, min [mm] 250 300
Minimum track width for 90° stacking, 20' 10600 10850
container (A1 [mm])
Minimum track width for 90° stacking, 40' 14200 14350
container (A2 [mm])
Standard Duplex mast
Lift height (H4 [mm]) 15220 16220 18720 21220 15280 16280 18780 21280
Mast height, min. (H3 [mm]) 8540 9040 10290 11540 8600 9100 10350 11600
Mast height, max (H5 [mm]) 15040 16040 18540 21040 15100 16100 18600 21100
Mast tilting, forward – back (α – ß [mm]) 3 – 3 3 – 3
Attachment
Height under twistlock (H10 [mm]) 2220 2280
Height under lifting hooks (H10 [mm]) - -
Side shift ± (V1 [mm]) 600 600
Weight
Kerb weight [kg x 103] 35.5 36.1 37.6 39.1 36.4 37.0 38.5 40.0
Axle load pressure front, (without load) [kg x 22.7 23.3 24.8 26.3 22.9 23.5 25.0 26.5
103]
Axle load pressure front, (with classed load) 34.9 35.5 37.0 38.5 36.7 37.3 38.8 40.3
[kg x 103]
Axle weight rear, (without load) [kg] 12800 13500
Axle weight rear, (with classed load) [kg] 8600 8700

Oils and lubricants, recommendation

Cargotec's stated service intervals in the maintenance manual are
conditional on oil selection according to the following table. The
table states recommended viscosity for different oil types and grades
depending on outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.
Oil type, quality °C -40 -30 -20 -10 0 +10 +20 +30 +40
°F -40 -22 -4 +14 +32 +50 +68 +86 +104
1.8 Engine, lubrication system
Volvo TAD760VE SAE 15W-40 (engine oil)
VDS-3 (Note 1) SAE 5W30 (engine oil)
Cummings QSB6.7 SAE 15W-40 (engine oil)

API CH-4 or ACEA E5 SAE 5W-30 (engine oil)
2.6 Transmission, lubrication system

ATF Dexron III DEXRON III (brand name)
3.3 Driveline/Axle, drive axle

API GL-5 SAE 80W-140
SAE 75W-90
4 Brakes (UTTO oil, Note 2)

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 SAE 80W140
oil API GL-5
SAE 75W90
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: Lubricating oil that fulfils VDS-2 and ACEA E5 may be used.
API CH-4 or CI-4 is approved for markets outside of Europe (instead of
ACEA E5).
Note 2: 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 disulphide intermix.
For slide plates, use lubricants approved by Cargotec. Order from

Cargotec Parts department. 0.65 kg cartridge for grease gun, part no.
923110.0360, and 5 kg can, part no. 923595.0003.
NOTE
Select grease grade according to relevant climate.
Electrical connector grease

Electrical connector grease 923836.0552.
Sealant silicone
Sealant silicone 923107.0308.
Silicone adhesive
Silicone adhesive 923854.0100.
Coolant
Only use ready-mixed recommended coolant. Select mixture of the
coolant that is adapted for correct temperature.
NOTE
It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protecting properties
decline with time, therefore the coolant must be changed according
to stated intervals.
CAUTION

Tightening torques, recommendations

The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tightening
torque should be reduced by approx. 5%.
For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque varies depending on surface

treatment. Certain combinations of bolts and nuts require lubrication
according to the following table.
State Screw Nut Lubrication

1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9

State 1 2 3 1 1
Fine M-thread
M8×1 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M10×1.25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M12×1.25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M16×1.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M18×1.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm

Quality 8.8 10.9 12.9

7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, connections for air

conditioning unit
O-ring coupling cooling coils
Hose diameter Thread Tightening torque
mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"
The above values should be considered guidelines and may vary

depending on installation.

Tightening torque, ORFS connections

Pipe and hose coupling
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170

Goods coupling
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400
Unit explanations
Unit Abbreviation
Newton metre Nm
Kilopond metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Meter m
Kilometre km

Conversion SI-units
SI-unit Conversion factor Non-SI Conversion factor SI
Torque
Nm x 10.2 = kg cm x 0.8664 = lb in
Nm x 0.74 = lbf ft x 1.36 = Nm
Nm x 0.102 = kg m x 7.22 = lb ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table, length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1 mm = 0.001 m
Conversion table, area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table, weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table, pressure

Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm

G:1
Contents G Terminology and index

Terminology and index .....................................................................................G:3
Terminology.....................................................................................................G:3

