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Maintenance DCF80-100 3B GB PDF
Maintenance DCF80-100 3B GB PDF
Maintenance DCF80-100 3B GB PDF
tonnes
Publ. no UDCF05.01GB
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
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A:6
Machine card.............................................................................................. A:7
Function descriptions ................................................................................. A:7
About the documentation .............................................................................. A:10
The documentation's parts ....................................................................... A:10
Ordering of documentation....................................................................... A:10
Feedback .......................................................................................................A:11
Form for copying .......................................................................................A:11
A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.
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.
Storage
NOTE
The maintenance manual shall be accessible to service personnel.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Only used equipment approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
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.
A Foreword General information about the maintenance manual's purpose, content and
reading instructions as well as survey for feedback of views and eventual
inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
Technical description, description of the machine's functions with schematic
5 Steering drawings and explanatory texts for the included components.
6 Suspension Overviews with the components' position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
9 Frame, body, cab and
accessories
10 Common hydraulics
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.
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.
Optional equipment
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 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.
7
2
6 3
014725
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12 12. Radiator
13. Bulb
D790-1 14. Control system, two control units with CAN-bus
13 14 15. Restriction
D797-F 16. Adjustable restriction
17. Inductive position sensor
15 16 18. Electrically controlled servo valve
19. Thermal bypass valve
17 18 20. Temperature-controlled switch
21. Temperature sensor
19 °C 20 °C
22. Pressure sensor
°C Pa
23. Pressure-controlled switch
21 22
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
23 Pa 24
26. Spring brake cylinder
27. Valve block
25 28. Shuttle valve
29. Non-return valve
26 27
28 29
014726
Ordering of documentation
The documentation is ordered from the dealer for Cargotec.
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Copy this form, write down your views and send it to us. Thanks for
your help!
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
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
AdBlue........................................................................................................ B:8
Clothing, etc. .............................................................................................. B:9
Several mechanics on the same machine.................................................. B:9
Working under machine ............................................................................. B:9
Lifting heavy components ........................................................................ B:10
Vibrations ................................................................................................. B:10
Noise ........................................................................................................ B:10
Solvents ....................................................................................................B:11
Fire and explosion risks............................................................................ B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:16
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:17
Spare parts............................................................................................... B:18
Non-ionised radiation ............................................................................... B:19
Environment.................................................................................................. B:20
General .................................................................................................... B:20
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!
Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.
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
• AdBlue, page B:8
• Clothing, etc., page B:9
• Several mechanics on the same machine, page B:9
• Working under machine, page B:9
• Lifting heavy components, page B:10
• Vibrations, page B:10
• Noise, page B:10
• Solvents, page B:11
• Fire and explosion risks, page B:12
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:16
• Tyres and rims, page B:17
• Lifting equipment, page B:17
• Spare parts, page B:18
• Non-ionised radiation, page B:19
Service position
General
General
009798
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
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to fine filter hydraulic oil.
Check that relief valve attachment is closed before the
engine is started.
009961
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 to work in these systems.
Hydraulic and brake systems are pressurised and the
oil can cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! Oil may
also be corrosive to mucous membranes in, e.g., eyes,
skin, and throat.
IMPORTANT
Always clean the area around components and
connections before loosening them. Dirt in oil systems
causes increased wear, which results in material
damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also start fires. Waste oils/fluids shall always
be handled and taken care of by companies that are
authorised for this work.
Fuel system
The following safety instructions shall be followed for work when
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces and
may ignite.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.
IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised for
this work.
AdBlue
The following safety instructions shall be followed for work when
handling AdBlue.
CAUTION
AdBlue can irritate the skin and eyes and when inhaled.
Health hazard!
Handle with care and avoid contact with skin, use
gloves. In the event of contact with skin and spillages
on clothing, rinse the skin with large amounts of water
and replace contaminated clothing and gloves. In
the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
CAUTION
AdBlue spilled onto hot components evaporates
quickly.
Irritation of eyes and respiratory system.
Turn your face away. Evaporated AdBlue can harm
mucus membranes in, for example, the eyes and throat.
In the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillages on the ground must be absorbed with sand or
other absorbent, non-combustible material.
Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
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.
WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
• Use axle stands and supports that stand securely.
• Lifting tools should be inspected and type approved for use.
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
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.
Safety actions
Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs. See the workshop
manual for methods.
Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.
Safety actions
• Use heavy gloves to protect against the cold and transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.
Noise
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) is more damaging than low tones at the
same sound level. Noise in the form of impulse sounds may also be
damaging, e.g., hammer blows.
Risks
Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.
Safety actions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.
Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are flammable.
Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
Safety actions
• Avoid inhaling solvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a solvent container without tight-sealing lid.
• Use solvents with a low content of aromatic compounds. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are solvent-resistant.
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 anaesthetises, 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.
Risks
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.
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.
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.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall first be drained of pressure
and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.
• Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
Coolant
The coolant in the machine’s cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
Refrigerant is used in the machine’s air conditioning system.
Risks
Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
Risks
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.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Risks
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.
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
Safety actions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regards
to securing the mast, carriage and attachment.
Get into the habit of always keeping the carriage lowered to the lowest
position when working on the machine.
Risks
Safety actions
Do not start work until the carriage is fully lowered. If the nature of the
work requires the carriage to be raised, it must be secured in some way.
Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Lift cylinder
• Valve block lift
• Tilt cylinder
• Twistlock, lifting hook
• Control breaker (for hydraulic function)
• Emergency switch
• Hydraulic cylinder, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units
Non-ionised radiation
WARNING
Extra equipment such as two-way radio, RMI, telephone,
etc. may emit non-ionised radiation.
Risk of interference with active or non-active medical
products.
Use a two-way radio, RMI, telephone, etc., when no
persons with active or non-active medical products
are nearby.
NOTE
When persons with active or non-active medical products are not
nearby, then telephone and two-way radio may be used in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.
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.
Recycling
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.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.
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.
Declarations
C Preventive maintenance
C Preventive maintenance
Preventive maintenance, general
It’s very important that preventive maintenance is performed according
to recommended intervals.
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.
Completed maintenance
Oper-
ating Operating
hours Actions hours Date Signature
50h 50h-check
500h 500h service
1000h 1000 service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000 service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000 service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000 service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000 service
9500h 500h service
10000h 2000h service
50h-check
On a new machine, the following checks shall be performed after 50
operating hours. The checks are performed to increase reliability and
safety.
1 Engine Reference
Bolted joints, attachments, mountings, hose clamps,
wear and chafing of hoses, cable harnesses, etc.
Sealing check oil, coolant, exhaust system
Fuel prefilter, water draining 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, checking Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Oil and oil filter, change Section 1 Engine, group 1.8 Lubrication system
Oil pressure
2 Transmission
Leakage check
Oil level, check Section 2 Transmission, group 2.6 Lubrication system
Transmission oil filter, changing Section 2 Transmission, group 2.6 Lubrication system
3 Driveline/Axle
Mounting propeller shaft, check-tightening Section 3 Driveline/Axle, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Driveline/Axle, group 3.3 Drive axle
4 Brakes
Leakage check
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check Section 4 Brakes, group 4.5.4 Parking brake unit
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Suspension, group 6.3 Tyres and rims
Wheel nuts, check-tightening Section 6 Suspension, group 6.3 Tyres and rims
7 Load handling
Hose connections, check-tightening
Bolted joints, check-tightening
Mast wheel and slide plates, function check
Sensors Check that all sensors are undamaged and free of grease.
Service schedule
Service shall be performed every 500 operating hours. Actions are
divided into 500h, 1000h and 2000h service.
Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.
Actions for 1000h service are performed at odd thousands of operating
hours: 1000h, 3000h, 5000h, etc.
Actions for 2000h service are performed at even thousands of
operating hours: 2000h, 4000h, 6000h, etc.
After service is performed, make a note in the check and service log,
see Check and service log, page C:4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hours
Air filter main cartridge C/R C/R C/R Checking indicators, change Section 1 Engine, group
when indicated. 1.6.1 Air cleaning system
Air filter safety cartridge C C/R C/R Changed every other time
main cartridge is changed.
Exhaust system C C C Sealing check Section 1 Engine, group
1.6.3 Exhaust system
Charge-air hoses C C Sealing check Section 1 Engine, group
1.6.4 Intercooler
Radiator C C C External check and cleaning. Section 1 Engine, group
1.7.4 Radiator and
expansion tank
NOTE
Do not use high pressure
wash.
Engine oil R R R For volume and quality, see Section 1 Engine, group
section F F Technical data. 1.8 Lubrication system
Engine oil filter R R R
2 Transmission
Breather filter C C Clean if necessary Section 2 Transmission,
group 2.2 Torque
converter
Transmission oil filter R R The transmission oil should be Section 2 Transmission,
changed every 1,000 hours or group 2.6 Lubrication
1 time/year. system
For volume and quality, see
section F F Technical data.
Transmission oil R R For volume and quality, see
section F F Technical data.
Transmission, calibration C C Calibration of transmission is Section 2 Transmission,
recommended every 1,000 group 2.8 Control system
operating hours. transmission
3 Driveline/Axle
Propeller shaft C C C Bolted joints and universal Section 3 Driveline/Axle,
joint. group 3.2 Propeller shaft
Drive axle oil R R For volume and quality, see Section 3 Driveline/Axle,
section F F Technical data. group 3.3 Drive axle
Mounting drive axle C C Section 3 Driveline/Axle,
group 3.3 Drive axle
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, change Section 4 Brakes, group
when needed. 4.5.4 Parking brake unit
Oil filter, brake system R R R Section 4 brakes, group
4.8.12 Oil filter brake
system
5 Steering
Link arms C/L C/L C/L Check bearings. Lubrication 500 hours,
page C:14
Sensor steering wheel C C C Section 5 Steering, group
reading mini-wheel/joystick 5.2.12 Sensor steering
control wheel reading
6 Suspension
Steering axle suspension C C Section 6 Suspension,
group 6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel Section 6 Suspension,
suspension shall be checked. group 6.2.2 Wheel spindle
Wheel hub steering axle, C Check bearing pre-load. Section 6 Suspension,
check group 6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and pressure, Section 6 Suspension,
change as needed. group 6.3 Tyres and rims
Wheel nuts C C Check-tightening. Section 6 Suspension,
group 6.3 Tyres and rims
Rim C* * Checking for cracks, every Section 6 Suspension,
2000 h or in connection with group 6.3.2 Rim
tyre changes.
