RTG E-One - Manual de Manutenção 41300-41303 (EN)

Rubber Tyred Gantry Crane
Kalmar E-one 2 412621-16L-2040C-ZE
Maintenance Manual
22.04.2015
s/n 41300-41303
2015
Original Instructions
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Cummins
Maintenance
manual 2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
9 Frame, body, cab and accessories
11 Common electrics
F Technical data
G Index
1
Table of content
A Foreword 3
Maintenance manual 3
Reading this manual 5
Feedback 7
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2
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A Foreword – Maintenance manual 3
A Foreword
Maintenance manual
General
Read the instructions in this manual carefully, and follow them
strictly so that the safety and reliability of the machine will be main‐
tained at the intended level.
Contact your superior if some parts of this manual lead to questions
or some important information seems to be missing.
We thank you for selecting Cargotec Finland Oy as the provider of
your machine. We believe that we can fulfil your expectations with
regard to the operational features and availability of maintenance
services.
Contents
This maintenance manual contains the following information:
Foreword General information about the purpose and contents of this maintenance
A manual, instructions for reading the manual, and a form for giving feedback
and correcting any inaccuracies.
B Safety Information regarding safety.
C Preventive maintenance Information about preventive maintenance. Maintenance tables.
0 Complete machine Technical description, information about the machine structure and functions,
and function-specific troubleshooting instructions.
1 Engine Each subfunction describes the components related to the function in
question. The most common components are thus mentioned in several
2 Transmission sections, but they are usually described in connection with the first function to
which the component is related.
3 Driveline/Axle In addition to the general description, there is also a detailed description of
the issues typical of the subfunction. The next subfunction using the same
4 Brakes component has descriptions of the components relevant to the new function
only.
5 Steering
Instructions for service procedures.
6 Suspension
7 Load handling
9 Frame, body, cab and accessories
11 Common electrics
F Specifications Technical specifications, conversion tables, unit conversion factors.
G Terminology and index General terms and abbreviations, their explanations, index of headings.
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4 A Foreword – Maintenance manual
Division into function groups

The division into function groups is the same for all machines manu‐
factured by Cargotec Finland Oy. The groups are indicated by num‐
bers with two digits (e.g., 4.3 Power-assisted brake system).
Machine-specific adaptations of the function groups are indicated by
a third or fourth digit (e.g., 4.3.9 Wheel brake or 4.3.9.1 Disc brake).
This results in certain headings (function groups) being omitted in
the documentation for certain machines since the machine lacks
that particular function. This means that there may be gaps in the
function group numbering (e.g., 2.7 Cooling system may be inclu‐
ded for certain machines, but may be missing for other machines).
References between different manuals (operator's manual, mainte‐
nance manual, and workshop manual) are used since the different
manual types have different purposes and thus different information
content.
References between sections within this maintenance manual are
indicated with the chapter and section number, e.g., "See Chapter
4, Brakes, Section 4.3.9., Wheel brake".
Conditions
The instructions are based on the use of generally available stand‐
ard tools. All lifting devices, e.g., slings, straps, and ratchet blocks,
must meet the national standards and regulations for lifting devices.
Cargotec Finland Oy will not accept any responsibility for modifica‐
tions performed without permission from Cargotec Finland Oy, or if
lifting devices, tools, or work methods other than those described in
this manual are used.
Storage
Keep the manual in good condition, and store it in a place where it
is always available to the service personnel.
About the machine

The information in this manual corresponds to the basic design and
appearance of the machine at the time of delivery. Due to customer
adaptations, there may be variations and/or deviations.
Cargotec Finland Oy reserves the right to modify specifications and
equipment without prior notice. All information and data in the man‐
ual are valid at the time of publication.
Copyright
This document may not be copied, presented, or delivered to a third
party without our explicit permission, or used for purposes other
than those allowed by us.
We reserve the right to alter the adjustment values, equipment, and
service and repair instructions for the machine without prior notice.
Cargotec Finland Oy
Maintenance manual
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A Foreword – Reading this manual 5
Reading this manual
Information on possible safety hazards

This manual includes three types of warnings containing instructions
on how to avoid situations that may compromise safety.
DANGER
Warns of a situation that involves immediate risk of personal injury or
death if the safety instructions provided are not observed.
WARNING
Warns of a situation that may cause personal injury, death, and/or
substantial damage to the machine or other property if the safety
instructions provided are not observed.
CAUTION
Warns of a situation that may cause moderate personal injury and/or
damage to the product or other property if the safety instructions pro‐
vided are not observed.
Important information
The word NOTE is used to emphasise issues concerning safety or
the maintenance instructions to which special attention must be paid
while working on the machine.
An example of how the word NOTE appears is presented below.
NOTE
Calls the reader's attention to an instruction that, e.g., emphasises
operational safety.
Optional equipment
The machine can be equipped with various accessories or optional
equipment. The equipment is marked with the symbol seen on the
left. The symbol is always accompanied with text representing and/
Fig. : The symbol indicates an optional equipment. or describing the equipment.
The NOTE symbol is clearly distinguished from the text, and it is
placed next to the text and picture representing the equipment.
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6 A Foreword – Reading this manual
Function descriptions
The function descriptions are presented as overviews in a chart for‐
mat that describe the function and the associated components and
signals.
The function descriptions describe the function in a logical order
from the input signal to the output signal. Most functions require that
certain preset conditions be met before the function can be activa‐
ted. In these cases, the required conditions are listed above the fig‐
ure.
The function descriptions use symbols to depict components like
valves and sensors.
An example of a function description is provided on the following
page.
Manual package
The following manuals are included in the machine delivery as
ordered:
• Operator's manual
• Maintenance manual
• Spare parts catalogue
Each manual can be ordered separately, in case extra copies of

instruction manuals or spare parts catalogue for the machine are
needed later.
Ordering the manuals

The manuals can be ordered from Cargotec Finland Oy's spare
parts department.
Refer to the publication number of the manual when placing the
order.
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A Foreword – Feedback 7
Feedback
Form for copying

It is the goal of Cargotec Finland Oy to provide everyone working on
the maintenance of Kalmar machines with access to the correct
information.
Your feedback is important for us to be able to improve the informa‐
tion.
Copy this form, write down your views, and send it to us. Thank you
for your participation!
To: Cargotec Finland Oy

Product Support
P.O. Box 387
FI-33101 Tampere
FINLAND
Fax: +358 3 265 8220
From: Company / sender: ...............................................................................................................................

Telephone:............................................................................................................................................
E-mail:...................................................................................................................................................
Date: .................................... - .................. - ........................................................................................
Manual Name / publication number:..................................................................................................................

information Chapter / page number:........................................................................................................................
Suggestions, ..............................................................................................................................................................
comments, ..............................................................................................................................................................
remarks, etc.
..............................................................................................................................................................
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8 A Foreword – Feedback
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1
Table of content
B Safety 3
General safety instructions 3
Safety instructions 4
Service Position 4
Electric systems 4
Several mechanics working on the machine 7
Working on top the machine 7
Working under the machine 8
Lifting heavy components 8
Vibration 9
Noise 9
Solvents 9
Fire and explosion risks 10
Fluid or gas under pressure 11
Coolant 12
Refrigerant 12
Air pollution 12
Tensioned springs 13
Rotating components and tools 14
Tyres 14
Regulations for safe maintenance work 15
Concerning the maintenance and repair personnel 16
Instructions for using shore supply (if equipped) 17
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B Safety – General safety instructions 3
B Safety
General safety instructions
General
Everyone performing maintenance and adjustment procedures on
the machine must follow the safety instructions included in this man‐
ual.
Maintenance must be carried out by professional and trained per‐
sonnel only.
Training on maintenance and occupational safety issues can be
ordered from our product support department if necessary.
Remember:
• Follow the safety instructions included in this manual.

• Obtain the training required by the job and, if necessary, ask
your work instructor for guidance on the issues regarding
safety at work.
• Follow local laws, safety instructions, and regulations.
• Do the job with equipment and tools that you have been trained
to use safely and properly.
• Work carefully but efficiently, and do not take any risks.
In this publication, Cargotec Finland Oy. has documented and

warned about situations and risks that may occur in connection with
operation as well as service and repairs of the machine under nor‐
mal conditions.
Therefore, it is very important that all persons working on the
machine acquaint themselves with and act according to the informa‐
tion in the maintenance manual and operator's manual.
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4 B Safety – Safety instructions
Safety instructions
General
Read the safety instructions before starting servicing or other work
on the machine, and follow them strictly to keep operational safety
at the intended level.
Service Position
General
The machine's service position is used during servicing, mainte‐
nance, and other procedures during which the machine must be sta‐
tionary
Service position:
• The machine is parked, and the parking brake is engaged.

• The spreader has been lowered fully.
• The engine is off.
• The main power is off.
Electric systems
DANGER
DANGER
The electric systems must be serviced and repaired by trained serv‐
ice personnel.
Electric systems of the machine
• High-current system 400/440 VAC

• Frequency 50/60 Hz
• Main power supply from external power source (zero emission
RTG ), see chapter F Technical data.
Risks
When using shore supply, there are energized parts in the machine
although the main switch is off.
Danger of electric shock if energized electric centre components are
touched.
Danger of electric shock if cables are damaged.
Danger of electric shock if voltage is switched on unexpectedly.
Danger of electric shock if components energized by shore power
are touched.
Battery acid splashing on the skin or in the eyes.
Burns caused by short circuit when handling batteries.
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B Safety – Safety instructions 5
Precautions
• Before commencing work, ensure that the electric system is

de-energized. The high-current system includes components
that remain energized for several minutes after the engine is
stopped. Wait for 10 minutes after stopping the engine before
commencing work on the electric system.
• Ensure that machine components are not energized by shore
power.
• Inform other people of the servicing being performed. Place
signs prohibiting the switching on of power in the appropriate
places.
• Regularly check the condition of the machine cables and the
shore power supply cable.
• Handle the batteries carefully.
• While working on the batteries, remove your watch, rings, and
other metal objects that could cause a short circuit. Use insula‐
ted tools.
• Working with the hydraulic system: when system is turned off
and main current broken there is no residual pressure in the
hydraulic system.
Zero emission RTG (option)
Power supply to the zero emission RTG can be provided with
following voltage levels:
• Over 1 kV (medium voltage), crane is equipped with medium

voltage transformer
• Below 1 kV (low voltage)
Refer to chapter F Technical data for the power supply voltage of

the crane.
Protection against direct contact of power supply
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DANGER
Do not open cable reel slipring housing (A) if the power supply cir‐
cuits are live.
Over 1 kV power supply: Do not open transformer housing if the
power supply circuits are live.
A Transformer location varies depending on crane’s equipment, see
Operator’s manual.
When the crane main switch is switched off, power supply circuits
from the land feeding point to the crane main switch are still live if
the main power supply is not switched off from the land feeding
point.
Land feeding point:
Before commencing any maintenance or repair of equipment in the
power supply circuit, always ensure the main power supply is
switched off from the land feeding point switchgear. The switchgear
must be locked, maintenance earthed and marked with appropriate
maintenance work warning sign. The safety instructions of the
switchgear manufacturer must be followed to ensure the safe opera‐
tion procedures.
Crane:
Crane main switch must be opened, locked to open position and
marked with maintenance work warning sign.
Protection against indirect contact of power supply
DANGER
There must be an earth fault monitoring device on the land feeding
point switchgear. In case of earth fault it will immediately open the
crane main switch.
Clothing
Wear appropriate work clothing. Remove loosely hanging clothing
(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewelry as it may get caught in moving parts.
Long hair must be tied up securely, otherwise it may easily get
caught in moving parts. Be careful when performing welding and
flame cutting work since hair catches fire easily.
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Several mechanics working on the machine

DANGER
WARNING
Be especially careful if several mechanics work on the machine at the
same time. Communicate so that everyone knows where the others
are and what they are doing.
Risks
Falling objects, such as tools, cause a risk of injury.
Movements performed by the operator, e.g., movement of lifting
equipment, may cause severe personal injuries.
Precautions
• Ensure that the spreader has been fully lowered or secured in

some other manner.
• Only one person at a time is allowed on the ladder.
• Do not leave objects in places from which they may fall when,
for example, the machine is moved.
• No personnel are allowed in the operating range of the rope
system and the ropes during the operation of the machine.
• Be aware of the risks when several persons work around the
machine.
• Make your co-workers aware of what you are working with.
Working on top the machine
NOTE
Always use trolley locking device during maintenance.
Risks
Oily platforms and ladders cause a risk of slipping and falling while
moving on the machine.
The risk of falling is high, especially when moving and working out‐
side of the handrails.
Precautions
• Carefully clean all platforms, walkways, and ladders to prevent

the risk of slipping.
• Always wear a safety harness when working outside of the
handrails.
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Working under the machine

Risks
The spreader may be lowered and cause a risk of injury.
Precautions
• Ensure that the spreader has been fully lowered or secured in

some other manner.
Lifting heavy components

WARNING
WARNING
Careless handling of heavy components can lead to serious personal
injury and material damage.
Use type approved lifting tools or other devices to move heavy com‐
ponents. Ensure that the device is stable and intact.
Risks
WARNING
Careless handling of heavy components can lead to serious personal
injury and material damage.
Use type approved lifting tools or other devices to move heavy com‐
ponents. Ensure that the device is stable and intact.
Unsuitable lift slings, straps, etc. may break or slip.