G:2

G Terminology and index – Terminology and index G:3

Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Attachment Part of the machine that grabs the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreader and levelling.
Axle distance Distance between drive axle and steering axle.
Bar Unit for measuring pressure.
Battery disconnector Cuts off current from battery.
Daily inspection The actions that should be performed daily to ensure the machine's functionality.
Decitonne Tenth of a tonne, measure of the machine's lift capacity.
Display "Window" showing digital information on steering wheel panel in cab.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
ECC Electric Climate Control. Climate control unit with thermostat-controlled cooling,
dehumidification, and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) of a pump.
Hanging load Lifted load.
FMI Fault Message Identifier.
Main fuse Located by battery. Cuts the power to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transmit power to different functions.
Indicator Manual "sensor", e.g., shows that a filter is clogged and needs to be replaced.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorised trained person.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to
regulations.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Trolley Lifts the load, located on the mast.
Lock hooks Two hooks that are inserted down/into holes in the container in order to secure the
container when lifting.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, e.g. release pressure and thus lower
a boom or a fork.

G:4 G Terminology and index – Terminology
Term Description
Machine model Machine type. Specified, for example: DCF 80–100. 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.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant mesh.
Product alternatives One of several alternatives is selected for a machine, e.g., engine alternative.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current's amplitude. In everyday language, a stepless valve, as
opposed to an Off/On valve. On, e.g., the transmission's valve housing.
Frame beam Supporting beams in the frame.
Recirculation Circulate over and over again.
Serial number Unique machine designation. Available on machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small user movement results in a big machine movement, e.g. power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Levelling Attachment is tilted, for example, if load stands on uneven ground.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Widening of attachment.
Mast Carrier of trolley, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
Steering axle Wheel axle with steering.
Buzzer Audible alarm to catch the operator's attention.
Option Optional equipment for machine.
Tilting Load is tilted forward or backward.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container for lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
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 – Index G:5
Index Engine's mechanical parts . . . .

Entertainment and communication
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 1:17
. . 9:32
Environment . . . . . . . . . . . . . . . . . . . B:21
Error codes . . . . . . . . . . . . . . . . . . 8:8, D:1
A Exhaust system . . . . . . . . . . . . . . . . . . 1:25
EXT-ATTACH . . . . . . . . . . . . . . . . . . . 8:24
About the documentation . . . . . . . . . . . . . . A:11 EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:23
About the maintenance manual . . . . . . . . . . . . A:3
Accumulator . . . . . . . . . . . . . . . . . . . . 4:8
Air cleaning system . . . . . . . . . . . . . . . . . 1:22
Air intake and exhaust outlet . . . . . . . . . . . . . 1:22 F
Alternator . . . . . . . . . . . . . . . . . . . . 11:10 Feedback . . . . . . . . . . . . . . . . . . . . A:12
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:21 Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:15
Axial piston pump with variable displacement . . . . . . 10:7 Foreword . . . . . . . . . . . . . . . . . . . . . A:3
Frame . . . . . . . . . . . . . . . . . . . . . . . 9:38
Frame, body, cab and accessories . . . . . . . . . . 9:3
B FREELIFT . . . . . . . . . . . . . . . . . . . . . 8:24
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:24