7 Load handling
Servo filter R R R Section 7 Load handling,
group 7.2.2 Servo filter
Lifting chains C C C Check damage, tension chain Section 7 Load handling,
when needed. group 7.2.9 Mast
Mast suspension C C
Slide plates mast C C C
Slide plates in trolley C C Check wear, adjust when Section 7 Load handling,
needed. group 7.2.11 Trolley
Attachment C C Damage.
Slide plates spreader beam C C Check wear, change as Section 7 Load handling,
needed. group 7.5.4 Spreader
beam
NOTE
Do not use high pressure
wash.
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.
1 Turn off the engine and turn off the system voltage.
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.
7
6
9
10 10
4 4
5 5
9
2-3 6 2-3
009129
1 1
Lubrication points, lubricating grease
NOTE
Be careful so that the seal is not damaged.
009125
1 NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.
NOTE
On machines with central lubrication, check that the lubrication
reaches the actual lubrication points, see section 9 Frame,
body, cab and accessories, group 9.14 Central lubrication.
2
7 Lower the wheel.
009126
Link arms
1 2 9 Lubricate both link arms' outer and inner bearings with grease.
NOTE
On machines with central lubrication, check that the lubrication
reaches the actual lubrication points, see section 9 Frame,
body, cab and accessories, group 9.14 Central lubrication.
009127
Lubrication points link arm
1. Inner bearing
2. Outer bearing
Brake pedal
10 Lubricate the brake pedal's hinge with grease.
11 Wipe off excess grease.
NOTE
1
Do not lift the door off the hinges.
NOTE
Do not lift the cover lid off the hinges.
2
1. Hinge, door
2. Hinge, cover lid
1 Mast
16 Start the machine and raise the mast to facilitate access to
2 lubrication points.
17 Turn off the engine.
18 Secure the mast in a way that ensures safety.
3
19 Lubricate the chain wheel, mast wheel, slide plates and the slide
plates' contact surfaces with lubricating grease, see section F
Technical data. For lowered lubrication points, lubricate the mast
wheel and the chain wheel down on the mast .
20 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
21 Grease the tilt cylinder axles with lubricating grease.
NOTE
Unload the mast when lubricating.
009128
2 Turn off the engine and turn off the main electric power.
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.
5-12
2 2
3
4
009144
9 Locking cylinders (4 pc) Side lift attachment with lifting hook, page C:22
10 Lock lug shafts (2 pc)
11 Side shift cylinders (2 pc)
12 Spreading cylinders (4 pc)
13 Electric connectors (not shown on diagram) Electric connectors, page C:23
Universal joint
6 Grease universal joints with lubricating grease.
Trolley
7 Turn off the engine.
8 Secure the trolley in a way that ensures safety.
9 Grease mast wheel and levelling cylinders with lubricating
grease, see section F Technical data.
1
013493
1 2
014808
014714
3
11 Grease contact pins (position 2). Check that the sensors are
undamaged and free from grease.
1 5
4
4
009376
Lubrication points for side lift attachment with lifting hook
18 Grease contact pins (position 5). Check that the sensors are
undamaged and free from grease.
19
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
20 Grease electric connectors with electric connector grease.
DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
mast and attachment.
DANGER
Welds in areas of high stress concentration must be
checked in accordance with recommended intervals.
The interval is calculated according to the machine
being used for normal handling and on a level, smooth
ground surface. For other handling or, e. g., rough
surface, the interval should be shortened.
If the welds show signs of cracking, take the machine
out of operation immediately and contact Cargotec
Support.
1 Turn off the engine and turn off the system voltage.
3 Visually inspect for damage and cracks in areas with high stress
concentration, see Checkpoints, page C:26. Check the whole
length of every weld.
Welds where cracks are suspected following visual inspection are
tested with magnetic particle inspection and liquid penetrant if
appropriate in accordance with the following:
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:25.
• Method:
a Alternating current AC
Rim b Contrast colour
• 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.
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.
Examples of cracks
1. Linear crack
2. Pointed crack
Checkpoints
1 Check the following welds carefully:
7
8
009660
1 9
Checking for cracks
009664
Mast
4
a) Horizontal support beams in mast.
009666
Mast mount
7
a) Mast mount in frame
009669
b) Welds between mast beam and mount tab.
009670
NOTE
There may be other variants of the side lift attachment than the
one shown here.
Trolley
9 a. Check the trolley's welding seams. Pay particular attention to
the grey-marked areas in accordance with the illustration.
b. Check the wheel pin welds in the trolley.
Check the inner mast wheel pins as well.
014839
Trolley
014728
009661
0 Complete machine
0 Complete machine
Complete machine, description
Kalmar DCF80-100 is a machine with mast for handling empty
containers. The machine has a lift capacity of 8-10 tonnes depending
on version.
The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the disc
brake type and acts on the drive axle's input shaft.
The wheels are mounted on the hubs with nuts and clamps. The drive
axle has twin wheels, the steering axle has single wheels.
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.2 Fuel system......................................................................................................1:8
1.2.1 Fuel tank .....................................................................................................1:9
1.2.3 Fuel prefilter ..............................................................................................1:10
1.2.4 Fuel filter ...................................................................................................1:12
1.2.12 AdBlue tank ...............................................................................................1:13
1.2.13 AdBlue filter ...............................................................................................1:15
1.6 Air intake and exhaust outlet..........................................................................1:18
1.6.1 Air cleaning system ...................................................................................1:20
1.6.3 Exhaust system .........................................................................................1:22
1.6.4 Intercooler .................................................................................................1:22
1.7 Cooling system ..............................................................................................1:24
1.7.4 Radiator and expansion tank ....................................................................1:24
1.7.5 Cooling fan ................................................................................................1:24
1.7.7 Coolant ......................................................................................................1:26
1.8 Lubrication system .........................................................................................1:31
1.9 Control system engine ...................................................................................1:34
1.10 Ignition/heating...............................................................................................1:35
1.11 Start/stop........................................................................................................1:36
1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.
The engines are low emission engines and meet emission regulations
from the USA (California) and Europe. The new engines provide
considerable improvement, not only for exhaust emissions but also
for the power and torque curve.
°C
. bar
0 rpm
P I kph
II
III D5
1, 5
7 <°
D
D
D
3 15 8 2
D794 UDS D790-1 D790-2
14 D
D793 D797-1 D795
12 10
D
D
D
D D
17
SENSORS H2O M M
13 4 18 19 11
6 9 5 16
014285
1. Ignition (S150) 11. Sensor fuel level (B757)
2. Control unit KIT (D790-2) 12. Control unit frame (D797-1)
3. Control unit engine (D794) 13. Sensor output shaft speed (B758)
4. Glow plug (E800-1) 14. Control unit, transmission (D793)
5. Starter motor (M654) 15. Control unit SCR (UDS)
6. Engine sensor 16. Pump unit AdBlue
7. Accelerator pedal (B690) 17. Water valve
8. Control unit cab (D790-1) 18. Level and temperature sensor AdBlue
9. Make-contact (closing switch) coolant level (B759) 19. Sensor exhaust temperature
10. Control unit KID (D795)
7
6
5
4
3
8
2
9
1
10
11
12
13
14
15
16
17
18
19
20
014546
22 21
Volvo TAD762VE, left side (in the machine's direction of travel)
1. Sensor flywheel speed 12. Fuel pump
2. Crankcase ventilation 13. Oil filter
3. Filling point engine oil 14. Sensor oil pressure
4. Injector and preheating (6 pcs.) 15. Fuel filter
5. Dipstick 16. Control unit engine (D794)
6. Preheating of air after intercooler 17. Sensor fuel pressure
7. Sensor coolant level (B757) 18. Oil plug
8. Sensor coolant temperature 19. Fuel prefilter
9. Thermostat housing 20. Sensor water-in-fuel
10. Alternator 21. Water trap
11. Water pump 22. Sensor camshaft speed
4
3
2
5
1
11
10
014547
9
8
Volvo TAD762VE, right side (in the machine's direction of travel)
1. Expansion tank 7. Starter motor
2. Filling point coolant 8. Intercooler
3. Connection cab heat 9. Condenser
4. Sensor boost pressure and temperature 10. Transmission oil cooler
5. Sensor fuel pressure (fuel distribution pipe) 11. Radiator engine
6. Turbo
0
P I
4
2 II 3 5
III
6
11
9
10 7
8
014715
Electric components machine
1. Accelerator pedal (B690) 7. Control unit, transmission (D793)
2. Ignition (S150) 8. Fuel tank
3. Control unit, cab KIT (D790-2) 9. Sensor fuel level (B757)
4. Control unit KID (D795) 10. Control unit frame (D797-1)
5. Control unit cab (D790-1) 11. Control unit frame option (D797-2)
6. Control unit engine alternative (D794)
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
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.
NOTE
Bleeding is not complete until there is no resistance in the pump.
014097
1. Hand pump
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
3
1
014209
1. Fuel filler
2. Drain plug, under tank
3. Fuel tank
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.
4 Open the drain cock (position 1) on the underneath and allow the
condensation water to run out. Close the cock when clean fuel
without water runs out.
5 Remove the water trap (position 2) from the fuel filter by turning it
clockwise.
6 Clean the water trap and refit it on the filter cartridge.
7 Close the drain cock and open the fuel cock.
8 Bleed the fuel system, see Fuel system, bleeding, page 1:8.
9 Turn on the system voltage and start the engine. Check that the
filter seals tight.
1
014216
1. Drain cock
2. Water trap
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
3
014214
1. Wiring
2. Fuel prefilter
3. Water trap
3
014215
1. Wiring
2. Fuel prefilter
3. Water trap
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
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.
NOTE
The fuel filter is self-draining. Wait a few seconds after the engine
has been switched off before removing the filter cover and filter
insert.
3
014217
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
NOTE
Only use gaskets that can withstand AdBlue.
1
014224
5 Lower the filler cap and filler pipe in a water bath. Let them remain
for at least two minutes.
014226
014227
NOTE
Always replace a damaged strainer.
014228
8 Flush the tank with hot water for at least ten minutes.
Then check that the tank is completely drained of water.
014229
014230
10 Reinstall the filler pipe.
11 Fill the tank with AdBlue. Refit the filler cap.
014231
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
CAUTION
Wait at least two minutes after switching the engine off
before removing the hoses for AdBlue so that the SCR
system has time to drain and depressurise.
2 Remove the plate covering the pump unit from below. The plate is
placed under the battery compartment on the machine's left-hand
side.
NOTE
Pull the connection straight out.
014232
5 Remove the hose from the filter holder by pressing in the catches.
014234
6 Remove the filter holder (position 1) from the pump unit. Remove
the filter insert (position 3).
NOTE
If the filter has been detached, it must be removed completely
before being reinstalled, even if it is to be reused.