The centre of gravity (balance point) 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 bal‐
ance is upset.
A component lifted using an overhead crane may start to swing
back and forth, which can cause a risk of injury.
Lift using a lifting device.
• Use lifting tools or equipment, especially when such equipment

is available for specific work operations.
If lifting must be performed without a lifting device:
• Lift near your body.

• Keep your back straight. Raise and lower with your legs and
arms, do not bend your back. Do not rotate your body while lift‐
ing. Ask for assistance in advance.
• Wear gloves. Gloves provide good protection against minor
crushing injuries and cuts to fingers.
• Always wear protective shoes.
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Vibration
General
In case of long-term use of vibrating tools, for example, percussion
drills or grinders, injuries may be sustained as vibrations are trans‐
mitted from tools to hands. This happens especially when the fin‐
gers are cold.
Precautions
• Use heavy gloves to protect against cold and vibrations.

• Switch between work duties to give your body time to rest.
• Change your working position and grip so that your body is not
stressed in only one position by the vibrations.
Noise
General
Noise louder than 85 dB (A) that lasts longer than 8 hours is consid‐
ered harmful to hearing. Tones at high frequencies are more dam‐
aging than low tones at the same sound level. Impact noise can
also be hazardous, e.g., hammer blows.
Risks
Hearing damage can occur at noise levels higher than the limits. In
severe cases, hearing damage can become permanent.
Precautions
• Use hearing protection. Ensure that it has been tested and pro‐
tects against the noise level in question.
Solvents
General
Fluids that (as opposed to water) dissolve grease, paint, lacquer,
wax, oil, adhesive, rubber, etc. are called organic solvents.
Such liquids include white (petroleum) spirits, petrol, alcohols, die‐
sel, xylene, trichloroethylene, and toluene.
Many solvents are flammable and constitute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi‐
ness, headaches, and nausea. They may also irritate mucous mem‐
branes in the throat and respiratory tracts.
If solvents come in direct contact with the skin, this may cause dry‐
ing and cracking. The risk of skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absor‐
bed by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depression,
nervousness, poor memory, or general tiredness and fatigue. Con‐
tinuous inhalation of petrol and diesel fumes is suspected to cause
cancer.
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Precautions
• Avoid inhaling solvent fumes and ensure good ventilation. If

necessary, wear a fresh-air mask or respiratory device with a
suitable filter for toxic gases.
• Never leave a solvent container open; seal the lid carefully.
• Use solvents with a low content of aromatic substances. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are solvent-resistant.
Fire and explosion risks

General
Examples of explosive substances are oils, petrol, diesel fuel,
organic solvents (lacquer, plastic, cleaning agents), rust proofing
agents, welding gas, gas for heating (acetylene), and high concen‐
trations of dust particles from combustible materials. Rubber tyres
are highly flammable and cause fires that spread explosively.
Risks
Examples of the causes of ignition include welding, cutting, smok‐
ing, sparks produced by grinding, and flammable materials coming
into contact with hot machine parts.
Petrol fumes, for example, are heavier than air and can thus run
down a sloping grade or down into a grease pit where, e.g., welding
flames can cause an explosion. Evaporated petrol has a very pow‐
erful explosive force.
Special cases
Diesel fuel oil with added petrol has a reduced flash point. There is
an explosion risk even at room temperature. The explosion risk due
to warmed diesel fuel oil is greater than for petrol.
When changing oil in the engine, hydraulic system, and transmis‐
sion, keep in mind that the oil may be hot and can cause burn inju‐
ries.
Welding on or near the machine: If diesel or other oils have leaked
out and have been absorbed by rags, absorbing agent, paper, or
other porous material, welding sparks can cause ignition and an
explosive spread of fire.
When a battery is being charged, the battery electrolyte forms
hydrogen gas, which is highly explosive. The risk of explosion is
especially high when a booster battery or a rapid-charge unit is
used, as these increase the risk of sparks.
Today's machines contain a lot of electronic equipment. During
welding, the control units and battery cables must be disconnected.
Otherwise, strong welding currents can short-circuit the electronics,
destroy expensive equipment, and may also cause an explosion or
fire.
Welding work must never be carried out on painted surfaces
(remove paint by blasting at least 200 mm around the welding or
cutting point). Use gloves, respiratory protection, and protective
safety glasses. Also, welding work must never take place near plas‐
tic or rubber materials without first protecting them from the heat.
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Paints, plastics, and rubber generate various substances when

heated that may be hazardous to health. Be careful with machines
that have been exposed to intense heat or fire.
Precautions
• Store explosive substances in approved and sealed containers.

• Ensure that there are no ignition sources near flammable or
explosive substances.
• Ensure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.
• At high temperatures epoxy paint releases toxic gases. During
repair welding adequate ventilation has to be ensured.
• Inhaling epoxy paint fumes irritates respiratory organs and
mucous membranes in the nose and the throat. During painting
ensure good ventilation.
• Before starting welding or other thermal work in the power unit,
check and / or repair all fluid and oil leaks and clean the work‐
ing area carefully.
Fluid or gas under pressure

General
Pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
Risks
There are injury risks in connection with work on:
• hydraulic and brake systems

• fuel system
• tyre repairs
• air conditioning system
Precautions
• Use safety glasses and protective gloves.

• Never work on a pressurized system.
• Never adjust a pressure relief valve to a higher pressure than
recommended by the manufacturer.
• Damaged hydraulic hoses must be replaced as soon as possi‐
ble! Check connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded accumulators must first be punctured before they
are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurizing.
• Never use your hands to detect a leak. A fine high-pressure
stream from a hydraulic hose can easily penetrate the skin and
cause very severe injuries.
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Coolant
General
The coolant in the machine's cooling system consists of water, anti-
corrosion compound, and (when needed) antifreeze fluid, for exam‐
ple, ethylene glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is pressurized when the engine is warm. Hot
coolant can jet out and cause scalding in case of a leak or when the
expansion tank cap is opened.
Inhaling ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Precautions
• Use protective gloves and safety glasses if there is a risk of

splashing or spraying.
• Carefully open the filler cap first to release the excess pres‐
sure. Be careful; hot steam and coolant may stream out.
• If possible, avoid working on the cooling system when the cool‐
ant is hot.
Refrigerant
General
Refrigerant is used in the machine's air conditioning system.
Risks
The air conditioning system operates at high pressure. Escaping
refrigerant can cause freeze burns.
Heated refrigerant (e.g., during the repair of leaks in the air condi‐
tioning system) produces gases that are very toxic if inhaled.
Precautions
• The air conditioning system must be serviced by authorized

and trained personnel only. Follow national legislation and local
regulations!
• Use protective gloves and safety glasses if there is a risk of
leaks.
• Make sure that there are no heat-producing sources or objects
close by (cigarette glow, welding flame).
Air pollution
General
Air pollution is the impurities in the air that are regarded as hazard‐
ous to health. Certain pollution is more prominent in certain environ‐
ments.
The following air pollution hazardous to health is especially promi‐
nent in workshops:
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• Carbon monoxide (fumes): Present in exhaust fumes. Odour‐

less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases):Present in exhaust fumes.
• Welding smoke: Especially hazardous to health when welding
on oily surfaces, galvanized, or lacquered materials.
• Oil mist: For example, when applying anti-corrosion agent.
• Grinding dust and gases: Generated when grinding and heat‐
ing plastics, lacquer, anti-corrosion agents, lubricants, paint,
etc.
• Isocyanates: Present in certain paints, fillers, adhesives, and
foam plastics.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
Sulphuric acid is generated when heating certain plastics and
paints.
Isocyanates can be released in the form of steam or dust when cut‐
ting, grinding, or welding. Isocyanates may also be present in aero‐
sols. They can irritate mucous membranes, producing symptoms
similar to asthma and impairing lung function. Even brief exposure
to high concentrations can cause problems of persistent high sensi‐
tivity.
Precautions
• Ensure adequate ventilation during welding, charging a battery,

and other work where hazardous gases are generated.
• Use suitable gloves and respiratory protection when there is a
risk of oil mist. Ensure that the protective equipment is oil-
resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Ensure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the work‐
shop. Connect an air extractor to the exhaust pipe so that the
exhaust fumes are removed from the workshop.
Tensioned springs
General
Examples of tensioned springs:
• suspension elements in rubber suspension

• return springs in the parking brake cylinder
• lock rings
• gas springs
Risks
If a tensioned spring is released, it is shot out by the spring force
and can also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe injuries if they are accidentally released in an uncontrol‐
led manner.
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Gas springs are tensioned with high force and can cause very
severe injuries if they are accidentally released in an uncontrolled
manner.
Precautions
• Use safety glasses.

• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when per‐
forming maintenance.
• Always use the recommended tools.
Rotating components and tools

General
Examples of rotating components and tools:
• cooling fan
• drive belts
• drive shafts
• drills
• grinders
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.
Drills, grinders, and other machines with rotating parts can cause
severe injuries if clothes or hair get caught and are wound up in the
machine.
Precautions
• See Clothing on page 6
Tyres
DANGER
DANGER
Tyres should be regarded as pressurized containers. They constitute
a risk of injury if handled incorrectly.
Never repair damaged tyres, rims, or lock rings. Tyre repairs should
only be performed by authorized service personnel.
Risks
Dismantling wheels: Tyres, rims, or lock rings can be thrown.
Inflating tyres: Tyres, rims, or lock rings can be thrown.
Precautions
• Deflate the tyre before starting to work on the wheel.

• Check that tyres, rims, and lock rings are intact. Never repair
damaged tyres, rims, or lock rings.
• Use a protective screen and safety glasses.
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Regulations for safe maintenance work

General
1. Thoroughly acquaint yourself with the RTG structure and the

manuals. Observe the instructions and warnings.
2. Try to determine the hazards, and avoid them. Report any
faults that you have noticed to your superior or to the person in
charge of repairs.
3. Fall protection: Working at heights on cranes or hoists, all per‐
sons shall wear safety harnesses that are fitted with a rope and
securely attached to a structural member of the crane.
4. Always use on protective clothing, overall, helmet, gloves,
safety shoes and etc.
5. Always observe sufficient caution and care when climbing into
or coming down from the RTG. Always move along the paths
designated as walkways. Keep the walkways clean. Remove
all safety risks, such as snow and ice, and other foreign matter.
Wipe away all oil leakages at once to prevent slipping.
6. Keep the RTG clean, especially the adjusting and control devi‐
ces.
7. Do not allow any unauthorized persons to operate the RTG
entrusted in your use. The operator of the RTG is responsible
for any damage caused by the machine.
8. Acquaint yourself in advance with the use of emergency exits.
9. Do not stand under a hanging container or load.
10. If problems arise, remember to stay calm. Think first, and then
act accordingly.
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Concerning the maintenance and repair personnel

General
1. The service and repair personnel of the RTG is responsible for

that the machine doesn’t cause damage to other persons in
connection with the service or repair work.
2. Be especially careful when you do maintenance work in abnor‐
mal conditions that require special working methods, for exam‐
ple, replacing the hoist ropes.
3. Before starting off, make sure that nobody is standing in front
or behind the RTG.
4. Avoid sudden stops and starts.
5. Always perform the maintenance and repair work according to
the instructions given.
6. By observing a danger spot, immediately report to the person
responsible for safety.
7. The machine must not be handed over for operation, until the
observed faults and damages have been repaired.
8. Observe the signs and instructions indicating free height. You
should know the exact total height of your RTG before driving
into places with restricted free height. Be especially careful with
temporary structures, hanging overhead power lines, etc.
Watch out also for objects at cabin height.
9. You may perform the service and repair work only in compli‐
ance with your actual qualification.
10. Don’t try to guess! Maybe you make a wrong guess, causing a
possible danger to yourself and the other personnel.
11. If necessary, consult a person being aware of how to proceed.
12. When servicing pressurized systems, proceed very carefully.
Non-discharged energy sources always are hazardous.
13. Follow unconditionally the instructions given.
14. If it is necessary to remove protective guards during the serv‐
ice, place warning signs and take other measures to protect
other persons from danger.
15. When changing driving direction, stop the carrier completely
with the service brake before moving the direction selector
lever.
16. Watch out for the edges of driveways where the surface may
be yielding and cause the danger of overturning.
17. Remember that the RTG is not intended for carrying persons.
18. Always stop the engines whenever you leave the RTG even for
a short while. Lower any load to the ground.
19. Make a detailed report on any collisions, including the damage
caused. This could prevent accidents from being repeated.
20. Observe the weight of your RTG , and its total weight loaded.
Do not drive on surfaces with insufficient load capacity.
21. If starting spray is used to aid cold-starting, strictly follow the
instructions on the use of these aerosols given later in this
manual.
22. Follow the periodic maintenance schedule. This ensures that
the controls and the whole RTG operate reliably and safely.
23. The engines must always be stopped when service or inspec‐
tions are being carried out.
24. The use of open flame is absolutely forbidden when checking
fuel or battery electrolyte levels.
Maintenance manual
208 001 EN
25. The radiator is pressurized when the coolant is hot - open the
radiator cap slowly and cautiously.
26. Hot exhaust pipe cause burns, extreme carefulness required.
27. Do not open the main switch when the engines are running.
28. Only authorized electricians can do maintenance for electrical
systems and open electrical boxes. Never do any maintenance
work when parts are live. Special carefulness with charged
components such as condensators of drive converters is
required.
29. Only a person that is well acquainted with the RTG’s control
and the cabin equipment is allowed to be in the cabin during
service and repairs.
30. Working with the hydraulic system: always have the system
turned off and main power cut off during maintenance work.
Use a pressure gauge to check that there is no residual pres‐
sure in the hydraulic system before starting work on the
hydraulics.
31. Driving is forbidden without fastened seat belts.
32. Never park the machine on a inclined plane.
Instructions for using shore supply (if equipped)