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:8 Fuel filter . . . . . . . . . . . . . . . . . . . . . 1:16
Battery voltage (30) . . . . . . . . . . . . . . . . 11:12 Fuel prefilter . . . . . . . . . . . . . . . . . . . . 1:13
Body structure . . . . . . . . . . . . . . . . . . . 9:39 Fuel system . . . . . . . . . . . . . . . . . . . . 1:10
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:4 Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:12
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3 Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:5
Breather filter hydraulic oil tank . . . . . . . . . . . 10:12
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:6
G
C General safety information . . . . . . . . . . . . . . B:3
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:33
CAB . . . . . . . . . . . . . . . . . . . . . . .
8:15
Cab interior . . . . . . . . . . . . . . . . . . . .
9:37
Cab structure and suspension . . . . . . . . . . . .
9:34
Cab undercarriage . . . . . . . . . . . . . . . . .
9:35 H
CAN bus . . . . . . . . . . . . . . . . . . . . 11:21 Heating, ventilation and air conditioning . . . . . . . . 9:13
CAN bus drivetrain . . . . . . . . . . . . . . . . 11:21 Hoses, pipes and valves . . . . . . . . . . . . . . . 10:8
CAN/POWER . . . . . . . . . . . . . . . . . .. 8:13 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:16
Central lubrication . . . . . . . . . . . . . . . .. 9:40 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:13
CLIMATE . . . . . . . . . . . . . . . . . . . .. 8:15 Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:12
Common electrics . . . . . . . . . . . . . . . .. 11:3
Common hydraulics . . . . . . . . . . . . . . . .. 10:3
Communication. . . . . . . . . . . . . . . . . . 11:21
Complete machine . . . . . . . . . . . . . . . .. 0:3
I
Condenser . . . . . . . . . . . . . . . . . . . .. 9:25 I/O . . . . . . . . . . . . . . . . . . . . . . . . 8:26
Container counter. . . . . . . . . . . . . . . . .. 7:46 Ignition voltage (15) . . . . . . . . . . . . . . . . 11:14
Control system . . . . . . . . . . . . . . . . . .. 8:3 Ignition/heating . . . . . . . . . . . . . . . . . . . 1:45
Control system engine. . . . . . . . . . . . . . .. 1:44 Intercooler . . . . . . . . . . . . . . . . . . . . . 1:26
Control system transmission . . . . . . . . . . . .. 2:13
Control units . . . . . . . . . . . . . . . . . . . 11:18
Controls and instruments . .
Coolant . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4:4, 9:4
. . 1:33
L
Cooling fan . . . . . . . . . . . . . . . . . . . . 1:29 Levelling. . . . . . . . . . . . . . . . . . . . . . 7:25
Cooling system . . . . . . . . . . . . . . . . 1:28, 2:12 Lifting hook . . . . . . . . . . . . . . . . . . . . 7:36
Crank mechanism . . . . . . . . . . . . . . . . . 1:21 Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:4
Lighting system. . . . . . . . . . . . . . . . . . . 9:28
LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:14
D Link arm . . . . .
Load carrier . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 5:8
. . 7:28
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:10 Load handling . . . . . . . . . . . . . . . . . . . 7:3
Diagrams . . . . . . . . . . . . . . . . . . . . . E:1 Lubrication system . . . . . . . . . . . . . . . 1:40, 2:9
Distribution of electricity . . . . . . . . . . . . . . 11:11
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:34
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:5 M
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3
Mast . . . . . . . . . . . . . . . . . . . . . 7:8, 7:24
Mast position sensor . . . . . . . . . . . . . . . . 7:10
E Mechanical transmission. . . . . . . . . . . . . . . 2:8
Moisture filter . . . . . . . . . . . . . . . . . . . 9:26
EL-STEERING . . . . . . . . . . . . . . . . . . . 8:24 Monitoring . . . . . . . . . . . . . . . . . . . . . 8:6
Electrical protection . . . . . . . . . . . . . . . . . 11:4 MOVE-CAB . . . . . . . . . . . . . . . . . . . . 8:25
Electronic box . . . . . . . . . . . . . . . . . . 11:17
ELSERV. . . . . . . . . . . . . . . . . . . . . . 8:20
Emergency stop switch voltage (15E) . . . . . . . . 11:15
Engine . . . . . . . . . . . . . . . . . . . . . . 1:3
O
ENGINE . . . . . . . . . . . . . . . . . . . . . . 8:17 Oil filter, brake system . . . . . . . . . . . . . . . . 4:15