014235 8 Install the hose to the filter holder. Check that the locks lock
1 securely.
NOTE
Ensure that the connection is connected straight.
AdBlue contains deionised water mixed with 32.5% urea. The urea is
broken down into ammonia, which reacts with NOx to create harmless
nitrogen and water vapour.
3
2
1
8 6
7
11
10
9
014287
1. Control unit NOx 7. Level and temperature sensor AdBlue
2. Silencer with integrated SCR catalyst 8. Exhaust pipe
3. Catalyst 9. AdBlue tank
4. End-pipe 10. Pump unit
5. Heat shield 11. Heating valve
6. Injector unit
1 008040
1. Dust reservoir
2. Air cleaner
3. Indicator air filter
NOTE
The filter insert should be changed, not cleaned.
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, or muffler when the
machine is in operation or has recently been turned off!
1.6.4 Intercooler
Intercooler, checking
1 Machine in service position, see section B Safety.
NOTE
Do not use high pressure wash.
4 Check the sealing and check that the intercooler's hoses and
clamps are in good condition.
2 Check the charge air pipes for visible cracks and other external
damage. If the pipes are damaged or if connections leak, the
boost pressure will be too low and engine power is reduced.
014249
Radiator, cleaning
NOTE
Do not use high pressure wash.
The drive belt has an automatic belt tensioner and does not need to be
adjusted. Check the condition of the belts, replace if necessary, see
Drive belt, replacement, page 1:25.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
2 Loosen the belt tensioner and lock it with a drift (position 1).
3 Remove the belt from the coolant pump (position 2) 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
014242
1.7.7 Coolant
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
NOTE
Open very carefully as hot coolant may jet up.
If the coolant level becomes too low, the warning light for low coolant
C B A 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.
014058
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
IMPORTANT
On machines with ECC or AC, it is of the utmost
importance that the engine's cooling system be refilled
with coolant that contains the correct mixture of
anti-freeze fluid; otherwise there is a risk that the air
conditioning will freeze up and fail during use.
Coolant, changing
Radiator performance is reduced due to deposits in the radiator and
radiator ducts. Clean the system in conjunction with changing the
coolant.
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
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
Cleaning may not be performed if there can be a risk
of freezing in the cooling system since the cleaning
solution does not have anti-freeze properties.
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system's expansion tank.
C B A
014058
2 Open all drain points. Drain the coolant from the radiator and
engine block with drain hose. The drain nipples are under the
radiator and on the right-hand side of the engine block.
3 Check that all coolant drains.
NOTE
There may be deposits inside the cock or the plug that must
be cleaned; otherwise there is a risk that coolant may remain
and cause freezing damage.
007394
the coolant line's lowest points. Allow the drain cocks or plugs to
remain open and ensure that the heating knob is set to full heat
during cleaning.
Drain point engine.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If there still are impurities after flushing for some time, cleaning
with coolant can be performed. Otherwise continue with Filling
point, page 1:30.
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.
NOTE
Use only cleaning agent approved by the engine manufacturer.
Carefully follow the instructions on the packaging.
Filling point
1 When the cooling system is completely free from impurities, close
the drain cocks.
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.
NOTE
Only use recommended coolant.
2 Add coolant so that the level lies between the MIN and MAX
markings. The engine must not be started until the system
has been bled and filled fully.
3 Start the engine when the system is bled and completely filled.
Open any bleeder valves some time after start, so that the trapped
air can escape.
Open all heat controls on the heater unit so that it is bled.
4 Stop the engine after about one hour and check the coolant level,
top up if needed.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
3 Remove the drain plug from the engine and drain the engine of oil.
4 Place a container under the oil filter.
5 Clean around the oil filter.
014238
2 Allow the oil to drain from the filter into the container.
8 Fit the new filter insert and a new O-ring.
3
9 Fit the filter cover and tighten to a torque of 40+10 Nm.
10 When the oil has run out fit the oil plug with a new gasket. Tighten
to a maximum torque of 55±10 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
11 Fill with engine oil to the correct level. Do not fill over MAX-level.
For volume and quality, see section F Technical data.
12 Start the engine, let it idle. Check that the oil pressure is normal.
13 Turn off the engine and check the oil level, see Oil level, check,
page 1:32. Top up as needed.
014237
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The engine's filler pipe (position B) and dipstick (position C) are under
the engine hood.
1 Machine in service position, see section B Safety.
2 Check the oil level when the engine has been warmed up. Wipe
off the dipstick before checking.
The dipstick has two markings, MAX and MIN, and the oil level
should be between them.
NOTE
On certain machines the oil dipstick is long. Wear gloves.
3 Top up with new engine oil if necessary (position B). For volume
and quality, see section F Technical data).
A
4 Fill - wait awhile - check on the dipstick.
C
NOTE
B
Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
014784
The control unit controls the amount of fuel to the unit injectors by
opening and closing a fuel valve by each injector. The unit injectors are
activated by an extra cam lobe on the camshaft, which compresses the
injector so that fuel is injected into the cylinder.
The fuel quantity is calculated by the control unit based on signals from
the sensors on the engine and a CAN message about the desired
engine speed (from the accelerator pedal via the cab control unit
(D790-1)).
1.10 Ignition/heating
Ignition/heating, description
The engine features preheating of the induction air, for faster start at
low temperatures. Preheating is activated when the ignition key is in
position II. When preheating is activated the preheating indicator light
comes on. The ignition sends signals to Control unit KIT (D790-2)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794).
1.11 Start/stop
Start/stop, description
The engine is started and stopped with the ignition. The ignition sends
signals to Control unit KIT (D790-2) and Control unit cab (D790-1)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794). Starter motor and stop device are controlled by Control unit
engine (D794).
There is a stop button on the engine that can be used to stop the engine
in an emergency, e.g. if the engine cannot be stopped by other means.
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 Transmission
Transmission, general information
The transmission converts the engine power to the drive wheels (drive
axle) via the propeller shaft and also power to drive the hydraulic oil
pumps for the hydraulic system and the brake system.
The torque converter and the transmission work together via a common
hydraulic system. The torque converter is a hydraulic clutch located
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.
2
F
R
D 1
19 <˚
22 Pa 6 D
D
18 7 3
D794 D790-1 D790-2
D D
D
D D
9 D
D ˚C Pa
8 12 13 14 15
Pa ˚C 20
5 16
11
4
009640
1. Multi-function lever (S162) 12. Sensor turbine speed (B751)
2. Shifting program selector on Control unit KIT (D790-2) 13. Sensor drum speed (B752)
3. Control unit KIT (D790-2) 14. Sensor output shaft speed (B758)
4. Transmission oil pump 15. Temperature monitor torque converter (S221)
5. Transmission oil filter 16. Oil cooler
6. Accelerator pedal (B690)
17. Control unit KID (D795)
7. Control unit cab (D790-1)
18. Control unit engine (D794)
8. Sensor oil pressure
19. Declutch pedal (S220-1)
9. Sensor engine speed and oil temperature (B758/766)
20. Break contact declutch (S220-2)
10. Control unit, transmission (D793)
21. Control unit frame (D797-1)
11. Solenoid valves for travel direction and gear position
in valve block transmission control 22. Sensor operator in seat (S230)
3 4
14 7
2
1
12
6 13
15
8
16
9
17
10
014736
19 18 11
1. Valve block transmission control 11. Oil filter transmission
2. Connection cooler (out from transmission) 12. Inlet radiator
3. Oil pump transmission 13. Outlet radiator
4. Power take-off 14. Transmission oil cooler
5. Cooling unit 15. Connection cooler (from cooler to sump)
6. Thermostat 16. Temperature monitor torque converter (S221)
7. Breather filter transmission 17. Sensor turbine speed (B751)
8. Sensor drum speed (B752) 18. Sensor output shaft speed (B758)
9. Sensor engine speed and oil temperature (B758/766) 19. Output shaft
10. Sensor oil pressure
3 4 5
2
11
10 9 8
014041
1. Accelerator pedal (B690) 7. Declutch pedal (S220-1)
2. Multi-function lever (S162) 8. Control unit, transmission (D793)
3. Control unit KIT (D790-2) 9. Control unit engine (D794)
4. Control unit KID (D795) 10. Control unit frame (D797-1)
5. Control unit cab (D790-1) 11. Break contact declutch (S220-2)
6. Sensor operator in seat (S230)
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
NOTE
Do not over-fill 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.
NOTE
Make sure that the drain plug's washer seal is also removed.
004331
A
B
008156
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The transmission's oil filling pipe and oil dipstick are located under
the hood.
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.
Mode Limp-Home
In case of:
• a malfunction of a control output from the transmission is detected.
• a malfunction connected to a sensor for “engine speed” is detected.
• two of three “vehicle speed” sensors are defective.
In the event that any of the above situations arise the transmission will
be placed in neutral. To be able to continue operation a gear must be
selected 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 Shutdown
When the control unit gives the control signal for “Shutdown”, the oil
pressure drops in all pressure modulators. This takes place in the
event of a serious malfunction.
Transmission, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
1 Stop the machine on level ground, select neutral, and apply the
parking brake. Let the engine idle.
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION DRIVETRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000062
TARGET TEMP XXX A. Apply the footbrake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position and apply full throttle for 10 seconds,
run the engine at idle speed.
D. Repeat steps B and C until the oil is warm.
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 and keep the engine speed at 1200 rpm
for 20 seconds.
When the temperature is correct MODE changes from 0 to 1.
000081
ACTION X XXXXrpm
NOTE
If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.
IMPORTANT
Calibration can be aborted at any time by selecting
travel direction reverse.
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 Driveline/Axle
Driveline/Axle, description
The machine's power transmission consists of propeller shaft and drive
axle with differential and hub reduction.
005193
9
8 7 9. Filling point and level check drive axle oil differential
10. Drain point drive axle oil differential
NOTE
Read safety instructions for oil before starting work, see section B
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.
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
1 the machine.
2 Machine in service position, see section B Safety.
2 008058
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)
8 Fill oil in the hubs until the oil level is flush with the filling and level
2. Level and filling plug differential holes. For volume and quality, see section F F Technical data.
3. Drain plug differential
NOTE
The oil is very viscous, fill the oil slowly. Check the level in
stages so that the oil has time to settle.
NOTE
Check that the seals are intact, clean and in the correct position.
10 Fill oil in the differential until the oil level is flush with the filler and
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.
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:4
4.1.1 Brake pedal .................................................................................................4:4
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Oil pump brake system................................................................................4:7
4.3.4 Accumulator ................................................................................................4:8
4.5 Parking brake system ......................................................................................4:9
4.5.4 Parking brake unit ..................................................................................... 4:11
4.8 Temperature control, cleaning and oil brake system......................................4:14
4.8.12 Oil filter, brake system ...............................................................................4:14
4 Brakes
Brakes, general
There are brakes to stop the machine. The brakes act on the drive axle
(steering axle does not have brakes).