General
When using shore supply, the following equipment operates when
the PLC main switch is off:
• Sockets (direct feed)

• All heaters (electrical housings, motors, generators, main die‐
sel, the radiator of the electrical compartment, the radiator in
the cabin) (direct feed)
• Battery charger (direct feed)
• Air conditioning in the cabin and the electrical compartment
(direct feed if the frequency of the machine and the shore sup‐
ply is the same)
• The lights in the equipment compartments (feed through the
light switches)
• Winch (direct feed to the winch main switch)
When using shore supply, the following equipment operates when

the PLC main switch is on:
• Cabin fans (automatically turns the radiator off - control with

the touch panel)
• All walkway lights (control with the touch panel or the push but‐
tons of the power unit and the rear frame)
CAUTION
Always use shore supply when RTG is not in use. If shore supply is
not used, the air conditioning devices do not operate and the electri‐
cal devices may get wet and damaged.
Always close the equipment compartments' doors when using shore
supply.
Maintenance manual
208 001 EN
DANGER
Danger when shore supply is on. High voltage 230V/ 400V is on
(gantry motors, trolley motor, hoist motor).
Maintenance manual
208 001 EN
1
Table of content
C Preventive maintenance 3
For the service personnel 3
Maintenance tables 5
Scheduled maintenance 12
Maintenance manual
208 001 EN
2
Maintenance manual
208 001 EN
C Preventive maintenance – For the service personnel 3
C Preventive
maintenance
General
Follow our maintenance programme carefully to ensure that the
operational safety and reliability of the machine are maintained at
the intended level.
The maintenance programme specifies the inspection and mainte‐
nance procedures as follows:
• Daily checks
• Visual/operating checks
• Scheduled maintenance
IMPORTANT
Maintenance and adjustment procedures must be carried out by pro‐
fessional and trained personnel only.
To meet the terms and conditions of the warranty agreement, use
only recommended fluids and original equipment and spare parts
available from our spare parts department.
Following the maintenance programme defined in this maintenance
manual is a prerequisite for maintaining the machine warranty.
For the service personnel
General
The maintenance instructions provide the service personnel with
information about the mechanisms and maintenance items of the
machine as well as guidelines for safe maintenance.
Familiarise yourself with the operation of the machine, the mainte‐
nance programme, maintenance items, and work instructions.
Always follow the maintenance instructions.
For regular maintenance, use the oils, greases, and fluids specified
later in this manual and the filters and other service parts available
from our spare parts department.
Absolute cleanliness should be observed especially during the regu‐
lar maintenance of the hydraulic and fuel systems to ensure the reli‐
able operation of the machine.
Work premises
Perform the maintenance in clean premises to prevent impurities
from entering the devices on the machine. Protect the premises
against dust from the environment; for example, if sand and metal
particles enter the oil and other fluid systems of the devices, severe
damage will be caused to the devices.
Maintenance manual
208 001 EN
4 C Preventive maintenance – For the service personnel
Ensure that maintenance can be performed without compromising

occupational safety.
Ensure that the used oils, greases, and fluids are delivered to a haz‐
ardous waste collection point in accordance with the applicable
instructions.
Reporting
Carefully document the maintenance procedures performed, writing
down any defects detected and repairs made.
If you notice any defects, immediately inform your supervisor or the
person responsible for the maintenance of the machine. The defects
must be repaired before continuing to use the machine.
Store the reports carefully so that they are easily available when
needed.
Maintenance manual
208 001 EN
C Preventive maintenance – Maintenance tables 5
Maintenance tables
Reading instructions for maintenance tables
IMPORTANT
Following applies when only power source for the crane is a diesel
generator:
• All service intervals are based on operating hours of main diesel

engine. For operating hours, see “Main diesel hours” counter on
the power unit.
Following applies when the crane is powered by external power sup‐

ply (Zero emission RTG):
• Service intervals, other than for engine, are based on operating

hours while the crane has been powered either by external
power supply or by diesel generator. For operating hours, use
the sum of “Supply hours” and “Generator hours” counters in the
EE-House.
• Service intervals for engine are based on operating hours of
main diesel engine. For operating hours, see “Generator hours”
counter in the EE-House.
Initial maintenance
Maintenance of a new machine during the first 500 hours of opera‐
tion.
For reading instructions, see chapter Reading instructions for main‐
tenance tables.
Maintenance manual
208 001 EN
6 C Preventive maintenance – Maintenance tables
Maintenance item Service interval / hours of operation Reference
1 Engine
Checking the condition and tension of After first 250 operating hours.
drive belts of auxiliary diesel Replace the belt if it has unacceptable
cracks, is frayed, or has pieces of
material missing.
Checking the radiator condition of After first 250 operating hours.

auxiliary diesel
3 Driveline / Axle
Changing oil of the wheel hubs (driven After first 100 operating hours. Chapter 3, section 3.3 Driven wheel
and nondriven wheels)
Changing oil of driven axle assembly, After first 100 operating hours. Chapter 3, section 3.3 Driven wheel
wheel hub planetary gear drive,
interaxle differential, wheel bearing
NOTE
Only 16 wheel RTG
Changing oil of non-driven axle After first 100 operating hours. Chapter 3, section 3.4 Non-driven
assembly wheel
NOTE
Only 16 wheel RTG
4 Brakes
Changing oil of hydraulic power unit for 3 months after commissioning of the Appendixes, section Emergency hoist
the emergency hoist brake crane. brake
7 Load handling
Checking the chain tension of After first 300 operating hours. Tighten Bromma spreader manual
spreader if needed.
Checking the operation of twistlocks of After first 100 operating hours. Tighten Bromma spreader manual
spreader the twistlocks if needed.
Lubrication of spreader Lubricate and check the various points Bromma spreader manual
as per the lubrication instructions after
first 50 and 300 operating hours.
Changing the pressure filter(s) of After first 500 operating hours. Appendixes, section Spreader
spreader's hydraulic unit hydraulic unit
Maintenance manual
208 001 EN
Changing the return filter(s) of After first 500 operating hours. Appendixes, section Spreader
Changing the air filter(s) of spreader's After first 500 operating hours. Appendixes, section Spreader
hydraulic unit hydraulic unit
Checking during operation of the hoist After first 500 operating hours.
motor that specified technical data are
met (power input, temperatures of
windings, bearings, coolants, etc.)
Checking during operation of the hoist After first 500 operating hours.
motor that running smoothness of
machine and running noise of bearings
have not deteriorated
Checking during standstill of the hoist After first 500 operating hours.
motor that no subsidence or cracks
have occurred in the foundation
Checking the hoist motor's cables and After first 500 operating hours.
insulating parts (as far as accessible)
are in proper condition and show no
signs of discolouration
Changing oil of the trim gear After first 100 operating hours. Chapter 7, section 7.2 Lifting/lowering
Cleaning the trim gear housing After first 100 operating hours.
11 Common electrics
Checking visually and mechanically During the first eight weeks: Check Chapter 11, section 11.5 Distribution
the condition of the cable carrier every two weeks of electricity
chains
Checking visually the energy chain for During the first eight weeks: Check Chapter 11, section 11.5 Distribution
foreign particles and dirt every two weeks of electricity
the connection elements every two weeks of electricity
the cable length and condition and the every two weeks of electricity
strain reliefs
the moving arm and the driver sledge every two weeks of electricity
the guiding channel every two weeks of electricity
Maintenance manual
208 001 EN
Changing oil of the cable reel gear After first 100 operating hours Appendixes, Cable reel
Zero emission RTG
Daily checks
WARNING
Never operate a defective machine.
If any defects are found during daily inspections, report the defects
immediately to your superior or those responsible for the machine's
maintenance.
Daily check of the machine is extremely important to ensure efficient

and safe operation.
It is recommended that the operator or the person responsible for
the maintenance of the machine carry out the inspections before
each shift. This way it can be ensured that work does not com‐
mence with a defective machine.
For reading instructions, see chapter Reading instructions for main‐
tenance tables.
Maintenance manual
208 001 EN
Item Inspection method Note Reference
General
Oil and fluid leaks Visually
1 Engine
Oil level Dipstick Chapter 1, section 1.8

Lubrication
Coolant level Visually Chapter 1, section1.7

Cooling system
Air filter Visually The filter must be changed if Chapter 1, section 1.6 Air
the clog warning indicator intake/exhaust outlet
shows completely red.
Fuel prefilter/water Visually Remove water if necessary. Chapter 1, section 1.2 Fuel
separator system
Condition and tension of Visually Replace the belt if it has

drive belts unacceptable cracks, is
frayed, or has pieces of
material missing.
Leakage of charge air pipe Visually/audio check Chapter 1, section 1.6 Air
intake/exhaust outlet
Shields and doors Visually
• Closed and locked

correctly
Coolant level of auxiliary Visually

diesel
Supply and fuel level of Visually

auxiliary diesel
Oil level of auxiliary diesel Dipstick
Condition and tension of Visually Every 250 operating hours.

drive belts of auxiliary diesel Replace the belt if it has
unacceptable cracks, is
frayed, or has pieces of
material missing.
Radiator condition of Visually Every 250 operating hours.

auxiliary diesel
3 Driveline / Axle
Oil leaks Visually
Maintenance manual
208 001 EN
4 Brakes
Operation of gantry brakes Brake test immediately after

moving off.
Checking the condition of Sight glass. Change the oil if it contains

the oil in the hydraulic power water or other impurities.
unit of the emergency hoist
brake.
5 Steering
Operation of steering gear Visually
Oil leaks of steering gear Visually
6 Suspension
Wheel pressure and Visually

condition, wheel attachment
7 Load handling
Oil level of skew gear Sight glass
Oil leaks of skew gear Visually
Noise of skew gear Audio check
Oil level of trolley gear Sight glass
Oil leaks of trolley gear Visually
Oil temperature of trolley Visually

gear
Noise of trolley gear Audio check
Oil level of hoist gear Sight glass
Oil leaks of hoist gear Visually
Oil temperature of hoist gear Visually
Noise of hoist gear Audio check
Ropes for possible damage Visually

and change in shape
Spreader and lifting devices Visually
Position sensors of spreader Visually Clean if needed Bromma spreader manual
Maintenance manual
208 001 EN
Chain tension of spreader Visually Every 300 operating hours. Bromma spreader manual
Tighten if needed
Operation of twistlocks of Visually Every 100 operating hours. Bromma spreader manual
spreader Tighten the twistlocks if
needed
Oil level of hydraulic system Sight glass

of spreader
Oil temperature of hydraulic Visually

system of spreader
9 Frame, body, cab, and accessories
Controls, instruments, and Visually Operation check before and

indicator lights after starting the engine
Operation of flashing Visually or by listening

beacons and buzzers
Cleanness of cabin windows Visually Clean if required
11 Common electrics
Covers and doors of electric Visually

centres
• Closed and locked

correctly
Checking visually the Visually Chapter11 , secttion 11.5

energy chain for foreign Distribution of electricity
particles and dirt
Checking visually and Visually Chapter11 , secttion 11.5

mechanically of cable length Distribution of electricity
and condition and strain
reliefs
Checking visually and Visually Chapter11 , secttion 11.5

mechanically of guiding Distribution of electricity
channel
Oil level of the cable reel Sight glass Zero emission RTG Appendixes, section Cable
gear reel
Cleanliness of the breather Visually Zero emission RTG Appendixes, section Cable
plug or the vent hole of the reel
cable reel gear
Maintenance manual
208 001 EN
Oil leaks of the cable reel Visually Zero emission RTG

gear
Noise of the cable reel Audio check Zero emission RTG
Scheduled maintenance
General
Maintenance procedures to be performed every 500 hours of opera‐
tion: after 500 hours, 1000 hours, 1500 hours, etc.
Maintenance procedures to be performed every 1000 hours of oper‐
ation: after 1000 hours, 2000 hours, 3000 hours, etc.
The daily checks must also be performed during scheduled mainte‐
nance.
For reading instructions, see section Reading instructions for main‐
tenance tables.
Maintenance item Service interval / hours of operation Note Reference
500 1000 2000 4000
Checking for oil and fluid leaks x
Lubrication x Lubrication must

be performed
regularly avoiding
use of too much
lubricant at the
same time.
(Greasing: e.g.
Multipurpose
grease, Beacon
EP/2). Some
greasing points
have shorter
lubrication
intervals.
Service interval / 500 hours of operation
Maintenance item Note
Checking for oil and fluid leaks
Maintenance manual
208 001 EN
Lubrication Lubrication must be performed regularly avoiding use of too

much lubricant at the same time. (Greasing: e.g.
Multipurpose grease, Beacon EP/2). Some greasing points
have shorter lubrication intervals.
Lubrication Lubrication must be performed regularly avoiding use of too

much lubricant at the same time. (Greasing: e.g.
Multipurpose grease, Beacon EP/2). Some greasing points
have shorter lubrication intervals.
Maintenance manual
208 001 EN
Engine
Table
500 1000 2000 4000
Changing oil Chapter 1, section1.8

x
Lubrication
Replacing the oil filter(s) x Chapter 1, section1.8

Lubrication
Replacing the fuel filter(s) x Chapter 1, section 1.2 Fuel

system
Cleaning the fuel filter(s) (if x Chapter 1, section 1.2 Fuel

using Spin- On Type) system
Empty dust collector of air filter x Chapter 1, section 1.6 Air