Oil pump brake system . . . . . . . . . . . . . . . 4:6 Speed limitation . . . . . . . . . . . . . . . . . . 8:6

OLS . . . . . . . . . . . . . . . . . . . . . . . 8:23 Speed reduction . . . . . . . . . . . . . . . . . . 7:46
OPT . . . . . . . . . . . . . . . . . . . . . . . 8:26 Spreader beam . . . . . . . . . . . . . . . . . . . 7:19
Other functions . . . . . . . . . . . . . . . . . . . 7:46 Spreading . . . . . . . . . . . . . . . . . . . . . 7:15
Start battery . . . . . . . . . . . . . . . . . . . . 11:8
Start/stop . . . . . . . . . . . . . . . . . . . . . 1:46
P Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Steering axle cradle . . . . . . . . . . . . . . . . . 6:4
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:42 Suspension . . . . . . . . . . . . . . . . . . 6:3–6:4
Parking brake pads . . . . . . . . . . . . . . . . . 4:13
Parking brake system . . . . . . . . . . . . . . . . 4:10
Parking brake unit . . . . . . . . . . . . . . . . . 4:12
Power assisted system . . . . . . . . . . . . . . . 5:4 T
Power-assisted brake system . . . . . . . . . . . . 4:5 Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Preventive maintenance . . . . . . . . . . . . . . . C:3 Technical data . . . . . . . . . . . . . . . . . . . F:3
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:4 Temperature control, cleaning and hydraulic oil . . . . . 10:9
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6 Temperature control, cleaning and oil brake system . . . 4:14
Terminology . . . . . . . . . . . . . . . . . . . . G:3
Terminology and index . . . . . . . . . . . . . . . G:3
R Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:22
Radiator and expansion tank . . . . . . . . . . . . . 1:28 Tilt cylinder . . . . . . . . . . . . . . . . . . . . 7:23
Reading instructions . . . . . . . . . . . . . . . . A:4 Tiltable cab . . . . . . . . . . . . . . . . . . . . 9:35
Rear view mirror . . . . . . . . . . . . . . . . . . 9:33 Torque converter/Clutch system . . . . . . . . . . . 2:7
Redundant CAN bus . . . . . . . . . . . . . . . 11:21 TRANSM . . . . . . . . . . . . . . . . . . . . . 8:19
Redundant voltage feed of control units . . . . . . . 11:13 Transmission. . . . . . . . . . . . . . . . . . . . 2:3
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:16 Trolley. . . . . . . . . . . . . . . . . . . . . . . 7:11
RMI . . . . . . . . . . . . . . . . . . . . . . . . 8:26 Twistlocks . . . . . . . . . . . . . . . . . . . . . 7:28
RMI (Remote Machine Interface) . . . . . . . . . . 11:22 Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:15
Roof window . . . . . . . . . . . . . . . . . . . . 9:33 Tyres and rims . . . . . . . . . . . . . . . . . . . 6:8
S V
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 Valve mechanism . . . . . . . . . . . . . . . . . . 1:17
Safety and emergency equipment. . . . . . . . . . . 9:9 VBFS . . . . . . . . . . . . . . . . . . . . . . . 8:23
Safety instructions . . . . . . . . . . . . . . . . . B:4 Voltage converter . . . . . . . . . . . . . . . . . 11:16
Safety valves. . . . . . . . . . . . . . . . . . . . 10:4 Voltage feed . . . . . . . . . . . . . . . . . . . 11:11
Seats . . . . . . . . . . . . . . . . . . . . . . . 9:10
Sensor hydraulic pressure lift cylinder . . . . . . . . . 7:7
Sensor steering wheel angle . . . . . . . . . . . . . 5:8 W
Service indicator . . . . . . . . . . . . . . . . . . 8:7
Servo filter . . . . . . . . . . . . . . . . . . . 7:6, 7:23 Wheel brake . . . . . . . . . . . . . . . . . . . . 4:9
Settings . . . . . . . . . . . . . . . . . . . . . . 8:27 Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:6
Side shift . . . . . . . . . . . . . . . . . . . . . 7:13 Wheel spindle . . . . . . . . . . . . . . . . . . . 6:6
Signalling system . . . . . . . . . . . . . . . . . . 9:30 Wiper/washer system . . . . . . . . . . . . . . . . 9:27


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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Empty container handler 8-10

9 Frame, body, cab and accessories

G Terminology and index

Maintenance Manual DCF 80-100 UDCF03.03GB

UDCF03.03GB Maintenance Manual DCF 80-100

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 DCF 80-100 UDCF03.03GB

Read operator's manual

Read the operator's manual

Read maintenance manual

refers to important information in the maintenance manual.

Read the maintenance manual

UDCF03.03GB Maintenance Manual DCF 80-100

Maintenance manual's content

For more information about function groups, see Function group

Maintenance Manual DCF 80-100 UDCF03.03GB

Function group structure

The maintenance manual and workshop manual contain different

References are indicated by either section and group numbers, e.g.

References are not given between Maintenance manual and Workshop

UDCF03.03GB Maintenance Manual DCF 80-100

Product alternatives and optional equipment

The information in the manual is divided in modules. For product

Equivalent information for different product alternatives is described

Information for optional equipment is described in separate sections

Maintenance Manual DCF 80-100 UDCF03.03GB

The machine card indicates of which drawings the machine consists,

The function descriptions describe the function in a logical flow from

The function descriptions use symbols to illustrate components such as

UDCF03.03GB Maintenance Manual DCF 80-100

4:10 4 Bromsar – Parkeringsbromssystem

4.5 Parkeringsbromssy stem

Hydrauloljepump broms och styrning (frå n tanken). Ventilblock

6. Ventilblock ackumulatorladdnings - och 12. Indikeringslampa parkeringsbroms

Maintenance Manual DCF 80-100 UDCF03.03GB

Symbol explanation function descriptions

Symbol explanation function descriptions

UDCF03.03GB Maintenance Manual DCF 80-100

About the documentation

Always specify publication number when ordering.

For publication number, see the machine card.

Maintenance Manual DCF 80-100 UDCF03.03GB

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

To: Cargotec Sweden AB

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

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

UDCF03.03GB Maintenance Manual DCF 80-100

Maintenance Manual DCF 80-100 UDCF03.03GB

UDCF03.03GB Maintenance Manual DCF 80-100

Cargotec has in this publication documented and warned for situations

A near accident is a warning!

Maintenance Manual DCF 80-100 UDCF03.03GB

Service position means:

UDCF03.03GB Maintenance Manual DCF 80-100

Hydraulic system, depressurising

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

5 Depressurise the attachment.

The figure above shows open valve.

Maintenance Manual DCF 80-100 UDCF03.03GB