1 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2 Check that the brake pedal returns all the way and that the
clearance between the brake pedal and brake valve is 1–1.5 mm.
If needed, adjust the brake pedal's stop bolt so that the clearance
becomes correct.
3 Check that the pedal's travel is smooth.
Oil pump brake system pumps oil (from the tank) which is cleaned in
the oil filter. The accumulator charging valve directs pressure to the
accumulators that store the pressure or direct the oil through the wheel
brake for cooling of the brake discs. The brake valve directs pressure
from the accumulators to the brake cylinder. The brake cylinder
compresses the discs in the brake units that brake the machine.
Make-contact (closing switch) brake pressure emits a signal so that the
brake light is switched on when the brake cylinder is pressurised.
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
009642
B
1. Oil pump brake system 8. Make-contact brake lights (S216)
2. Oil filter, brake system 9. Break contact (opening switch) (S204)
3. Accumulator charging valve 10. Control unit frame (D797-1)
4. Accumulators 11. Brake lights (H411L & H411R)
5. Brake valve 12. Control unit KIT (D 790-2) Warning lamp brake
pressure
6. Brake cylinder
7. Wheel brakes
4
1 2
5 6
3 8
9
12
008061
11 10
1. Brake lights (H411L and H411R) 7. Break contact (opening switch) (S204)
2. Control unit KIT (D 790-2) Warning lamp brake 8. Distribution block drive axle
pressure
9. Make-contact brake lights (S216)
3. Brake valve
10. Oil filter, brake system
4. Control unit frame (D797-1)
11. Oil pump brake system
5. Wheel brake
12. Accumulators
6. Accumulator charging valve
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
008050
Measuring outlet accumulator pressure
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
NOTE
Check that the accumulator drain valve is completely closed
and tighten 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 light for low brake pressure is activated earlier, one
of the brake system's accumulators is probably defective and
these should therefore be checked further.
Oil pump brake system pumps oil (from the tank) which is cleaned
in the oil filter. The accumulator charging valve directs pressure to
the accumulators that store the pressure. The parking brake unit is
released with pressure from the accumulators by the parking brake
valve in the accumulator charging valve 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
009641
B
1. Oil pump brake system 7. Control unit frame (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
1 4
2 5 6
12
008062
11 10 9 8
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.
2 Turn off the engine and turn the start key to position I.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is clean from oil and dirt.
NOTE
To avoid turning the adjustment screw as well, it must be held
still when tightening the lock nut.
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.
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.
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 directs oil through the drive axle's brake units, which
cools the brakes and then returns 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
002611
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
The filter protects the brake system from impurities. It
is very important that new impurities do not enter the
brake system when changing filter.
NOTE
Leave the valves open when changing.
NOTE
The filter holder is heavy, loosen it carefully.
008051 NOTE
Note the position of the O-rings.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
11 Start the engine and check that the filter holder does not leak.
12 Fit the cover plates over the space next to the transmission.
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 reading....................................................................5:9
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.
The steering wheel (via the steering 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 of the steering
valve before other functions, e.g. load handling. The steering cylinder
acts on the wheel spindles. The link arms are located between the
steering cylinder and wheel spindles.
2
PP P
C
CF LS
T
5
P
LS T L R
3
1
6
008053
Joystick control and mini-wheel function in the same way, the difference
is in the design of the control.
NOTE
The standard steering wheel always has priority over joystick control
or mini-wheel steering. Joystick control or mini-wheel steering are
disabled as soon as a steering wheel movement is made.
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
009639
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. Control unit frame (D797-2) 10. Steering cylinder
5. Solenoid valve steering right (Y636-3) or Solenoid 11. Steering wheel
steering left (Y636-4) 12. Sensor steering wheel reading (B770)
6. Control valve joystick control or mini-wheel 13. Control unit, cab KIT (D790-2)
4 6
5 7
014828
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
008074
Electric components
1. Sensor steering wheel reading (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. Control unit frame option (D797-2)
Also check that the sensor for the steering wheel reading is secure in
its bracket and that the multi-function levers are secure by unfastening
the bottom of the steering wheel panel.
002628
1. Indicator ring
2. Sensor steering wheel reading (B770)
6 Suspension
Contents 6 Suspension
6 Suspension .........................................................................................................6:3
6.2 Suspension ......................................................................................................6:4
6.2.1 Steering axle cradle ....................................................................................6:4
6.2.2 Wheel spindle..............................................................................................6:5
6.2.3 Wheel hub ...................................................................................................6:5
6.3 Tyres and rims .................................................................................................6:7
6.3.1 Tyres .........................................................................................................6:14
6.3.2 Rim ............................................................................................................6:15
6 Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the driveline/axle, see section 3 Driveline/Axle, group3.3 Drive axle.
6.2 Suspension
Suspension, description
The steering axle cradle is mounted to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journalled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journalled wheel hubs where
the wheels are mounted.
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. Spindle bolt / bearing
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
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
NOTE
Be careful so that the seal is not damaged.
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.
CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
When removing drive wheels, make sure that the
wheels are secured when removing the spacer rings.
If the wheels move they may move the spacer rings,
which may result in crushing injuries.
When installing drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,
pieces of wood, metal filings, etc.
Check if tyre wear is abnormal, this could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.
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.
DANGER
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.
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Do not exceed prescribed air pressure! When changing
tyre or rim version, another air pressure may apply,
contact Cargotec.
1. Lock ring
2. Rim bead seat taper
3. Rim
2 Check the air pressure in the tyres, see section Tyres, inflating,
page 6:14.
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 6:15.
4 If the tyres and rims have no defects, check-tighten the wheel nuts.
Tighten crosswise to a torque of:
• 650 Nm oiled screw.
008153
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.
b) If this does not work, undo the valve in the rim and release the air.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove 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.
12 Install the outer drive wheel. Take care that the screw threads
are not damaged.
13 Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
16 Test-drive the machine and check that the wheels are secure.
2 Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.
b) If this does not work, undo the valve in the rim and release the air.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove the wheel nuts.
6 Remove the wheel and position it safely so that it does not fall or
move.
Installing
7 Fit the wheel.
8 Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
9 Inflate the tyre, see Tyres, inflating, page 6:14.
10 Lower the machine and remove the jack.
11 Test-drive the machine and check that the wheels are secure.
12 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.
005124
6.3.1 Tyres
Tyres, inflating
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:7.
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must
be dismantled and the rim checked for damage.
Never install rim components by striking with a
hammer while inflating. Never strike fully or partly
inflated tyres or rim sets.
Never inflate tyres before all parts are in place.
008153
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.
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.
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
6:15.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimise risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and size.
Over-dimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
2 Carefully clean the outside of the rim edge with a steel brush.
005375
Max 0,5 mm
005377
005374
O. Circumference
D. Diameter
• Method:
a Alternating current AC
Rim b Contrast colour
• 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.
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.
Examples of cracks
1. Linear crack
2. Pointed crack
7 Load handling
7 Load handling
Load handling, general
The function load handling refers to, e.g. lifting/lowering, side shift,
tilt, levelling and securing a load. Load handling also includes help
functions to handle loads, e.g. container counter.
• Other
Lifting/lowering - Container counter
Side shift
014023
Spreading
009150
Tilt
014021
Levelling
7.2 Lifting/lowering
Lifting/lowering, function description
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 that 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 the carriage is also lifted at the
same time as the inner mast. The lift cylinders are pressurised by the
Control valve lift and tilt.
009149
servo means that the control levers are electrical and send voltage
signals to the control system to control the lifting/lowering function.
Damping
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
014729
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. Control unit frame (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
1 2 3 4 5 6 7
11
10
009179
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
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
3 Turn the start key to position 0 and turn off the system voltage.
009161
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 quality see section F
Technical data.
NOTE
Hydraulic oil level is checked when all hydraulic oil pistons are
pushed in.
009188
7.2.9 Mast
3 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.
4 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
009673
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.
NOTE
Do not over-shim; this will increase the wear on the slide plates.
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
Adjusting
3 Check that the pins for the outer washers are securely fastened.
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).
NOTE
If the chain is slack when the carriage is in its lowest position,
the chain must be tightened.
009153
11 Adjust the chains so that the carriage is lifted evenly in the mast.
4 NOTE
1. Locking washer Reinstall only new locking washers.
2. Lower nut
3. Upper nut • Adjust the nuts on each side to balance the carriage so that
the distance between the carriage and mast is 10-20 mm.
4. Chain tightener
• Tighten the nuts with 2000 Nm and lock them with locking
washers.
• Test lift and check that the lifting chain stretches equally on
each side so that the carriage is balanced.
Repeat adjustments as needed.
12 Lubricate the chains after completed inspection.
014740
7.2.11 Trolley
2 Turn off the engine and turn off the system voltage.
NOTE
The thickness of the slide plate should be at least 10 mm.
5 Check the clearance between the side lift attachment and the
trolley.
NOTE
If the measured clearance between the trolley's slide plates
and the attachment's main beam is greater than 5 mm, the
clearance must be adjusted using spacer plates.
3
6 Check that the slide surface is clean and lubricate the slide surface
2 of the side lift attachment.
013681
7 Start the machine and side shift the attachment to both of its
3 end positions. Check that the clearance between trolley and
The illustration shows slide plates between trolley and attachment is sufficient along the whole of the attachment and
attachment. that there is no metallic contact.
8 For adjustment and replacement, see Workshop manual.
1. Upper slide plates
2. Lower slide plates
3. Attachment's mounting
2 Turn off the engine and turn off the system voltage.
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
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 spacer plates.
2 Turn off the engine and turn off the system voltage.
1 NOTE
The thickness of the slide plate should be at least 10 mm.
NOTE
Generally, the upper slide plate is adjusted on the front side
of the trolley and the lower slide plate on the back side of the
trolley with spacer plates.
1
NOTE
2 Do not over-shim; this will increase the wear on the slide plates.
NOTE
Check that the attaching bolts for all slide plates are tightened.
009190
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
3. Control unit frame (D797-1) (Y6021)
4. Solenoid valve activation main pump (Y6062) 10. Control valve attachment
5. Shuttle valve 11. Side shift cylinder
2 3 5
4
014030
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
7.5 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.
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. Control unit frame (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)
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) Solenoid 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
If the machine is also equipped with 30 foot stop and this is activated,
spreading stops at 30 foot. Activate spreading again to go to the next
position.