Changing coolant filter(s), if in x Chapter 1, section 1.7 Cooling

use system
Cleaning breather tube x Chapter 1, section 1.6 Air

Checking the fan hub bearing x Chapter 1, section 1.6 Air

clearance intake/exhaust outlet
Inspection of the vibration x Chapter 1, section 1.6 Air

damper mounting intake/exhaust outlet
Adjusting valves and injectors x Chapter 1,section 1.5

Mechanical parts
Changing air filters (2 pcs) x Chapter 1, section 1.6 Air

when red indicator flag is at intake/exhaust outlet
the raised position
Steam cleaning of engine x
Inspection of turbo charger x
Inspection of idler pulley x

assembly of the engine
Inspection of water pump of x

the engine
Replacing the fuel filter x Appendixes, section Auxiliary

element of auxiliary diesel power unit
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking the air induction x Appendixes, section Auxiliary

system of auxiliary diesel power unit
for leaks, damage and
restrictions
Replacing the air cleaner x Appendixes, section Auxiliary

element of auxiliary diesel power unit
Checking the external nuts, x Appendixes, section Auxiliary

bolts and unions of auxiliary power unit
diesel for tightness
Draining and cleaning the x Appendixes, section Auxiliary

engine mounted fuel tank of power unit
auxiliary diesel
Checking the free movement x Appendixes, section Auxiliary

of the engine and speed power unit
controls of auxiliary diesel
Cleaning and checking, or x Appendixes, section Auxiliary

replacing, the fuel injector power unit
nozzles of auxiliary diesel
Replacing the fan drive belt of x Appendixes, section Auxiliary

auxiliary diesel power unit
Checking the oil pressure of x Appendixes, section Auxiliary

auxiliary diesel power unit
Replacing the oil filter and oil x At least once a Appendixes, section Auxiliary
of auxiliary diesel year. power unit
Flushing the cooling system of x At least once a Appendixes, section Auxiliary

auxiliary diesel year. power unit
Maintenance manual
208 001 EN
Changing oil
Replacing the oil filter(s)
Replacing the fuel filter element of auxiliary diesel
Checking the air induction system of auxiliary diesel for

leaks, damage and restrictions
Replacing the air cleaner element of auxiliary diesel
Changing oil
Replacing the fuel filter(s)
Cleaning the fuel filter(s) (if using Spin-On Type)
Empty dust collector of air filter
Changing coolant filter(s), if in use

Checking the external nuts, bolts and unions of auxiliary

Maintenance manual
208 001 EN
Changing oil
Cleaning fuel filter(s) (if using Spin-On Type)
Cleaning breather tube
Checking the fan hub bearing clearance
Inspection of the vibration damper mounting
Adjusting valves and injectors


Draining and cleaning the engine mounted fuel tank of

auxiliary diesel
Checking the free movement of the engine and speed

Cleaning and checking, or replacing, the fuel injector

Replacing the fan drive belt of auxiliary diesel
Checking the oil pressure of auxiliary diesel
Maintenance manual
208 001 EN
Changing oil
Cleaning fuel filter(s) (if using Spin-On Type)
Cleaning breather tube
Checking the fan hub bearing clearance
Changing air filters (2 pcs) when red indicator flag is at the

raised position
Inspection of the vibration damper mounting
Changing coolant and flushing cooling system
Adjusting valves and injectors
Steam cleaning of engine
Inspection of turbo charger
Inspection of idler pulley assembly of the engine
Inspection of water pump of the engine


Draining and cleaning the engine mounted fuel tank of

auxiliary diesel
Checking the free movement of the engine and speed

Cleaning and checking, or replacing, the fuel injector

Maintenance manual
208 001 EN
Replacing the fan drive belt of auxiliary diesel
Checking the oil pressure of auxiliary diesel
Replacing the oil filter and oil of auxiliary diesel At least once a year.
Flushing the cooling system of auxiliary diesel At least once a year.
Maintenance manual
208 001 EN
Driveline / Axle
Table
500 1000 2000 4000
Checking the oil level of wheel x Chapter 3, section 3.3 Driven

hubs wheel and 3.4 Non-driven wheel
Lubrication of the cardan shaft x Chapter 3, section 3.3 Driven

and lower bearing wheel
Adjusting of wheel bearings x Chapter 3, section 3.3 Driven

wheel
Lubrication of bearings of the x Chapter 3, section 3.3 Driven

gantry brake motor wheel
Checking the tightness of all x At least

fixing bolts of mechanical and once a
electrical joints of the gantry year.
brake motor
Greasing of bearing housing, x Chapter 3, section 3.4 Non-driven

vertical axle, pivot axle, steering wheel
cylinder and arm, ball head,
pinion bearing
NOTE
Only 16 wheel RTG
Changing oil of driven axle x Chapter 3, section 3.3 Driven

assembly, wheel hub planetary wheel
gear drive, interaxle differential,
wheel bearing
NOTE
Only 16 wheel RTG
Changing oil of non-driven axle x Chapter 3, section 3.4 Non-driven

assembly wheel
NOTE
Only 16 wheel RTG
Maintenance manual
208 001 EN
Checking the oil level of wheel hubs
Lubrication of the cardan shaft and lower bearing
Greasing of bearing housing, vertical axle, pivot axle,

steering cylinder and arm, ball head, pinion bearing
NOTE
Only 16 wheel RTG
Maintenance manual
208 001 EN
Lubrication of the cardan shaft and lower bearing
Changing oil of the wheel hubs (driven and non-driven

wheels)
Adjusting of wheel bearings
Changing oil of driven axle assembly, wheel hub planetary

gear drive, interaxle differential, wheel bearing
NOTE
Only 16 wheel RTG
Changing oil of non-driven axle assembly
NOTE
Only 16 wheel RTG
Greasing of bearing housing, vertical axle, pivot axle,

steering cylinder and arm, ball head, pinion bearing
NOTE
Only 16 wheel RTG
Lubrication of bearings of the gantry brake motor
Checking the tightness of all fixing bolts of mechanical and At least once a year.
electrical joints of the gantry brake motor
Maintenance manual
208 001 EN
Brakes
Table
500 1000 2000 4000
Checking the air gap of the x Adjust if needed. Chapter 4, section 4.3. Service
gantry brake brake system
Checking the hoist brake x Chapter 4, section 4.3. Service

alignment brake system
Checking the air gap between x Chapter 4, section 4.3. Service

brake pads and brake disc brake system
(brake shoe lift-off) of the hoist
brake
Checking the lining wear / x Chapter 4, section 4.3. Service

lining thickness of the hoist brake system
brake
Checking the condition of the x Chapter 4, section 4.3. Service

hoist brake disc brake system
Checking the reserve stroke of x Chapter 4, section 4.3. Service

the hoist brake thruster brake system
Checking the braking torque of x Chapter 4, section 4.3. Service

the hoist brake brake system
Checking the adjustment of x Chapter 4, section 4.3. Service

limit switches and manual brake system
release devices of the hoist
brake
Checking the wear of the x Chapter 4, section 4.3. Service

automatic wear compensator brake system
of the hoist brake
Checking the operation of the x Chapter 4, section 4.3. Service

hoist brake/ brake system brake system
Dynamic hoist brake test x Or once a year, Chapter 4, section 4.3. Service
whichever brake system
comes first.
Static hoist brake test for x Or once a year, Chapter 4, section 4.3. Service
system with two hoist brakes whichever brake system
comes first.
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking the hoist brake/

brake system outside the
regular inspection intervals if:
• Prolonged braking times

or braking distances
appear
• Extreme operating
conditions appear:
Overspeeding of the
brake disc.
And/or excessive braking
times.
• A limit switch indicates
lining wear or lack of
releasing stroke
• After a longer period of
brake-standstill or drive
standstill
• After hoist emergency
stop
Checking the emergency hoist x

brake hydraulic system for
leakages
Checking the operating x Chapter 4, section 4.3. Service

pressure of the emergency brake system
hoist brake
Checking the oil level in the x Chapter 4, section 4.3. Service

hydraulic unit of the brake system
emergency hoist brake
Checking visually the condition x

of the emergency hoist brake
Checking the air gap between x Chapter 4, section 4.3. Service

brake pads and brake disc brake system
(release stroke) of the
Checking the lining wear / x Chapter 4, section 4.3. Service

lining thickness of the brake system
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking the condition of the x Chapter 4, section 4.3. Service

emergency hoist brake disc brake system
Checking the adjustment of x Chapter 4, section 4.3. Service

limit switch of the emergency brake system
hoist brake
Changing oil in the hydraulic x Or once a year, Appendixes, section

unit of the emergency hoist whichever Emergency hoist brake
brake comes first.
Bleeding the emergency hoist x Appendixes, section

brake system Emergency hoist brake
Checking the emergency hoist

brake/ brake system outside
the regular inspection intervals
if:
• Prolonged braking times

or braking distances
appear
• Extreme operating
conditions appear:
Overspeeding of the
brake disc.
And/or excessive braking
times.
• A limit switch indicates
lining wear or lack of
releasing stroke
• After a longer period of
brake-standstill or drive
standstill
• Any leaks appear
• After hoist emergency
stop
Inspection and maintenance of x Chapter 4, section 4.3. Service

the skew brake brake system
skew brake brake system
steering brake brake system
Maintenance manual
208 001 EN
500 1000 2000 4000

brake of the steering gear brake system
brake motor
trolley brake brake system

the trim brake brake system
Checking the air gap of the x If the brake Chapter 4, section 4.3. Service
trim brake micro switch brake system
sends an alarm
to the display
panel in the
cabin, the brake
must be
checked and
possibly
adjusted, or the
brake pads must
be replaced.
Brake pad
clearance
=0.3mm.
NOTE
The micro
switch
disables the
operation of
the brakes
when the
clearance
has
increased
2.5-fold
=0.75mm.
Checking the air gap of the x Zero emission Appendixes, section

cable reel brake RTG. Emergency hoist brake
Checking the friction lining x Zero emission Appendixes, section

medium of the cable reel brake RTG. Emergency hoist brake
Checking the torque of the x Zero emission Appendixes, section

cable reel brake RTG. Emergency hoist brake
Maintenance manual
208 001 EN
Checking the emergency hoist brake hydraulic system for

leakages
Checking the operating pressure of the emergency hoist

brake
Checking the oil level in the hydraulic unit of the emergency

hoist brake
Maintenance manual
208 001 EN
Checking the air gap of the gantry brake Adjust if needed.
Checking the hoist brake alignment
Checking the air gap between brake pads and brake disc
(brake shoe lift-off) of the hoist brake
Checking the lining wear / lining thickness of the hoist brake
Checking the condition of the hoist brake disc
Checking the reserve stroke of the hoist brake thruster
Checking the braking torque of the hoist brake
Checking the adjustment of limit switches and manual

release devices of the hoist brake
Checking the wear of the automatic wear compensator of

the hoist brake
Checking the operation of the hoist brake / brake system

leakages

brake

hoist brake
Checking visually the condition of the emergency hoist

brake
(release stroke) of the emergency hoist brake
Checking the lining wear / lining thickness of the