1a
1b
3 5
D790-1 D795
4 D791-1
10 9 7 6 8 6 7 9 10
1 5
3
10
9
8
7 8-10
014031
1. Spreader beam 7. Sensor damping 20' and 40' (B769L & B769R), 30'
2. Spreading cylinders stop, Sensor damping 30' (B777L & B777R)
5. Solenoid valve spreading out (Y6018L & Y6018R) 10. Indicator plate 40'
014737
Spreader beams
1000 mm
013683
3 Check that the clearance between slide plates and main beam is
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
adjustment shims.
Y2
Y1
4 For adjustment and replacement, see Workshop manual.
X2
013689
X1
Right side
Y2
Y1
X2
013690
X1
Left side
2 Turn off the engine and turn off the system voltage.
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 spacer plates.
2 Turn off the engine and turn off the system voltage.
2 NOTE
The thickness of the slide plate should be at least 10 mm.
NOTE
009189
NOTE
Check that the attaching bolts for all slide plates are tightened.
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.
009150
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
009656
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. Control unit frame (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 14. Tilt cylinders
out (Y6010)
1 2 3 4
009178
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
7.7.8 Mast
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the attachment is angled in the
horizontal direction. This enables the machine to handle loads on
uneven ground surfaces.
014021
servo. Electric servo means that the control levers are electrical and
send voltage signals to the control system to control the levelling
function.
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. Control unit frame (D797-1) left (Y6036)
4. Solenoid valve activation main pump (Y6062-1) 10. Control valve
5. Shuttle valve 11. Levelling cylinders
2
3
014032
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
7.9.1 Twistlocks
Twistlocks, function description
The container is secured in place on the side lift attachment with two
twistlocks.
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)
4. Control unit attachment (D791-1)
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. Control unit frame (D797-1) Sensor locked twistlocks (B7205LL and B7205RL)
9. Solenoid valve activation main pump (Y6062-1)
1 3
4
5
11
10 6
7
014033
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.
5 4
NOTE
1. Sensor unlocked twistlock The contact pin should move easily and spring back completely.
2. Sensor contact
6 Check that the lock guide and lift pin can move freely.
3. Sensor locked twistlock
4. Lift pin 7 Fit a crowbar between lift pin (position 5) and the lift pin's guide,
check clearance max. clearance: 1-1.5 mm.
5. Contact pin
8 Turn twistlocks to locked position and check wear of the lift pin.
Replace the lift pin as required.
9 Repeat steps 1-8 on both twistlocks.
m
Max. 4 mm
m
0
.7
in
M
009776
DANGER
Twistlocks should be checked in accordance with
recommended intervals. The interval is calculated
according to the machine being used for normal
handling and on a level, smooth ground surface. For
other handling or, e.g., rough surface, the interval
should be shortened.
If there are signs of cracking, the machine must be
immediately taken out of operation and Cargotec
Service contacted.
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.
NOTE
Check for cracks shall take place every other year or every 4000
operating hours.
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
014717
contact pins is needed to detect contact (light indicator on the
1 2 sensor is lit). The movement should be 3–4 mm.
Right side
1. Sensor contact
2. Contact pin
7 If necessary, loosen the lock nut and screw in/out the sensor 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
1 2 the distance between the sensor and the indicator plate is 5±1 mm.
Right side
1. Sensor unlocked twistlock
2. Sensor locked twistlock
014720
2 1
Left side
1. Sensor unlocked twistlock
2. Sensor locked twistlock
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 lamps on the side lift
attachment, as well as in the cab, show the status of the lock lugs.
Lock lugs are activated manually or automatically and can open if the
machine moves forward at a speed under 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 functions, and the machine's
speed is limited to max 5 Km/h.
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).
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, upper 13. Hydraulic oil pump
and lower (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. Control unit frame (D797-1)
1 3
4
5
6 7
12 11
10
9 13 9 8
8
7 14
014034
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
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.
014019
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
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.
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change lifting hooks that shows signs of cracks or
other external damage, or lifting hooks with more than
10 000 operating hours.
NOTE
Check for cracks shall take place every other year or every 4000
operating hours.
NOTE
Lifting hooks are heavy, be careful when removing.
2 Check for cracks within the marked area on the lifting hooks
without causing damage.
014722
3 If the lifting hooks show signs of cracking, they must be replaced
with new ones.
Area for checking for cracks on lifting hooks
4 Install approved lifting hooks.
NOTE
Use new bolt and new lock nut.
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.
DANGER
Wear results in reduced strength.
Fatal danger!
Replace lock lugs that show signs of wear, cracks or
exterior damage.
3
009643
1. Clevis pin
2. Lock lug
3. Mounting lock cylinder
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 unaffected 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 lit.
B
014724
4 Adjusting:
Secure the contact pin in an appropriate way so that the
B 1 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
A C lamp (B1) illuminates.
Lights on the side lift attachment 6 When measurement (B) decreases to 18 mm, the light (B2) for
contact with the lower container should be lit.
A Green light Lock lugs locked 7 Adjusting:
B1 Orange light Contact (upper container) Secure the contact pin in an appropriate way so that the
measurement (B) is 18 mm. Then move the sensor along the oval
B2 Orange light Contact (lower container)
mounting hole and screw it in at exactly the position it has when
C Red light Lock lugs released lamp (B2) illuminates.
The sensor is fitted with a light indicator that can be used to check
the sensor's functioning.
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 light indicator should
be lit.
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
014035
contact still is not lit, replace the sensor.
lights up when the side lift attachment lies against the upper
container.
Lights on the side lift attachment
3 Check that the indicator light (B2) lights up when the lifting hooks
A Green light Lock lugs locked are engaged.
B1 Orange light Contact (upper container) 4 Check that the indicator light (B2) goes out after lifting.
B2 Orange light Contact (lower container) 5 Lift an empty container enough that indicator light contact (B2)
goes out.
C Red light Lock lugs released
6 The inductive sensors for contact should be adjusted so that they
let off a signal when the contact pins are pushed in, see Sensor
contact, checking and adjusting , page 7:46.
009377
3
7 Check that lock lugs lock correctly, adjust lock cylinders as needed.
Right side
1. Sensor detecting upper container
(B7203LU/RU)
2. Sensor unlocked lock lug (B7204R/L)
3. Sensor locked lock lug (B7205LL/RL), lower
4
D795
D791-1
3 D
D
1 2
004297
1. Twistlock: Sensor contact left and right (B7203L and Lifting hook: Sensor locked lock lug left and right
B7203R) (B7205LL and B7205RL)
Lifting hook: Sensor contact left, lower and upper 3. Control unit attachment (D791-1)
and right, upper and lower (B7203LL, B7203LU-2,
4. Control unit KID (D795)
B7203RL and B7203RU-2)
2. Twistlock: Sensor locked twistlock left and right
(B7205LL and B7205RL)
8 Control system
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.
Settings is the tool for setting and adapting the machine’s functions.
The function keys are used to navigate in the display menus for
service and troubleshooting, for example.
000053
A
A Function keys (KIT)
B Warning and indicator lights
C Display (KID)
D Alarm indicator
Function keys
Function keys
The function keys (A) are used to navigate in the menu system.
Also used to enter values in the system, change light contrast in the
keys/indicator panel, and to acknowledge warning.
000055
Operating menus
Operating menus
014252
• Operating menu heating and air conditioning
Examples of available operating menus • Operating menu statistics
• Operating menu container counter
• Operating menu load handling
• Operating menu service interval
• Operating menu printer
• Operating menu code lock
Event-controlled information
8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
• Bypass
• Speed limitation
• Service indicator
8.2.2 Bypass
Bypass, description
Bypass is activated with the bypass switch.
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
000056
3 Enter code for resetting service indicator.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
PRESENT XXXXh
Height warning alerts when the set maximum lifting height is reached.
Height warning is adjustable according to customer requirements.
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.
When the error code has been acknowledged the display returns
to previously selected menu. If the error code is active, it is stored
in the error code list under operating menu for service.
Example of automatic display figure
If the error code is active it is repeated to remind the operator
of the error status, stop every 3rd minute, warnings every 5th
minute.
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.
8.4 Diagnostics
Diagnostics, general
The machine has built-in functions for troubleshooting called diagnostic
test. The diagnostic test consists of several menus that are shown in
the display. The menus are grouped for faster access.
005592
FEEDBACK 0 and ammeters that measure the signal on the connectors out to
components or in from components.
1. DIAG = Diagnostic menus Output signals are control of solenoid valves, lights, relays, etc.
2. Menu group (CAB = cab functions)
Input signals are sensor signals, signals from controls and switches,
3. Menu number feedback control signals, etc.
4. Total number of menus in the loop. The number
of menus depends on how the machine is The figure shows an example of a menu, here for diagnostics of
equipped, which is why the number of menus is windshield wiper. The table below indicates what you can read out
indicated by (X) in this manual. from the menu figure.
5. Variable
6. Signal value
7. Menu heading
000056
3 Enter the code for diagnostics.
The code is obtained from Cargotec Support.
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
8.4.1 CAN/POWER
CAN/POWER, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
SEGMENT ERROR X
8.4.2 LIGHTS
LIGHTS, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.3 CAB
CAB, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
009155
8.4.4 CLIMATE
CLIMATE, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.5 HYD
HYD, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
009156
SET OUTPUT +/- X SET OUTPUT +/- X
8.4.6 ENGINE
ENGINE, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
014712
IND. SEVERITY XX
8.4.7 TRANSM
TRANSM, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.9 ATTACH
ATTACH, menu overview
For side lift attachment with hook locking
X X
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.10 OLS
OLS, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
009162
8.4.11 EXTRA
8.4.11.1 VBFS
8.4.11.2 EL-STEERING
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
009163
FEEDBACK XXX FEEDBACK XXX
8.4.11.3 EXT-ATTACH
8.4.11.4 FREELIFT
8.4.11.5 MOVE-CAB
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
009164
FEEDBACK XXX
8.4.11.6 OPT
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
009165
8.4.11.7 I/O
8.4.11.8 RMI
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
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
The body consists of fenders, 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.
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
008108
14
004394
17
16 Extra working lights attachment and carriage
Left-hand dashboard panel 21. Switch working lights mast (S105-3)
Extra working lights mast
22. Switch rotating beacon (S110)
23. Switch hazard lights (S109)
24. Switch headlights (S100)
25. Switch seat heater (S143)
(Can be in driver's seat)
26. Switch for electrically-heated rearview mirrors (S199-4)
27. Spare
28. Switch for supplemental heater (S199-1)
29. Spare
30. Spare
31. Socket 12 VDC
61 60 59 58 57
56. Switch for windshield wiper roof, continuous
Steering wheel panel 57. Switch for interior lighting
58. Switch for windshield wiper rear, interval
59. Switch for windshield wiper rear, continuous
60. Function keys for control and monitoring system
61. Driving direction indicator, Forward Neutral Reverse
62. Shifting program A, automatic shifting
63. Shifting program 1, locked to gear position one
64. Shifting program 2, locked to gear position two
77
008131
78 8 79 70
1 2 3 4
9 8 7 6
10
014713
11 12 13 14
1. Operating menu engine and transmission 8. Operating menu service
2. Operating menu engine 9. Operating menu heating and air conditioning
3. Operating menu for oil temperature 10. Operating menu code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
7. Operating menu statistics 14. Operating menu statistics, lift statistics
1 2 3 4
009176
1. Event menu start interlock
2. Event menu contact twistlock
3. Event menu twistlocks
4. Event menu open door
5. Event menu automatic spreading
Event menus overview
Event menus overview
1 2 3 4
009781
1. Event menu start interlock
2. Event menu contact
3. Event menu open door
4. Event menu automatic spreading
4 6,7,8,11 2
10
1, 8
008394
5 3
1. Reverse alarm 8. Camera with monitor , used to give better visibility
to the rear when operating the machine. The monitor
2. Revolving beacon
is located inside the cab on the left side.
3. Horn
9. External rearview mirrors, used to provide increased
4. Electrically powered loud horn visibility when manoeuvring and handling loads and
show glimpses of the area around the side of the
5. Fire extinguisher (located outside or inside cab) machine.
If the machine is supplied with a fire extinguisher, it 10. Blinking brake lights when reversing
should be of the type ABE according to EN 3 pt. 1, 2,
4 and 5. With such a fire extinguisher, it is possible 11. Control switch for load handling (servo circuits)
to extinguish fires in both solid organic materials and
Breaks all transmission of power and control signals
fluids. Adapted fire extinguishing equipment can be
to the hydraulics.
ordered from Cargotec.
6. Seat belt 12. Emergency exit cab, right door or rear window
(not positioned in figure).
7. Buzzer in cab to indicate alarm or forgotten action,
e.g., if the operator leaves the cab without first
applying the parking brake.
9.3 Seats
Seats, description (product alternative standard
seat)
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
1 2 The seat has the following equipment:
• mechanical adjustment
3 • armrest right
• seat belt
• armrest left
4
• seat heating
• head restraint
8 6
006825
7
Controls for standard seat
1. Adjustable lower back (lumbar) support
2. Adjustable arm rest, right
3. Adjustable arm rest, left
4. Adjustable tilt, backrest
5. Adjustable suspension position
6. Adjustable seat angle
7. Adjustable seat height
8. Longitudinal adjustment
BE-GE 9120 is the same seat as the standard seat but equipped with
1 2 air suspension. The air suspension automatically adapts the seat
height and suspension to the operator's weight. The air suspension
is supplied by a special compressor installed on the underside of
3 the cab.
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
4 several adjustment features and meets high comfort requirements.
8 • armrest left
6
006826
7 • seat heating
Controls BE-GE 9120 • head restraint
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
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
11
10
34 567
004691
9 8 2
Controls Isringhausen 6800
1. Longitudinal adjustment
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
The heating and ventilation system used heat from the engine's
cooling system via a heater to warm the outdoor air. Outdoor air is
forced by the fan through the heater and on through channels in the
cab's interior, and is then directed at, e.g., the windshield (defroster)
or the feet.
At the air inlet before the cab fan there is a filter that cleans the air
before it is forced into the machine.
001839
1 2 3 17
D D 16
D
4 ˚C D
D
˚C
D 6
7 D
D790-1 D790-2 D795
15 D
11
M D794
M
14 D 10
˚C
5 M ˚C 9
D D 8 12
13
M
009891
1. Switch fan (S118) 10. Control unit engine (D794)
2. Switch temperature (S117) 11. Water valve (Y673)
3. Switch air distribution (S139) 12. Heat exchanger
4. Sensor cab temperature (B775-1) 13. Actuator recirculation (M612)
5. Sensor temperature outlet fan (B775-2) 14. Fan motor heat (M657)
6. Sensor outdoor temperature (B774) 15. Damper motor (Y672)
7. Control unit cab (D790-1) 16. Switch defroster on Control unit KIT (D790-2)
8. Engine 17. Operating menu on Control unit KID (D795)
9. Sensor engine temperature
The air conditioning adds the following functions to the heating and
Defroster nozzles ventilation unit:
• dehumidification of the air when it is humid
• cooling of the air when it is warm
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690
1. Switch temperature (S117) 15. Damper motor (Y672)
2. Switch fan (S118) 16. Control unit frame (D797-1)
3. Switch air distribution (S139) 17. Magnetic clutch (M645)
4. Sensor cab temperature (B775-1) 18. Compressor
5. Sensor temperature outlet fan (B775-2) 19. Condenser
6. Sensor outdoor temperature (B774) 20. Moisture filter
7. Control unit cab (D790-1) 21. Pressure switch (S246)
8. Engine 22. Expansion valve
9. Water valve (Y673) 23. Sensor temperature in refrigerant circuit (B775-3)
10. Sensor engine temperature 24. Heat exchanger for cooling
11. Heat exchanger 25. Switch defroster on Control unit KIT (D790-2)
12. Control unit engine (D794) 26. Operating menu on Control unit KID (D795)
13. Actuator recirculation (M612)
14. Fan motor heat (M657)
1 2 3
16
15
13
6
7
12
8
11
005221
10 9, 14
1. Operating menu on Control unit KID (D795) 10. Cab fan (M657)
2. Switch defroster on Control unit KIT (D790-2) 11. Fresh air and recirculation damper (M612)
3. Sensor outdoor temperature (B774) 12. Fresh air filter
4. Control unit cab (D790-1) 13. Heat exchanger (cold and heat)
5. Sensor cab temperature (B775-1) (inside of the left 14. Sensor temperature refrigerant (B775-3)
control panel, behind a grating)
(located the copper pipe inside the expansion valve)
6. Switch air distribution (S139)
15. Air distributor (Y672)
7. Switch temperature (S117)
16. Sensor temperature outlet fan (B775-2) (in air
8. Switch fan (S118) distributor)
9. Expansion valve
2 3
4
5
014731
7
CAUTION
Authorisation is required to perform repairs on the
climate control unit.
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
WARNING
Electric fans can injure hands.
Risk of personal injury.
Avoid placing hands near the cooling fans when the
engine is running.
NOTE
The air conditioning does not work at temperatures below approx.
0 ºC since the pressure in the refrigerant circuit is too low. If the
pressure in the refrigerant circuit becomes too low the low pressure
switch cuts off power supply to the compressor's magnet clutch,
which means that the air conditioning stops working.
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.
3 Check that the drain for the cooling element's condensation water
is not clogged.
5 Start the engine and engage the cooling function with setting on
maximum cooling.
Let the engine run at min. 1,500 rpm. (At temperatures below
approx. 0 ºC, the cooling function will not start due to low pressure
in the system.)
013669
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.
3 All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
5 Check that the compressor cuts in and out normally. Run the
cab fan at low speed and let the compressor work at high rpm.
When the temperature in the air vents nozzles is close to 0 ºC,
the compressor cuts out via the thermostat or ECC and cuts in
again when the temperature has increased approx. 3-7 ºC. (If the
compressor does not cut out, there is a risk of the evaporator icing
up and cooling performance decreasing.)
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 ºC.
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
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.
7 Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.
9 Connect the yellow filler and vacuum hose to the nitrogen tube.
Open the cock on the tube and then the cock on the pressure
side. Open the valve on the cylinder and then the valve on the
pressure side. Now the gas flows through the system and back
to the suction side of the compressor, which can be seen on the
blue pressure gauge which slowly indicates a pressure equivalent
to the pressure in the cylinder (see red pressure gauge). (If the
blue pressure gauge does not move then there is a stop in the
system.) Turn off the valve on the pressure side and then the
cock on the tube.
10 Now the system contains a mix of nitrogen gas and air. This gas
amount is enough to indicate a leak.
12 Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.
13 Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then, open the cock on the pressure side, use vacuum suction
for at least 30 minutes. Preferably longer.
14 First close both 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.
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 tube. 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 tube.
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
1
Supplemental heater, an option for the heating unit, uses excess heat
in the engine's cooling system to keep the cab warm.
3 2
004909
9.4.8 Condenser
Condenser, cleaning
014732
1. Condenser
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
IMPORTANT
Working on the air conditioning requires special
authorisation.
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.
The wiper arm is attached to the wiper motor's shaft over a splined
taper. The shaft is made of hardened steel and the wiper arm's
E C bracket is made of a mild die cast material.
When installing it is important to make sure that the splines are free
D from metal burrs or similar. Also, the nuts shall be tightened so tight
that the splines are pressed into the bracket and work like drive
flanges. Counterhold the wiper arm when installing so that the torque
is not transmitted to the motor as it may be damaged (16–20 Nm
002214
A tightening torque).
A Wiper motor front The wipers turn off automatically 2 minutes after the operator has left
the cab. The wipers are activated automatically when the operator sits
B Wiper motor roof in the set, selects a gear, or if the accelerator pedal is pressed down.