Checking the condition of the emergency hoist brake disc
Checking the adjustment of limit switch of the emergency

hoist brake
Checking the air gap of the cable reel brake Zero emission RTG
Checking the friction lining medium of the cable reel brake Zero emission RTG
Maintenance manual
208 001 EN
Checking the torque of the cable reel brake Zero emission RTG
Maintenance manual
208 001 EN


the hoist brake

leakages

brake

hoist brake

brake


hoist brake
Changing oil in the hydraulic unit of the emergency hoist

brake
Maintenance manual
208 001 EN
Bleeding the emergency hoist brake system
Inspection and maintenance of the skew brake
Checking the air gap of the cable reel brake Zero emission RTG
Checking the friction lining medium of the cable reel brake Zero emission RTG
Checking the torque of the cable reel brake Zero emission RTG
Maintenance manual
208 001 EN


the hoist brake
Dynamic hoist brake test
Static hoist brake test for system with two hoist brakes

leakages

brake

hoist brake

brake


hoist brake
Maintenance manual
208 001 EN
Changing oil in the hydraulic unit of the emergency hoist

brake
Bleeding the emergency hoist brake system
Inspection and maintenance of the skew brake
Checking the air gap of the skew brake Adjust if needed.
Checking the air gap of the steering brake Adjust if needed.
Inspection and maintenance of brake of the steering gear

brake motor
Checking the air gap of the trolley brake Adjust if needed.
Inspection and maintenance of the trim brake
Maintenance manual
208 001 EN
Steering
Table
500 1000 2000 4000
Checking during operation of x

the gantry brake motor that
running smoothness of
machine and running noise of
bearings have not deteriorated
Checking during standstill that x

no subsidence or cracks have
occurred in the foundation of
the gantry brake motor
Checking steering gear for x Chapter 5, section 5.2 Power

leakage assisted system
Checking oil level of steering x Chapter 5, section 5.2 Power

gear assisted system
Changing oil of the steering x Chapter 5, section 5.2 Power

gear assisted system
Cleaning of steering gear x

housing
Cleaning of breather plug of x

steering gear
Checking fixing screws for x At least once a Chapter 5, section 5.2 Power
tightness of the steering gear year. assisted system
brake motor
Checking during operation of the gantry brake motor that

running smoothness of machine and running noise of
Checking during standstill that no subsidence or cracks

have occurred in the foundation of the gantry brake motor
Maintenance manual
208 001 EN
Checking during operation of the gantry brake motor that

running smoothness of machine and running noise of

have occurred in the foundation of the gantry brake motor
Checking steering gear for leakage
Checking oil level of steering gear
Changing oil of the steering gear
Cleaning of steering gear housing
Cleaning of breather plug of steering gear
Checking fixing screws for tightness of the steering gear At least once a year.
brake motor
Suspension
Table
500 1000 2000 4000
Checking the wheel nuts x Chapter 6, section 6.3 Tyres

tightening torque and rims
Checking the condition of the x At least once a

outer shell of wheel rim year.
Checking the wheel nuts tightening torque
Maintenance manual
208 001 EN
Checking the condition of the outer shell of wheel rim At least once a year.
Maintenance manual
208 001 EN
Load handling
Table
500 1000 2000 4000
Cleaning vent plug of trolley x

gear
Lubricating seals of trolley x

gear
Cleaning grease nipples of x

trolley gear
Checking trolley gear unit for x

leakage
Checking the tightness of x

fixing screws of cardan shaft of
the trolley gear
Changing oil of trolley gear x Chapter 7, section 7.4 Side

movement
Cleaning the trolley gear x

housing
Lubrication of bearings of x Chapter 7, section 7.2 Lifting/

trolley motor lowering
Cleaning the breather plug of x

the hoist gear
Changing oil of hoist gear x Chapter 7, section 7.4 Side

movement
Cleaning the hoist gear x

housing
Checking fixing screws for x

tightness of hoist gear
Lubrication of seals and x Chapter 7, section 7.4 Side

cleaning of grease nipples of movement
the hoist gear

the hoist motor that specified
technical data are met (power
input, temperatures of
windings, bearings, coolants,
etc.)
Maintenance manual
208 001 EN
500 1000 2000 4000

the hoist motor that running
smoothness of machine and
running noise of bearings have
not deteriorated
Checking during standstill of x

the hoist motor that no
subsidence or cracks have
occurred in the foundation
Lubricating the bearings of x Chapter 7, section 7.2 Lifting/

hoist motor lowering

fixing bolts of mechanical and
electrical joints of hoist motor
Checking the alignment of x Chapter 7, section 7.2 Lifting/

hoist machinery lowering
Checking the hoist motor's x

insulation resistance of
windings is satisfactory
Checking that no bearing x

insulation is short-circuited in
the hoist motor
Checking the hoist motor's x

cables and insulating parts (as
far as accessible) are in proper
condition and show no signs of
discolouration
Greasing the hoist ropes x Depending on

climatic
conditions, rope
lubrication
interval may be
extended to 2
months. Spread
mineral oil
(Engine oil 10W/
Diesel oil
CD10W) with a
brush.
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking the ropes at full x

length paying special attention
to the following: terminal
points; section that goes over
the pulley; section straight
above the balancing wheel.

the trolley motor that running
smoothness of machine and
running noise of bearings have
not deteriorated
Checking during standstill that x

no subsidence or cracks have
occurred in the foundation of
the trolley motor

fixing bolts of mechanical and
electrical joints of the trolley
motor
Tightening of the most x Chapter 7, section 7.2 Lifting/

important screws and bolts lowering
Checking the oil level of the x Chapter 7, section 7.4 Side

skew gear movement
Changing oil of the skew gear x At least every 6 Chapter 7, section 7.4 Side
years. movement
Checking the skew gear for x Chapter 7, section 7.4 Side

leakage movement
Lubrication of the skew geared x Chapter 7, section 7.4 Side

brake motor movement
Checking fixing screws for x At least once a

tightness of skew geared year.
brake motor
Checking the condition of x Change

bearings of skew geared brake bearings every 6
motor years if needed.
Checking the length of chain of x Chapter 7, section 7.4 Side

skew movement
Cleaning the skew gear x

housing
Maintenance manual
208 001 EN
500 1000 2000 4000

the skew gear
Checking the trim gear for x Chapter 7, section 7.2 Lifting/

leakage lowering
Checking the operation of trim x At least once a

gear year.
Checking the oil level of trim x Chapter 7, section 7.2 Lifting/

gear lowering
Lubrication of the trim geared x Chapter 7, section 7.2 Lifting/

brake motor lowering
Changing oil of trim gear x Chapter 7, section 7.2 Lifting/

lowering
Checking the operation of x Chapter 7, section 7.2 Lifting/

sensors for trim turning lowering
Checking the tightness of x At least once a Chapter 7, section 7.2 Lifting/

fixing screws of trim device year. lowering
Cleaning the trim gear housing x

trim gear
Checking the condition of the x Bromma spreader manual

glide plates of spreader
Replacing the pins and x Bromma spreader manual

spherical washers of the
twistlocks of spreader
Checking the gears of the x Bromma spreader manual

telescoping system of
spreader
Inspection of the twistlocks of x Chapter 7, section 7.2 Lifting/

headblock using liquid lowering
penetrant or magnetic particle
examination
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking the spreader's x At least once a Bromma spreader manual

twistlock nut and the floating year.
mechanism and ensure that all
parts are properly tightened
down
Checking that the spreader's x At least once a Bromma spreader manual

twistlock pin can be moved year.
easily and it indicates the
correct position
Lubrication of spreader x Bromma spreader manual
Dismantle, inspect and x Bromma spreader manual

perform crack detection of the
spreader
Replacing the glide plates of x Minimum Bromma spreader manual

the spreader thickness 17
mm.
Checking the chain elongation x Renew chain Bromma spreader manual

of the spreader and gears when
max trimming
allowance is
achieved.
Checking the nitrogen x Appendixes, section Spreader

pressure in the spreader's hydraulic unit
hydraulic accumulators
Adjustment of pressure in the x Appendixes, section Spreader

spreader's hydraulic system hydraulic unit
Changing hydraulic oil of x Appendixes, section Spreader

spreader's hydraulic system hydraulic unit
Cleaning the housing of x Appendixes, section Spreader

Changing the return filter(s) of x Appendixes, section Spreader

Changing the pressure filter(s) x Appendixes, section Spreader

of spreader's hydraulic unit hydraulic unit
Changing the air filter(s) of x Appendixes, section Spreader

Maintenance manual
208 001 EN
500 1000 2000 4000
Cleaning the breather plug of x Appendixes, section Spreader

Checking the trolley frame x At least once a

weldings year.
Cleaning vent plug of trolley gear
Lubricating seals of trolley gear
Cleaning grease nipples of trolley gear
Lubrication of the skew geared brake motor
Cleaning the breather plug of the hoist gear
Greasing the hoist ropes Depending on climatic conditions, rope lubrication interval
may be extended to 2 months. Spread mineral oil (Engine
oil 10W / Diesel oil CD10W) with a brush.
Checking the ropes at full length paying special attention to

the following: terminal points; section that goes over the
pulley; section straight above the balancing wheel.
Checking the condition of the glide plates of spreader
Lubrication of spreader
Changing the return filter(s) of spreader's hydraulic unit
Changing the pressure filter(s) of spreader's hydraulic unit
Changing the air filter(s) of spreader's hydraulic unit
Cleaning the breather plug of spreader's hydraulic unit
Maintenance manual
208 001 EN
Checking trolley gear unit for leakage
Lubrication of bearings of trolley motor
Checking during operation of the trolley motor that running

smoothness of machine and running noise of bearings have
not deteriorated

have occurred in the foundation of the trolley motor
Lubrication of seals and cleaning of grease nipples of the

hoist gear

Checking the tightness of fixing screws of cardan shaft of

the trolley gear
Lubrication of the trim geared brake motor
Checking during operation of the hoist motor that specified

technical data are met (power input, temperatures of
Checking during operation of the hoist motor that running

not deteriorated
Checking during standstill of the hoist motor that no

subsidence or cracks have occurred in the foundation
Dismantle, inspect and perform crack detection of the

spreader
Maintenance manual
208 001 EN
Replacing the glide plates of the spreader Minimum thickness 17mm.
Checking the chain elongation of the spreader Renew chain and gears when max trimming allowance is
achieved.
Tightening of the most important screws and bolts
Maintenance manual
208 001 EN
Checking trolley gear for leakage
Changing oil of trolley gear
Cleaning the trolley gear housing
Lubrication of bearings of trolley motor
Checking the oil level of the skew gear
Changing oil of the skew gear At least every 6 years.
Checking the skew gear for leakage
Checking fixing screws for tightness of skew geared brake At least once a year.
motor
Checking the condition of bearings of skew geared brake Change bearings every 6 years if needed.
motor
Checking the length of chain of skew
Cleaning the skew gear housing
Cleaning the breather plug of the skew gear
Lubricating the bearings of hoist motor
Checking the alignment of hoist machinery
Checking the tightness of fixing bolts of mechanical and

electrical joints of hoist motor
Checking that the hoist motor's insulation resistance of

windings is satisfactory
Checking that no bearing insulation is short-circuited in the

hoist motor
Checking the hoist motor's cables and insulating parts (as

far as accessible) are in proper condition and show no
signs of discolouration
Maintenance manual
208 001 EN
Checking during operation of the hoist motor that specified

technical data are met (power input, temperatures of
Checking during operation of the hoist motor that running

not deteriorated
Checking during standstill of the hoist motor that no

subsidence or cracks have occurred in the foundation
Checking during operation of the trolley motor that running

not deteriorated

have occurred in the foundation of the trolley motor
Checking the tightness of fixing bolts of mechanical and

electrical joints of the trolley motor
Lubrication of seals and cleaning the grease nipples of the

hoist gear
Changing oil of hoist gear
Cleaning the hoist gear housing
Checking fixing screws for tightness of hoist gear