C Wiper motor rear
D Washer motor and reservoir
E Wiper, front
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) 21. Direction indicator (H422, H423, H426 & H427)
2. Switch work lighting attachment (S105-2) 22. Running lights (H416-1, H416-2, H417-1 & H417-2)
3. Switch working lights mast (S105-3) 23. Driving lights low beams (E400L & E400R)
4. Switch headlights (S100) 24. Driving lights high beams (E402L-1 & E402R-1)
5. Switch rotating beacon (S110) 25. Tail lights (H412L & H412R)
6. Break-contact door (S266-LE & S266-RI) 26. Brake lights (H411L & H411R)
7. Switch step lighting (S141)
27. Working lights mast (E404L-1 & E404R-1)
8. Control unit cab (D790-1)
28. Extra work lights mast (E404L-4 & E404R-4)
9. Multi-function lever (S162)
Extra work lights front fender (E404L-4 &
10. Lever direction indicator (S161) E404R-4)
11. Switch interior lighting on Control unit KIT (D790-2)
29. Control unit frame option (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 fender (E404L-2 &
14. Work lights cab roof (E406L-1 E406R-1, E406L-2 E404R-2)
and E406R-2)
31. Control unit attachment (D791)
15. Back-up lights (E405L & E405R)
16. Rotating beacon (H428) 32. Work lights Twistlock attachment (E404L-3 &
E404R-3)
17. Interior lights (E434-1)
Work lights Lifting hook attachment with lock lug
18. Step lighting (E433) (E404UL, E404UR, E404LL and E404LR)
19. Make-contact brake lights (S216) 33. Extra work lights Twistlock attachment (E404L-5
20. Control unit frame (D797-1) & E404R-5)
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 4 5 6 6 7 9
30 3,8,10
12
29
28
27
26
008397
22,23,24,25 21 19,20 18 17 16 15 11,13,14
1. Working lights mast (E404L-1 & E404R-1) 17. Switches, see Controls and instruments, overview,
page 9:4
2. Extra work lights mast (E404L-4 & E404R-4)
18. Switch step lighting (S141)
3. Relay working lights cab roof (K3017-1 & K3017-2)
19. Control unit frame option (D797-2)
4. Multi-function lever (S162) 20. Control unit frame (D797-1)
5. Control unit KIT (D790-2) 21. Make-contact brake lights (S216)
6. Interior lights (E434-1) 22. Direction indicators front (H422 & H423)
7. Work lights cab roof (E406L-1 & E406R-1) 23. Running lights front (H416-1 & H417-1)
8. Extra work lights cab roof (E406L-2 & E406R-2) 24. Driving lights low beams (E400L & E400R)
9. Rotating beacon (H428) Driving lights high beams (E402L-1 & E402R-1)
10. Control unit cab (D790-1) 25. Extra work lights front fender (E404L-4 & E404R-4)
11. Running lights rear (H416-2 & H417-2)
26. Work lights lifting hook attachment (E404LL &
12. Back-up lights (E405L & E405R), white
E404LR)
13. Tail lights (H412L & H412R) red
27. Control unit attachment (D791-1)
Brake lights (H411L & H411R)
28. Work lights twistlock attachment (E404L & E404R)
14. Direction indicators rear (H426 & H427)
29. Extra work lights carriage (E404L & E404R)
15. Break-contact door (S266-LE & S266-RI)
30. Work lights lifting hook attachment (E404UL &
16. Step lighting (E433) E404UR)
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 2 3 4
17 6
7
15
16
D6
13 18
14 M
8 19
D790-1 5 D790-2 D795
9
D797-1 D791-1
20
10 11 21
009767
12
1 2 3 4 5 6
008395
19 18 17 16 15 14 13 12 10,11 9 8 7
1. Control unit KID (D795) 11. Control unit cab (D790-1)
2. Buzzer cab (H853) 12. Make-contact operator in seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switches, see Controls and instruments, overview,
5. Lever direction indicator (S161) page 9:4
6. Rotating beacon (H428) 15. Loud horn (H850-1)
7. Back-up alarm (H965) 16. Control unit frame (D797-1)
8. Back-up lights (E405L & E405R) 17. Direction indicators front (H422 & H423)
9. Direction indicators rear (H426 & H427) 18. Control unit attachment (D791-1)
10. Relay loud horn (K3016) 19. Buzzer automatic spreading (H9003)
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component location
The function of the window panes is to enclose the cab and to give
C the operator good visibility. Tempered glass windows are standard on
all trucks. Roof windows are a safety feature and are therefore always
D made of polycarbonate plastic.
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!
003206
4
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.2 Doors
Doors, description
The cab has two doors, the left is the driver's door and the right is the
emergency exit. The doors have:
• hand rail
• handle
• keylock
• opening window (emergency exit door )
There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be controlled with the diagnostics menu, see section
8 Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5
MOVE-CAB, menu 1.
Doors, checking
1 Machine in service position, see section B Safety.
008393
WARNING
Presence under tilted cab.
Fatal danger!
Ensure that no one is present under or near a tilted cab.
Visibility is impaired!
NOTE
Only manoeuvre the cab while stationary!
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 may not exceed 5 km/h, the
operator 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.
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
009659
1. Hydraulic oil pumps 7. Sensor, cab up (B769-2) / cab down (B769-1)
2. Switch automatic/manual cab tilt (S199-2) 8. Control unit frame option (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. Control unit frame (D797-1) 13. Return filter
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 Attend to as needed.
009658
Tilt cassette
9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:
2 1
014666
3 4 5 6
1. The rear section of the frame with counterweights
2. Engine compartment with engine and transmission mounts
3. The rear section of the frame with drive axle mounts
4. Bracket front fenders
5. Cab mounts (4 points)
6. Steering axle mounts
2 1
008392
3
1. Counterweight
2. Hood engine compartment
3. Fenders
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.
NOTE
The system can be lubricated manually through the grease
nipple on the distribution block.
Overview of central lubrication. Example figure.
1. Lubricant nipple, filling point, lubricating grease 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
2. Safety valve
3. Lubricant nipple, manual lubrication of the
system
4. Indicator pin
5. Switch, manual operation
9.15 Paint/coatings
Paint and surface finish, description
The machine is finished with an alkyd based single component paint
that is applied by brush or sprayed. For colour code (RAL), see
machine card.
Check the machine often for stone chips, impact damage, and
scratches to the paintwork, repair these immediately to avoid corrosion
on the underlying metal. Only use touch-up paint for minor stone chip
damage and scratches, major damage to paintwork should be repaired
by a paint shop.
NOTE
Before performing touch-ups, the surface area must be carefully
cleaned.
10 Common hydraulics
10 Common hydraulics
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering,
and certain cab functions with hydraulic pressure.
Pressure plate
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.
9 2
8
3
7
6 4
5
009654
1. Feed pressure control valve attachment 6. Max. pressure hydraulic oil pump 1
2. Max. brake pressure 7. Steering pressure
3. Gas pressure brake accumulators 8. Servo pressure lift and extension
4. Hydraulic oil pressure brake accumulators 9. Max. pressure hydraulic oil pump 2
5. Gas pressure servo accumulator
008083
1 2 1 3 2 4 5 Tank
1. Cover plate for hydraulic oil filter
2. Filler plug hydraulic oil
3. Sight glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs hydraulic oil
008086
Accumulator
Accumulator
1 1. Accumulator
008087
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from four pumps. Three of
1 them for working hydraulics/steering, and one for the brake system.
The pumps are assembled into two pump banks mounted on the
gearbox 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) feeds the brake system's brake
2 and cooling circuit over an accumulator charging valve, see section 4
Brakes.
3
The main pump (position 3) supplies the steering as well as the
008082
control valve for load handling. The priority valve ensures that there is
always pressure for steering, the residual flow goes to control valve
1. Hydraulic oil pump and quick-lift pump for load load handling.
handling
2. Hydraulic oil pump for brake system, cooling
and filtering
3. Main pump for steering and load handling
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. Accumulator servo pressure 16. Pressure limiting valve
7. Servo filter 17. Control valve attachment
8. Control unit frame (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
1 2
7
3
6
5
4
008088
1. Collecting 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
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.
˚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 2
10
8
5
008085
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
1 Turn off the engine and turn off the main electric power.
NOTE
Read safety instructions for oil before starting work, see section B
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 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter
insert as environmentally hazardous waste. Note position of the
parts.
Magnetic rod
NOTE
The oil level is checked with the mast lowered and the attachment in
the 20-foot position.
2 Check the oil level in the hydraulic tank. The oil level should be
visible in the sight glass. Fill oil as required. For oil grade, see
section F Technical data.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
2 Remove the filler cap and pump out the hydraulic oil in a collection
container.
3 When most possible oil has been pumped out. Place a container
under the hydraulic oil tank's drain plug and drain the last hydraulic
oil.
4 Fit the drain plug when the oil has drained.
NOTE
Make sure that the drain plug's washer seal is also removed.
1. Cover plate for oil filter
5 If the hydraulic oil filters are to be changed, change them before
2. Filling point hydraulic oil filling the tank with oil, see Hydraulic oil filter, changing, page
3. Sight glass hydraulic oil 10:12.
6 Fill new hydraulic oil in the filler holes on the filter's cover
plates. This filters the oil and protects the hydraulic system from
contamination.
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked when all hydraulic
cylinders are in the retracted position.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
11 Common electrics
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.
3
4
F5
93
D7
F5
F5
8
8-1
6
X1
F5
8-2
K1
8-3
K3 K4
K2
009173
5
4
11.2.2 Fuses
Fuses, description
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
The electrical system has three main circuits (30-, 15-, and
15E-voltage), see Distribution of electricity, description, page 11:12.
The main circuits are fused several times with main fuses and circuit
fuses.
Main fuses
Main fuses
1
2 The main fuses divide the machine's voltage feed into smaller parts
to maintain as many functions as possible in case of damage to
3 cables harnesses.
4 By the cab's and frame's electrical distribution boxes there are fuse
plates that describe the different fuses.
009167
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)
Circuit fuses
Circuit fuses
Circuit fuses are grouped in fuse holders that are located in the
electrical distribution box on the frame and the electrical distribution
box in the cab.
By the fuse holders there are fuse plates with information about fused
function and fuse rating.
C
009169
D
E
A Circuit fuses in cab F58-4, 15-fuses (ignition
voltage) and 30-fuses (battery voltage).
B Circuit fuses in cab F58-5, 15-fuses (ignition
voltage).
C 30-fuses F58-1, (battery voltage)
D 15-fuses F58-2, (ignition voltage)
E 15E-fuses F58-3, (control switch voltage)
SUPPLY POWER
A1 10A KCU (KALMAR CAB UNIT)
X2044980 1
B2 5A KCU,START UP (KALMAR CAB UNIT)
F58-4 15
C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
MAIN POWER
F6 25A OPT SEAT HEATER, TURNABLE SEAT
F58-4 30
G7 15A OPT WORK LIGHT
CAB
H8 15A OPT AIRCUSHIONED SEAT
E5 10A SERVICE
014092
H8 10A OPT COMPRESSOR HORN
014278
Fuses, changing
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
11.3 Batteries
11.3.1 Start battery
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
2 Turn off the engine and turn off the system voltage.
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.
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.
11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. Location is dependent on
engine alternative.
014036
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.
D797-2 D797-1
(+)
D797-2 D797-1
(+) 6. Control unit cab (D790-1) activates emergency stop switch
Redundant CAN-bus communication voltage (15E). See Emergency stop switch voltage (15E),
description, page 11:16.
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 11:16.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:15.
3. Redundant voltage feed to control units is cut off.
4. Cab control unit (D790-1) disconnects the redundant CAN bus.
See Redundant CAN-bus, description, page 11:21.
5. Cab control unit (D790-1) disconnects the redundant voltage feed.
See Redundant voltage feed of control units, description, page
11:14.
6. Control unit cab (D790-1) awaits start-up signal. Other electronics
are powerless.