Checking the tightness of fixing screws of cardan shaft of

trolley gear
Checking the trim gear for leakage
Checking the operation of trim gear At least once a year.
Checking the oil level of trim gear
Changing oil of trim gear
Maintenance manual
208 001 EN
Checking the operation of sensors for trim turning
Checking the tightness of fixing screws of trim device At least once a year.
Lubrication of the trim geared brake motor
Cleaning the trim gear housing
Cleaning the breather plug of trim gear
Dismantle, inspect and perform crack detection of the

spreader
Checking the condition of the glide plates of spreader
Replacing the glide plates of the spreader
Checking the chain elongation of the spreader Renew chain and gears when max trimming allowance is
achieved.
Replacing the pins and spherical washers of the twistlocks

of spreader
Checking the gears of the telescoping system of spreader
Inspection of the twistlocks of headblock using liquid

penetrant or magnetic particle examination
Checking the spreader's twistlock nut and the floating At least once a year.
mechanism and ensure that all parts are properly tightened
down
Checking that the spreader's twistlock pin can be moved At least once a year.
easily and it indicates the correct position
Calibrate load cells using the touch panel (if E-One2). At least once a year or after changing the ropes.
Checking the nitrogen pressure in the spreader's hydraulic

accumulators
Maintenance manual
208 001 EN
Adjustment of pressure in the spreader's hydraulic system
Changing hydraulic oil of spreader's hydraulic system
Cleaning the housing of spreader's hydraulic unit
Tightening of the most important screws and bolts
Checking the trolley frame weldings At least once a year.
Maintenance manual
208 001 EN
Frame, body, cab and accessories
Table
500 1000 2000 4000
Cleaning and checking the x Cleaning and Chapter 9, section 9.2 Safety
condition of the anemometer inspection and emergency equipment
should be done
every 500 hours
or depending on
climate
conditions every
three months.
Checking all weldings of the x At least once a Chapter 9, section 9.12 Frame
main crossbeams from the year.
centre to distance of 3.5m
including run rails
Checking the weldings of the x At least once a

flange of the pivot arm year.
Checking the weldings of the x At least once a Chapter 9, section 9.12 Frame
lower end of the vertical year.
column to height of 3 m from
the sill beam
Checking and tighten the bolt x At least once a Chapter 9, section 9.12 Frame
and screw connections year.
Checking tightness and Every 3000 Chapter 9, section 9.12 Frame

condition of frame joint bolts hours of
operation, at
least once a
year.
Checking PLC wiring in x PLC wiring’s

driver’s cabin fastening should
be checked
twice a year
from the hole
under the seat.
Seat can be
tilted by opening
locking bolts at
the front of the
base of the seat.
Cleaning the machine exterior At least once in

thoroughly with pressure 6 months.
washer to remove dust, salt
and other impurities from the
structures.
Maintenance manual
208 001 EN
500 1000 2000 4000
Inspecting visually the paint At least once in Appendixes, section Touch-up

condition for cracks, rust and 6 months. After repair painting
other damages. Inspection is every accident.
carried out for all painted
surfaces on the crane.
Damaged paint must be
immediately repaired by
properly cleaning and repair
painting the area according to
instructions in document
TO4158.
Cleaning and checking the condition of the anemometer Cleaning and inspection should be done every 500 hours or
depending on climate conditions every three months.
Maintenance manual
208 001 EN
Checking all weldings of the main crossbeams from the At least once a year.
centre to distance of 3.5m including run rails
Checking the weldings of the flange of the pivot arm At least once a year.
Checking the weldings of the lower end of the vertical At least once a year.
column to height of 3 m from the sill beam
Checking and tighten the bolt and screw connections At least once a year.
Checking PLC wiring in driver’s cabin PLC wiring’s fastening should be checked twice a year from
the hole under the seat. Seat can be tilted by opening
locking bolts at the front of the base of the seat.
Maintenance manual
208 001 EN
Common electrics
Table
500 1000 2000 4000
Checking the condition of the x

starting batteries

starting batteries of the
auxiliary diesel
Checking visually and x Chapter 11, section 11.5

mechanically the condition of Distribution of electricity
the cable carrier chains
Checking visually the energy x Chapter 11, section 11.5

chain for foreign particles and Distribution of electricity
dirt

mechanically the connection Distribution of electricity
elements

mechanically the cable length Distribution of electricity
and condition and the strain
reliefs

mechanically the moving arm Distribution of electricity
and the driver sledge

mechanically the guiding Distribution of electricity
channel
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking and cleaning cable x Appendixes, section Cable

reel slip ring bodies: reel
• Basic cleaning of the

complete slip ring body. NOTE
• Removal for humidity and
Danger of electric shock.
dust from the insulator
See chapter B Safety,
surfaces with a soft cloth
section Electric systems for
or a pencil.
safety instructions.
• Examination of the
insulators as to damage
or replacement.
• Examination or cleaning
of the ring sliding
surfaces on which the
current collectors are
running.
• Removal of enamel
beads, arcing spots or
oxidationen.
• Inspection of the current
collectors for wear or
replacement.
• Control of the fixing and
connecting screws for
tight fit.
Cleaning of the ring sliding

surfaces can be made with a
very fine abrasive paper.
Changing oil of the cable reel 10 000 hours of Appendixes, section Cable
gear operation or reel
every 3 years,
whichever
comes first.
Replacing the lubricating 20 000 hours of Appendixes, section Cable

grease of the cable reel motor operation. reel
Checking the temperature of x

the cable reel gear bearings
and oil sump (max. 80°C)
Checking the lubricating oil of x

the cable reel gear visually for
water content
Checking the drive gear of the x

cable reel for extraordinary
noise
Maintenance manual
208 001 EN
500 1000 2000 4000
Checking the breather of the x

cable reel gear for cleanliness
Checking the cable reel gear x

for oil leaks. Small oil leak
from the output shaft is
acceptable

power supply cable
Checking the condition of the starting batteries
Checking the condition of starting batteries of auxiliary

diesel
Checking visually and mechanically the condition of the

cable carrier chains
Checking visually and mechanically the connection

elements
Checking visually and mechanically the cable length and

condition and the strain reliefs
Maintenance manual
208 001 EN
Checking visually the energy chain for foreign particles and

dirt
Checking visually and mechanically the moving arm and

the driver sledge
Checking visually and mechanically the guiding channel
Checking and cleaning the slip ring bodies of the cable reel:
• Basic cleaning of the complete slip ring body. NOTE

• Removal of humidity and dust from the insulator
Danger of electric shock. See chapter B Safety, section
surfaces with a soft cloth or a pencil.
Electric systems for safety instructions.
• Examination of the insulators for damage or
replacement.
• Examination or cleaning of the ring sliding surfaces on
which the current collectors are running.
• Removal of enamel beads, arcing spots or oxidation.
• Inspection of the current collectors for wear or
replacement.
• Control of the fixing and connecting screws for tight fit.
Cleaning of the ring sliding surfaces can be made with a

Checking the temperature of the cable reel gear at bearings

Checking the lubricating oil of the cable reel gear visually

for water content
Checking the drive gear of the cable reel for extraordinary

noise
Checking the breather of the cable reel gear for cleanliness
Checking the cable reel gear for oil leaks. Small oil leak
from the output shaft is acceptable
Checking the condition of the power supply cable
Maintenance manual
208 001 EN
Checking the condition of the endpoints of the energy chain
Checking the condition of the strain reliefs of the energy

chain
Checking the wear of the energy chain
Checking the energy chain for obstructions
Checking the condition of the roller links of the energy chain
Checking the condition of the cables and hoses of the

energy chain
Checking the condition of troughs of the energy chain
Checking the operation of the moving arm of the energy

chain

replacement.
replacement.



for water content

noise
Maintenance manual
208 001 EN
Maintenance manual
208 001 EN
Checking the condition of the endpoints of the energy chain
Checking the condition of the strain reliefs of the energy

chain
Checking the wear of the energy chain
Checking the energy chain for obstructions
Checking the roller links of the energy chain
Checking the cables of the energy chain
Checking the troughs of the energy chain
Checking the moving arm of the energy chain
Checking if the residual current devices (RCD) function

properly by pressing the test buttons.

replacement.
replacement.



for water content

noise
Maintenance manual
208 001 EN
Technical data
Table
500 1000 2000 4000
Tighten mounting bolts x Chapter F Technical data
Tighten mounting bolts
Maintenance manual
208 001 EN
Maintenance manual
208 001 EN
1
Table of content
0 Complete machine 3
Maintenance manual
208 001 EN
2
Maintenance manual
208 001 EN
0 Complete machine – Troubleshooting without error code 3
0 Complete machine
Troubleshooting, general work
instructions
When troubleshooting, it is important to work in a structured and
logical manner. The person doing the troubleshooting must be very
familiar with the operation of the machine and its main components.
In order to be able to locate any malfunctions in the steering and
other systems, the person must be able to read the machine circuit
diagrams in a professional manner.
Follow the troubleshooting sequence indicated in the maintenance
manual to ensure that the condition of the components and systems
is checked systematically and any malfunctions are located without
delay.
When troubleshooting, it is important to understand how the
machine functions, as certain malfunctions can be identified directly
using function descriptions. The functions of the machine are descri‐
bed in chapters 1 Engine - 9 Frame.
Troubleshooting
1. Check that there is battery voltage available.
• Check that the fuses are intact.
2. Check that all oil and fluid levels are normal.
• Fuel
• Engine
• Gears
• Hubs
• Hydraulic, spreader
• Coolant
3. Check the error codes on the display.
4. If error codes are displayed, refer to the error code list. See
Troubleshooting with error code.
5. If no error codes are displayed, check the appropriate function
description in Chapters 1–9. See Troubleshooting without error
code .
Troubleshooting without error code

The function descriptions contain information about the components
that are involved in the function and how these components work
together. In certain cases, there is information about which condi‐
tions apply to enable activation of the function.
Maintenance manual
208 001 EN
4 0 Complete machine – Troubleshooting with error code
1. Select the appropriate section, 1-9.

2. Read the description of the function in question to get an over‐
all understanding of which components are affected and how
these interact.
3. Use the function description and check the signals for the func‐
tion to find where in the function chain that signal or reaction is
incorrect.
4. The malfunction is probably between the two units where the
signal is incorrect. Start by checking the component that should
send the signal.
5. If the component that should send the signal is intact, check
the transmission of the signal in the cables or hydraulic hoses.
For more information about cables, see Troubleshooting
cables .
6. If cables or hoses between components seem to be intact,
check the component receiving the signal.
Troubleshooting with error code

1. Read the message on the display.
2. Check the details from the error code list.
3. Use the function group to find more information if needed.
Sections 1–9 provide function descriptions and descriptions of
components, their positions, and in certain cases work instruc‐
tions for checking and adjusting components.
4. If possible, exclude component malfunction by testing the sus‐
pected component separately.
Electric components can usually be checked by resistance
measurements using a multimeter.
Hydraulic components are most often checked by measuring
pressure; in such cases, this is described in the function group
or in connection with preventive maintenance.
5. If the component’s measurement values are correct, continue
by troubleshooting the hydraulic hoses and cables. See Trou‐
bleshooting cables .
Troubleshooting cables
DANGER
Risk of electric shock!
Before commencing work, ensure that the electric system is de-ener‐
gised.
NOTE
Troubleshoot all cables in the same way to prevent damaging the con‐
trol units, components, or measuring instruments.
Maintenance manual
208 001 EN
0 Complete machine – Troubleshooting cables 5
1. For de-energising the electric system, see Chapter B Safety,

section Electric systems.
2. Refer to the appropriate circuit diagram, check the connections
and any joints of the suspected cable.
3. Check the cable as follows:
a) Disconnect the connector from both the control unit and
component.
b) Connect the other end of the cable to a point on the frame
structure where the cable touches the metal surface with‐
out a film of paint or coating.
c) Use a multimeter to measure the cable resistance
between the cable and the machine frame.
d) The cable is intact if the multimeter shows constant resist‐
ance.
Maintenance manual
208 001 EN
6 0 Complete machine – Troubleshooting cables
Maintenance manual
208 001 EN
1
Table of content
1 Cummins 3
1.2 Fuel system 3
1.2.1 Removing water from the water separator 4
1.2.2 Replacing the fuel prefilter 4
1.2.3 Replacing the fuel filter 5
1.2.4 Bleeding the fuel system 6
1.2.5 Cleaning the fuel tank 7
1.5 Mechanical parts 8
1.5.1 Adjusting the valve clearances and unit injector rocker arms 8
1.6 Air intake / exhaust outlet 14
1.6.1 Checking the air filter indicator 15
1.6.2 Replacing the air filter 15
1.6.3 Empty dust collector of air filter 16
1.6.4 Clean and check the crankcase breather tube 16
1.6.5 Check the vibration damper 16
1.6.6 Check the fan hub bearing clearance 17
1.7 Cooling system 18
1.7.1 Checking the coolant level 19
1.7.2 Changing the coolant filter 19
1.7.3 Changing the coolant and flushing the cooling system 20
1.7.4 External cleaning of the radiator 21
1.8 Lubrication system 22
1.8.1 Checking the oil level 24
1.8.2 Replacing the oil filter 25
1.8.3 Changing oil 26
Maintenance manual
208 001 EN
2
Maintenance manual
208 001 EN
1 Cummins – 1.2 Fuel system 3
1 Cummins
1.2 Fuel system
Description
Fuel is transferred from the fuel tank by a feed pump. The feed
pump starts when the main power is switched on.
The fuel flows to the engine fuel pump through filters. Overflow from
the engine returns to the tank.
Component position
Fig. : Flow diagram, Fuel system
1. Fuel supply from tank

2. Fuel filter
3. Gear pump
4. Fuel shut-off valve
5. Rail metering actuator
6. Timing actuator
7. Rail metering supply to actuator
8. Timing fuel supply to injector
9. Injector
10. Fuel drain to tank
Maintenance manual
208 001 EN
4 1 Cummins – 1.2 Fuel system
1.2.1 Removing water from the water separator

Instructions
CAUTION
The fuel is highly flammable. Do not smoke or use an open flame
when handling the fuel.
Avoid skin contact with the fuel. Use protective gloves.
IMPORTANT
Be careful not to discharge fuel into the environment. Use an appro‐
priate container, and deliver the fuel to a hazardous waste collection
point.
1 Place the fuel container below the filter.

2 Loose the drain valve nut completely so that the valve drops
down from the filter about 25 mm (1 inch). Drain the water and
the sediment out.
3 Retighten the drain valve nut when clean fuel is draining out.
1.2.2 Replacing the fuel prefilter

Instructions
CAUTION
Maintenance manual
208 001 EN
IMPORTANT
priate container, and deliver the fuel and the used filter to a hazard‐
ous waste collection point.
Ensure absolute cleanliness. Impurities in fuel cause damage to the
system.

2 Clean the filter and the area around it.
3 Open the valve at the bottom, and drain the fluid from the filter
into the container.
4 Remove the filter, and move the water separator to the new
filter.
5 Tighten the new filter into place by hand.
NOTE
Do not use a tool for tightening to prevent damage to the filter.
6 Start the engine, and check the filter for leaks.
1.2.3 Replacing the fuel filter

Instructions
CAUTION
IMPORTANT
point.
Take care to ensure absolute cleanliness. Impurities in fuel cause
damage to the system.
Maintenance manual
208 001 EN
6 1 Cummins – 1.2 Fuel system

3 Remove the filter element.
NOTE
Fill the new filter with clean fuel prior to installation.
4 Apply a thin film of clean engine oil to the filter gasket sealing
surface.
5 Install the filter onto the filter head. Turn the filter until the gas‐
ket contacts the filterhead surface. Tighten the filter an adi‐
tional 3/4 of a turn.
6 Bleed the fuel system; see 1.2.4 Bleeding the fuel system.
1.2.4 Bleeding the fuel system

General
The fuel system is bled using the pressure generated by the feed
pump, which is used to move fuel from the fuel tank.
Instructions
CAUTION
IMPORTANT
point.
Maintenance manual
208 001 EN
1 Push the button (1) down on the integrated fuel system mod‐
ule.
2 Crank the engine until a solid stream of fuel comes out of the
1 port.
3 Release the button (1).
4 Crank the engine for 20 seconds. If the engine does not start
within 20 seconds, wait 2 minutes.
5 Repeat these steps until the engine starts.
6 Start the engine. After the engine has started, close the valve.
If the engine does not start after bleeding, bleed the system
again.
1.2.5 Cleaning the fuel tank

Instructions
CAUTION
IMPORTANT
point.
1 Drain the fuel tank into the container through the drain valve.
2 Rinse the tank with clean fuel.
3 Close the valve, and fill the tank.
Maintenance manual
208 001 EN
8 1 Cummins – 1.5 Mechanical parts
1.5 Mechanical parts
1.5.1 Adjusting the valve clearances and unit

injector rocker arms
General
The adjustments are to be performed when the engine is cold. Let
the engine cool down for at least 30 minutes after use.
WARNING
Batteries can emit explosive gases. To avoid personal injury, always
ventilate the compartment before servicing the batteries. To avoid
aching, remove the negative (-) battery cable first and attach the neg‐
ative (-) battery last.
Disconnect the battery.
NOTE
Read the entire procedure for overhead adjustment before attempting
to perform this operation.
Valves, injectors, and engine brake (if equipped) must be correctly

adjusted for the engine to operate efficiently. Valve, injector, and
engine brake adjustment must be performed using the values listed
in this section.
Adjust the valves, injectors, and engine brakes every 3,000 hours.
Adjustment should be made after any major repair. After a major
repair, the adjustment interval again becomes every 3000 hours.
Adjust
All overhead valve, injector, and brake adjustments must be made
when the engine is cold (any stabilized coolant temperature at 60°C
[140°F] or below).
CAUTION
Do not use solvent to clean the rocker cover gasket. Solvent can
damage the gasket material and cause it to swell.
Locate the valve set marks on the outside of the vibration damper.
The set marks are A, B, and C:
• Set to mark A to adjust cylinders 1 or 6.

• Set to mark B to adjust cylinders 2 or 5.
• Set to mark C to adjust cylinders 3 or 4.
Maintenance manual
208 001 EN
1 Cummins – 1.5 Mechanical parts 9
NOTE
Two complete revolutions are required to set all valves and injectors.
WARNING
Do not straighten a bent fan blade or continue to use a damaged fan.
A bent or damaged fan blade can fail during operation and cause per‐
sonal injury or property damage.
The crankshaft rotation is clockwise as viewed from the front of the

engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.
Barring Device
Remove one capscrew and loosen the second capscrew, then

rotate cover.
Maintenance manual
208 001 EN
Use a 1-112-inch socket, and bar engine over counterclockwise.
NOTE
Rock the barring device back and forth until it disengages.
Each cylinder has four rocker levers:
• The exhaust valve rocker lever (1)

• The injector rocker lever (2)
• The intake valve rocker lever (3)
• The engine brake rocker lever (4).
The valves and the injectors on the same cylinder are adjusted at
the same index mark on the vibration damper.
QSX15
Injector and valve adjustment sequence
Bar engine in Pulley position Set cylinder Set cylinder

direction of injector
rotation
Start A 1 1
Advanced to B 5 5
Advanced to C 3 3
Advanced to A 6 6
Advanced to B 2 2
Advanced to C 4 4
Firing order: I-5-3-6-2-4
Rotate the air compressor drive in the direction of engine rotation,

clockwise. Align the A mark on the vibration damper with the pointer
on the gear cover.
NOTE
For illustrative purposes, position A is shown as the first step. It is not
necessary to start with position A, as long as the proper sequence is
followed.
Maintenance manual
208 001 EN
Check the valve rocker levers on the given cylinder to see if both
exhaust valves are closed.
NOTE
Both valves are closed when both rocker levers are loose. If both
valves are not closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with the pointer
again.
Loosen the injector adjusting screw locknut on the cylinder.

Use a dial-type torque wrench, Part No. 3375044 with a range of 0
to 150 in-Ib to tighten the injector rocker lever adjusting screw. If the
screw chatters during setting. Repair the screw and lever as
required.
NOTE
Do not use a click-type torque wrench. Back out the adjusting screw
one or two turns.
Back out the adjusting screw one or two turns.

Hold the torque wrench in a position that allows you to look in a
direct line at the dial. This is to make sure the dial with be read
accurately.
Make sure the parts are aligned, and squeeze the oil out of the
valve and injector train by tightening the adjusting screw.
NOTE
Use this initial adjustment to preload the valve train and injector.
Tighten the injector adjusting screw.

Torque Value: 8 N•m [70 in-Ib]
Tighten the injector lever adjusting screw.
Torque Value: 8 N•m [70 in-Ib]
Maintenance manual
208 001 EN
Hold the injector lever adjusting screw, and tighten the adjusting
screw locknut.
Torque Value: 75 N•m [55 ft-Ib]
After setting the injector on a cylinder, set the valves on the same
cylinder.
With the set mark aligned with the pointer on the gear cover and
both valves closed on the cylinder, loosen the locknuts on the intake
and exhaust valve adjusting screws.
Back out the adjusting screw one or two turns.
Select a feeler gauge for the correct valve lash specification.
Valve Lash Specifications
Intake Exhaust
0.36 mm 0.69 mm
[0.014 in] [0.027 in]
Insert the feeler gauge between the top of the crosshead and the
rocker lever nose pad.
Maintenance manual
208 001 EN
Tighten the adjusting screw.

Torque Value: 0.6 N•m [5 in-Ib]
NOTE
Use torque wrench adapter, Part No. 3375044, to tighten the locknut.
Hold the adjusting screw in this position. The adjusting screw must
not turn when the locknut is tightened.
Torque Value: 45 N•m [33 ft-IbJ
After tightening the locknut to the correct torque value, remove the
feeler gauge.
Repeat the process to adjust all injectors and valves according to
the chart shown earlier in this procedure.
QSX15
Injector and valve adjustment sequence
Bar engine in Pulley position Set cylinder Set cylinder

direction of injector
rotation
Start A 1 1
Advanced to B 5 5
Advanced to C 3 3
Advanced to A 6 6
Advanced to B 2 2
Advanced to C 4 4
Firing order: I-5-3-6-2-4
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208 001 EN
14 1 Cummins – 1.6 Air intake / exhaust outlet
1.6 Air intake / exhaust outlet
Component position, air intake system
6 5
2
1
3
1. Intake air inlet to turbocharger

2. Turbocharger to air to charge air cooler
3. Charge air cooler
4. From charge air cooler to intake manifold
5. Intake valve ports
6. Intake valves
Component position, exhaust system
2 1. Exhaust valve ports

2. Exhaust manifold
3. Turbocharger turbine
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1 Cummins – 1.6 Air intake / exhaust outlet 15
1.6.1 Checking the air filter indicator

Instructions
The air filter is replaced during scheduled maintenance. Depending
on conditions, the air filter may clog during a relatively short operat‐
1 ing period.
The air filter is equipped with a clog warning indicator (1).
Check the indicator regularly. The filter must always be replaced if
the clog warning indicator shows completely red.
1.6.2 Replacing the air filter

Instructions
1 Open the filter housing cover.
2 Remove the air filter (the larger filter element).
3 Check the safety cartridge (the smaller filter element); replace
if necessary. The safety cartridge is usually replaced every
other time the air filter is replaced.
4 Install the new air filter, and mount the cover.
5 Reset the clog warning indicator by pressing the button on its
end.
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208 001 EN
16 1 Cummins – 1.6 Air intake / exhaust outlet
1.6.3 Empty dust collector of air filter

Instructions
Empty dust collector of air filter. Dust collector is located under air
filter.
1.6.4 Clean and check the crankcase breather

tube
Instructions
1 Remove the crankcase breather tube from the breather vent
tube.
2 Use solvent to clean the inside of the crankcase breather
tube, and dry with compressed air.
3 Use air pressure to blow through the vent tube.
4 Replace the vent tube if it is clogged.
1.6.5 Check the vibration damper

Instructions
CAUTION
The silicone fluid in the damper will become solid after extended
service and will make the damper inoperative. An inoperative damper
can cause major engine or driveline failures.
Maintenance manual
208 001 EN
1 Cummins – 1.6 Air intake / exhaust outlet 17
Check the dampers for evidence of fluid loss, dents, and wobble.
Inspect the vibration damper thickness for any deformation or rais‐
ing of the damper front cover plate.
1.6.6 Check the fan hub bearing clearance

Instructions
Fan hubs with "stepbore" shafts and no bearing spacers must be
0.08 to 0.25 mm [0.003 to 0.010 in] end clearance.
Fan hubs with "through-bore" shafts with inner and outer bearing
spacers must be 0.08 to 0.41 mm [0.003 to 0.016 in] end clearance.
Maintenance manual
208 001 EN
18 1 Cummins – 1.7 Cooling system
1.7 Cooling system
Flow diagrams, cooling system
7 1. Coolant inlet
3 2. Coolant flow from coolant filter
6 3. Coolant by-pass flow from thermostat
4. Coolant flow to water pump
5. Coolant flow from water pump
6. Coolant flow past oil cooler
7. Coolant flow to cylinder head
6
1
2
3 4 5
C A) Coolant flow from cylinder block to cylinder head

B) Coolant flow from cylinder head to thermostat housing
C) Coolant flow to radiator
D D) Coolant by-pass passage
E) Coolant by-pass flow to water pump
F) Coolant by-pass Closed
G) Thermostats
A
B
B D C B
E
G
Maintenance manual
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1 Cummins – 1.7 Cooling system 19
1.7.1 Checking the coolant level

Instructions
CAUTION
Do not open the radiator cap (1) when the engine is hot.
Steam or hot coolant may be discharged from the radiator and cause
burns.
Open the cap carefully, and wait for the fluid to cool down before add‐
ing fluid.
The engine must be turned off at least 30 minutes before the

1 inspection.
Open the cap of the tank carefully.
The coolant should be at the level of the cap hole (1).
If necessary, add coolant using the filling pump (2).
1.7.2 Changing the coolant filter

Instructions
CAUTION
Open the cap of the tank carefully when the engine is warm.
burns.
Be careful when draining the cooling system; coolant at the operating
temperature may cause burns.
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20 1 Cummins – 1.7 Cooling system
IMPORTANT
Be careful not to discharge coolant into the environment. Use an
appropriate container, and deliver the coolant to a hazardous waste
collection point.
NOTE
While changing the coolant filter, the on/off valve must be in the OFF
position. Then the coolant flow is cut off to and from the coolant filter.
1 Open the radiator pressure cap.

2 Remove and discart the coolant filter.
3 Clean the gasket surface of the filter head.
4 Apply a thin film of clean engine oil to the filter gasket sealing
surface before installing the filter.
NOTE
After installing the coolant filter, the ON mark on the coolant filter col‐
lar must be properly aligned.
5 Tighten the coolant filter 1/2 of a turn after initial gasket con‐
tact.
6 Install the radiator cap.
Operate the machine until the coolant tempetature is above 82 °C
(180 °F), and check for coolant leaks.
After the air has been purged from the system, check the coolant
level again.
1.7.3 Changing the coolant and flushing the

cooling system
Instructions
CAUTION
Open the cap of the tank carefully when the engine is warm.
burns.
Be careful when draining the cooling system; coolant at the operating
temperature may cause burns.
Maintenance manual
208 001 EN
1 Cummins – 1.7 Cooling system 21
IMPORTANT
Be careful not to discharge coolant into the environment. Use an
appropriate container, and deliver the coolant to a hazardous waste
collection point.
1 Open the radiator pressure cap carefully.