When all control units have redundant voltage feed and bus
communication, the system is ready to receive, process signals.
D797-2 D797-1
(+) When redundant voltage feed is activated the following takes place.
1. Start-up signal is sent to Control unit cab (D790-1), see A in
B illustration.
D791
2. A hold circuit is activated in Control unit cab (D790-1) which
activates the control unit's control logic.
3. Control unit cab (D790-1) activates redundant voltage feed to the
other control units, see B in illustration.
D790-1 D790-2 D795
Control unit cab (D790-1) has four outputs for voltage feed, other
control units have two inputs for redundant voltage feed. In case
of failure of one feed, the control unit is supplied from the other
feed.
004767
D797-2 D797-1
(+)
A Start-up signal is sent
B All control units are supplied with voltage
D794
CAUTION
Maximum take-off from the voltage converter is 12 V /
20 A (including radio).
5 6
4 7
3
15
2
1 8
16
9 17
10 18
11 19
12
13
14
009171
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
Control unit cab and control units on the frame and attachment have
indicator lamps that can be used to check basic information on the
status of other control units.
1 2 3 4
014738
8 7 6
1. Control unit attachment (D791-1) 5. Control unit, transmission (D793)
2. Control unit KID (D795) 6. Control unit engine (D794)
3. Control unit KIT (D790-2) 7. Control unit, frame (D797-1)
4. Control unit cab (D790-1) 8. Control unit frame option (D797-2)
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
D797-2 D797-1
(+) Signals can be checked with diagnostic menu.
Principle illustration redundant CAN-bus
D794 D793
Principle illustration CAN-bus drivetrain
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.
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 Error codes
D Error codes
Information is found in the Workshop
manual
See Workshop manual DCF 80-100, section D Error codes.
E Diagrams
E Diagrams
Information is found in the Workshop
manual
See Workshop manual DCF 80-100, section E Diagrams.
F Technical data
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.
3. Driveline/Axle
Drive axle, type Kessler D81
Kessler D91
4. Brakes
Footbrake system - wheels affected Wet Disc Brake – drive wheel
Parking brake system - wheels affected Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels
Dimension, front and rear 12.00x24 / 14.00x24
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air filled. Spare and replacement tyres should be of
brand names approved by Cargotec.
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
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.
7 Load handling
Oil grade See Oils and lubricants, recommendation, page F:9.
10 Common hydraulics
Oil grade See Oils and lubricants, recommendation, page F:9.
Hydraulic oil tank, volume 360 l
Hydraulic oil system, volume 450 l
β α
A2
100 100
H4
H5
B S
H3
R1
R2
H6
H8
H10
100
014020
100
L3 L2 A1
L
7 Load handling
Oil planetary gear hydraulic motor, hypoid oil SAE 80W140
API GL-5
SAE 75W90
Disc brake hydraulic motor, See "10 Common
hydraulics" below
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
*) The oil in the brake system must fulfil one of the quality requirements.
Grease
NOTE
Select grease grade according to relevant climate.
Sealant silicone
Silicone adhesive
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.
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.
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
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
Goods coupling
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
Term Description
Machine model Machine type. Indicated, 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 Circulates again and again.
Serial number Unique machine designation. Available on machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small user movement results in a big machine movement, e.g. power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Levelling Attachment is tilted, for example, if load stands on uneven ground.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Widening of attachment.
Mast Carrier of trolley, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
Steering axle Wheel axle with steering.
Buzzer Audible alarm to catch the operator’s attention.
Option Optional equipment for machine.
Tilting Load is tilted forward or backward.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container for lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
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.
Index ENGINE . . . . . . . . . . . .
Entertainment and communication
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 8:17
. . 9:35
Environment . . . . . . . . . . . . . . . . . . . B:20
Error codes . . . . . . . . . . . . . . . . . . 8:8, D:1
A Exhaust system . . . . . . . . . . . . . . . . . . 1:22
About the documentation . . . . . . . . . . . . . A:10 EXT-ATTACH . . . . . . . . . . . . . . . . . . . 8:23
About the maintenance manual . . . . . . . . . . . . A:3 EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:22
Accumulator . . . . . . . . . . . . . . . . . . . . 4:8
AdBlue filter . . . . . . . . . . . . . . . . . . . . 1:15
AdBlue tank . . . . . . . . . . . . . . . . . . . . 1:13 F
Air cleaning system . . . . . . . . . . . . . . . . . 1:20 Feedback . . . . . . . . . . . . . . . . . . . . . A:11
Air intake and exhaust outlet . . . . . . . . . . . . . 1:18 Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:15
Alternator . . . . . . . . . . . . . . . . . . . . 11:11 Foreword . . . . . . . . . . . . . . . . . . . . . A:3
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:20 Frame . . . . . . . . . . . . . . . . . . . . . . . 9:42
Axial piston pump with variable displacement . . . . . . 10:7 Frame, body, cab and accessories . . . . . . . . . . 9:3
FREELIFT . . . . . . . . . . . . . . . . . . . . . 8:23
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:26
B Fuel filter . . . . . . . . . . . . . . . . . . . . . 1:12
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:9 Fuel prefilter . . . . . . . . . . . . . . . . . . . . 1:10
Battery voltage (30) . . . . . . . . . . . . . . . . 11:13 Fuel system . . . . . . . . . . . . . . . . . . . . 1:8
Body structure . . . . . . . . . . . . . . . . . . . 9:43 Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:9
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:4 Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:5
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3
Breather filter hydraulic oil tank . . . . . . . . . . . 10:12
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:6 G
General safety information . . . . . . . . . . . . . . B:3
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:36
C
CAB . . . . . . . . . . . . . . . . . . . . . . .8:15
Cab interior . . . . . . . . . . . . . . . . . . . .9:41 H
Cab structure and suspension . . . . . . . . . . . .9:37 Heating, ventilation and air conditioning . . . . . . . . 9:14
Cab tilt . . . . . . . . . . . . . . . . . . . . . .9:38 Height limitation . . . . . . . . . . . . . . . . . . 8:7
Cab undercarriage . . . . . . . . . . . . . . . . .9:38 Height warning . . . . . . . . . . . . . . . . . . . 8:7
CAN bus . . . . . . . . . . . . . . . . . . . . 11:21 Hoses, pipes and valves . . . . . . . . . . . . . . . 10:8
CAN-bus drivetrain . . . . . . . . . . . . . . . . 11:21 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:16
CAN/POWER . . . . . . . . . . . . . . . . . . . 8:13 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:13
Central lubrication . . . . . . . . . . . . . . . . . 9:44 Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:12
CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:15
Common electrics . . . . . . . . . . . . . . . . . 11:3
Common hydraulics . . . . . . . . . . . . . . . . . 10:3 I
Communication. . . . . . . . . . . . . . . . . . 11:21
I/O . . . . . . . . . . . . . . . . . . . . . . . . 8:25
Complete machine . . . . . . . . . . . . . . . . . 0:3
Ignition voltage (15) . . . . . . . . . . . . . . . . 11:15
Condenser . . . . . . . . . . . . . . . . . . . . . 9:27
Ignition/heating . . . . . . . . . . . . . . . . . . . 1:35
Container counter. . . . . . . . . . . . . . . . . . 7:49
Intercooler . . . . . . . . . . . . . . . . . . . . . 1:22
Control system . . . . . . . . . . . . . . . . . . . 8:3
Control system engine. . . . . . . . . . . . . . . . 1:34
Control system transmission . . . . . . . . . . . . . 2:13
Control units . . . . . . . . . . . . . . . . . . . 11:19 L
Controls and instruments . . . . . . . . . . . . 4:4, 9:4 Levelling. . . . . . . . . . . . . . . . . . . . . . 7:30
Coolant . . . . . . . . . . . . . . . . . . . . . . 1:26 Lifting hook . . . . . . . . . . . . . . . . . . . . 7:40
Cooling fan . . . . . . . . . . . . . . . . . . . . 1:24 Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:5
Cooling system . . . . . . . . . . . . . . . . 1:24, 2:12 Lighting system. . . . . . . . . . . . . . . . . . . 9:30
LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:14
Link arm . . . . . . . . . . . . . . . . . . . . . . 5:8
D Load carrier . . . . . . . . . . . . . . . . . . . . 7:33
Load handling . . . . . . . . . . . . . . . . . . . 7:3
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:10
Lubrication system . . . . . . . . . . . . . . . 1:31, 2:9
Diagrams . . . . . . . . . . . . . . . . . . . . . E:1
Distribution of electricity . . . . . . . . . . . . . . 11:12
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:37
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:5 M
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3 Mast . . . . . . . . . . . . . . . . . . . . . 7:9, 7:29
Mechanical transmission. . . . . . . . . . . . . . . 2:8
Moisture filter . . . . . . . . . . . . . . . . . . . 9:27
E Monitoring . . . . . . . . . . . . . . . . . . . . . 8:6
MOVE-CAB . . . . . . . . . . . . . . . . . . . . 8:24
EL-STEERING . . . . . . . . . . . . . . . . . . . 8:23
ELECTRIC SERVO . . . . . . . . . . . . . . . . . 8:19
Electrical protection . . . . . . . . . . . . . . . . . 11:4
Electronic box . . . . . . . . . . . . . . . . . . 11:18 O
Emergency stop switch voltage (15E) . . . . . . . . 11:16 Oil filter, brake system . . . . . . . . . . . . . . . . 4:14
Engine . . . . . . . . . . . . . . . . . . . . . . 1:3 Oil pump brake system . . . . . . . . . . . . . . . 4:7
S V
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 VBFS . . . . . . . . . . . . . . . . . . . . . . . 8:22
Safety and emergency equipment. . . . . . . . . . . 9:10 Voltage converter . . . . . . . . . . . . . . . . . 11:17
Safety instructions . . . . . . . . . . . . . . . . . B:4 Voltage feed . . . . . . . . . . . . . . . . . . . 11:12
Safety valves. . . . . . . . . . . . . . . . . . . . 10:4
Seats . . . . . . . . . . . . . . . . . . . . . . . 9:11
Sensor steering wheel reading . . . . . . . . . . . . 5:9 W
Sensor, hydraulic pressure lift cylinder . . . . . . . . . 7:9
Service indicator . . . . . . . . . . . . . . . . . . 8:7 Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:5
Servo filter . . . . . . . . . . . . . . . . . . . 7:7, 7:29 Wheel spindle . . . . . . . . . . . . . . . . . . . 6:5
Settings . . . . . . . . . . . . . . . . . . . . . . 8:26 Wiper/washer system . . . . . . . . . . . . . . . . 9:29
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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
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continuous, reliable and sustainable performance of equipment. www.cargotec.com