1 2 Drain the coolant into the container through the drain valve.
3 Use the hand pump to fill the system with clean, hot water into
which you have mixed radiator cleaner. Follow the radiator
cleaner manufacturer’s instructions.
4 Fill the system with new coolant; for the coolant type, see sec‐
tion F Technical data.The coolant should be at the level of the
cap hole (1). Add coolant using the filling pump (2).
The engine must be turned off at least 30 minutes before the check‐
ing the coolant level.
1.7.4 External cleaning of the radiator

Instructions
Clean the radiator with a steam cleaner and rinse with running
water.
NOTE
Do not use high pressure; this might damage the radiator.
Maintenance manual
208 001 EN
22 1 Cummins – 1.8 Lubrication system
1.8 Lubrication system
Component position, Lubricating oil system
1. Lubricating oil flow from oil pan through suction tube

2. Flow from suction tube to oil pump
3. Pressure regulator
4. High-pressure relief valve
5. Flow from oil pump to oil cooler/filter head housing
6. Oil return from oil cooler/filter head housing to main oil rifle
7. Main oil rifle
8. Flow to main bearing
9. Flow from main bearing to crankshaft
10. Flow to cylinder head
11. Flow to piston cooling nozzle
12. Flow to idler gears
13. Oil transfer from main oil rifle
14. Flow to air compressor
15. Rifle sensing regulator pump to inlet
Maintenance manual
208 001 EN
1 Cummins – 1.8 Lubrication system 23
1. Lubricating oil flow from cylinder block to cylinder head

2. Flow around grooved head to drilled camshaft and rocker lever
shafts
3. Flow to injector rocker lever shafts
4. Flow to injector rocker levers
5. Flow to injector camshaft journal bearings
6. Flow to fuel pump
7. Flow to valve rocker lever shafts
8. Flow to valve rocker levers
9. Flow from valve camshaft journal bearings
10. Intake valve rocker lever
11. Engine brake lever
12. Exhaust valve rocker lever
13. Injector rocker lever
14. Oil drain from overhead (front and rear)
Maintenance manual
208 001 EN
1. Lubricating oil flow from oil pump

2. Thermostat
3. Oil cooler by-pass flow
4. Flow through oil coolers
5. Flow return to filter head
6. Filter by-pass valve
7. Oil filter
8. Flow to turbocharger
9. Flow to main oil rifle
10. Oil drain from turbocharger
11. Thermostat open - oil flows through oil coolers
12. Thermostat closed - oil flows directly to oil filter
13. Flow to oil filter
1.8.1 Checking the oil level

Checking the oil level
IMPORTANT
Ensure absolute cleanliness. Impurities in oil cause damage to the
system.
Maintenance manual
208 001 EN
1 The engine must be turned off at least 30 minutes before the

2 inspection.
2 Clean the dipstick (2) and check the oil level.
MAX 3 The oil level must be between the marks on the dipstick. If
necessary, add oil through the refilling point (1). For the oil
type, see Chapter F Technical data.
MIN
1 2
1.8.2 Replacing the oil filter

Instructions
CAUTION
Avoid skin contact with oil. Use protective gloves.
IMPORTANT
Be careful not to discharge oil into the environment. Use an appropri‐
ate container, and deliver the oil and the used filter to a hazardous
waste collection point.
Ensure absolute cleanliness. Impurities in oil cause damage to the
system.
Maintenance manual
208 001 EN
1 Place the container below the filter for the oil that flows out.
3 Remove the filter.
4 Lubricate the rubber seal of the new filter with a small amount
of engine oil.
5 Tighten the new filter element into place to an additional 3/4
turn after the gasket contacts the filter head surface.
NOTE
The o-ring can stick on the filter head. Make sure it is removed.
NOTE
If the lubricating oil filter head adapter comes off during the removal,
reinstall it by using a small amount of loctite on the threads.
1.8.3 Changing oil

Instructions
CAUTION
IMPORTANT
ate container, and deliver the oil and the used filter to a hazardous
waste collection point.
Take care to ensure absolute cleanliness. Impurities in oil cause
damage to the system.
Maintenance manual
208 001 EN
1 Run the engine until it is warm.

2
2 Drain the oil with the hand pump (3) into a container.
3 Fill the engine with oil through the filler point (1) until the oil
level is between the marks on the dipstick (2). For the oil vol‐
ume and type, see chapter F Technical data.
4 Run the engine for about 30 seconds, and check the oil level.
Refill if necessary.
1 3 2
Maintenance manual
208 001 EN
Maintenance manual
208 001 EN
1
Table of content
2 Transmission 3
2.5 Electrical transmission 3
2.5.1 Checking the generator mounting 4
Maintenance manual
208 001 EN
2
Maintenance manual
208 001 EN
2 Transmission – 2.5 Electrical transmission 3
2 Transmission
General
This chapter describes the generator, which generates the electric
power used to run the machine’s electric transmission system.
2.5 Electrical transmission
Safety
DANGER
Danger! High voltage!
The electric systems must be serviced and repaired by trained per‐
sonnel.
For safety instructions, see Chapter B,section Electric systems.
Description
Single speed generator

A diesel engine runs the generator A at a constant speed of
1500/1800 rpm. The generator generates three-phase alternating
current (400/440 VAC) with a frequency of 50/60 Hz. The electric
power is used to run the electric drive motors.
Variable speed generator (VSG)
With VSG-RTG the generator output voltage and frequency will vary
depending on the diesel engine rpm. Regardless the diesel engine
Maintenance manual
208 001 EN
4 2 Transmission – 2.5 Electrical transmission
rpm, the voltage and frequency supplied for auxiliary loads (for
example, lighting and air conditioning) are kept constant. Typically
engine speed varies between 900…1800rpm and auxiliary loads
voltage is 400/440VAC with a frequency of 50/60Hz.
2.5.1 Checking the generator mounting

Instructions
1 Tighten the generator mounting screws 1, torque 93,4 Nm.
2 Check the condition of the vibration dampers 4.
NOTE
If the coupling part 2 has to be changed, attach it to the flywheel with
screws 3 (120 Nm). Use a thread locker.
4
93,4 Nm
1
93,4 Nm
3
2 120 Nm
Maintenance manual
208 001 EN
1
Table of content
3 Driveline/axle 3
3.3 Driven wheel 3
3.3.1 Checking / Changing the wheel hub, the differential carrier and the angle gear lubrication oil 4
3.3.2 Changing a wheel 5
3.3.3 Lubrication points 7
3.4 Non-driven wheel 9
3.4.1 Checking / Changing the wheel hub lubrication oil 9
3.4.2 Changing a wheel 9
3.6 Electrical drive 11
3.6.1 Component position 18
Maintenance manual
208 001 EN
2
Maintenance manual
208 001 EN
3 Driveline/axle – 3.3 Driven wheel 3
3 Driveline/axle
General
The driveline/axle consists of the electric transmission from the gen‐
erator to the drive motors and the mechanical transmission from the
drive motors to the wheels.
3.3 Driven wheel
Description
3
1
Maintenance manual
208 001 EN
4 3 Driveline/axle – 3.3 Driven wheel
The axle of the driven wheels includes the wheel hubs (1), the dif‐
ferential carrier (2) and the angle gear (3).
The power is transmitted to the wheel via the angle gear, the differ‐
ential carrier and the reduction gear integrated into the wheel hub.
3.3.1 Checking / Changing the wheel hub, the

differential carrier and the angle gear
lubrication oil
Changing the wheel hub oil
Check the oil type in chapter F Technical data.
1. Rotate the wheel hub, so that the oil drain plug A is in the low‐
est position.
2. Open the drain plug A and drain the oil into a container.
3. Close the drain plug A.
B B 4. Open the oil fill plug B and fill the oil until it is level with the bot‐
tom edge of the fill hole.
5. For driven wheels, wait a few minutes for the oil to flow to the
mm
wheel hub.
6. Add oil if necessary.
7. Close the filling plug B.
A A
1
Maintenance manual
208 001 EN
Changing the differential oil
The oil type is the same as in the wheel hub, see Chapter F Techni‐
cal data.
1. Open the drain plug 1 and drain the oil into a container.
2. Close the drain plug 1.
3. Open the oil fill plug 3 and fill the oil until it is level with the bot‐
4. Wait a few minutes for the oil to flow into the differential.
6. Close the filling plug 3.
Changing the angle gear oil
The oil type is the same as in the wheel hub, see Chapter F Techni‐
cal data.
2 1. Open the drain plug 2 and drain the oil into a container.
2. Close the drain plug 2.
3. Open the oil fill plug 4 and fill the oil until it is level with the bot‐
4. Wait a few minutes for the oil to flow into the gear.
6. Close the filling plug 4.
mm
mm
4 3
3.3.2 Changing a wheel

General
CAUTION
Use appropriate lifting equipment for handling a removed wheel.
Maintenance manual
208 001 EN
Instructions
1 1
4 4
2 2
3 3
NOTE
Use a turn stopper (1) to avoid excessive turning.
It is recommended to drive the trolley in middle position.

1 Place a jack (minimum capacity 50 tn) (2) under an axle.
NOTE
If necessary use temporary supports (3) under the jack (2).
2 Place a plate (4) (approx. 200x200x10mm) between the jack

(2) and the axle.
3 Lift the wheel up.
4 Deflate the tyre.
5 Remove the wheel nuts, and remove the wheel with the lifting
device.
6 Remove grease and oil from the threads. Do not use any
lubricant on the threads.
Maintenance manual
208 001 EN
7 Install the new wheel, and inflate the tyre to the recommended
pressure. Tighten the wheel nuts crosswise. See Section
Tightening torques of the wheel nuts.
IMPORTANT
Pay attention to the cleanness of rim, wheel hub and wheel nuts. Any
paint, oil or grease on these surfaces prevents proper tightening of
wheel nuts. Loose nuts allow rim to move which causes severe dam‐
age to hub.
8 Re-tighten wheel nuts 50 hours after a wheel change.
3.3.3 Lubrication points

Sill beams
1
3
1 2 1
1
1. Grease nipple for bearing housing , vertical axle

2. Grease nipple for pivot axle
3. Grease nipple for steering arm
4. Grease nipple for pinion bearing
Maintenance manual
208 001 EN
Manual greasing, gantry motor
Pos Lubrication points, gantry motor Qty
1 Bearings of gantry motor (volume 2

40g)
Maintenance manual
208 001 EN
3 Driveline/axle – 3.4 Non-driven wheel 9
3.4 Non-driven wheel
Description
The axle includes the wheel hubs (1).
3.4.1 Checking / Changing the wheel hub

lubrication oil
Instructions
The wheel hub oil level must be at same level as the fill hole (2).
Add oil if necessary. For non-driven wheels, wait a few minutes for
the oil to flow to the wheel hub. See the oil type Chapter F Technical
data.
The drain plugs are located at points (1).
2 2
1 1
3.4.2 Changing a wheel

Instuctions
See section 3.3 Driven wheel.
Maintenance manual
208 001 EN
10 3 Driveline/axle – 3.4 Non-driven wheel

Sill beams
1
3
1 2 1
1
1. Grease nipple for bearing housing , vertical axle

2. Grease nipple for pivot axle
3. Grease nipple for steering arm
4. Grease nipple for pinion bearing
Maintenance manual
208 001 EN
3 Driveline/axle – 3.6 Electrical drive 11
3.6 Electrical drive
Safety
DANGER
Danger! High voltage!
The electric systems must be serviced and repaired by trained per‐
sonnel.
For safety instructions, see Chapter B, section Electric systems.
Description
Diesel generator power supply: Electrical transmission consists of
AC-Generator, rectifier, inverters and electric drive motors. System
is powered by the AC-generator, which is run by a diesel engine.
Zero emission power supply: Electrical transmission consists of rec‐
tifier, inverters and electric drive motors. System is powered by
external power source through a cable. Crane is equipped with
medium voltage transformer if power supply voltage is more than 1
kV.
PLC verifies with proximity switches that wheel positions are correct
on all corners and permits driving.
Driving speed is adjusted by gantry Joystick located at operator´s
cabin; inverters adjust the speed of the motors on the basis of joy‐
stick position.
When Joystick is moved, gantry brakes are opening and they stay
open until driving speed goes back to zero then brakes will close.
When braking (decelerating), gantry motors are acting as electrical
brakes, command of braking comes when gantry joystick goes to
neutral position.
Diesel generator power supply: Re-generative power from the
motors are fed to DC-link where braking units feed all excess
energy to braking resistors, which are transferring braking energy to
heat.
Zero emission power supply: Re-generative power from the motors
are fed to DC-link where Active Interface Module (AIM) feeds all
excess energy to electricity distribution network.
PLC system is checking machine vicinity with cat-whisker type
switches or ultra-sonic/laser sensors, when machine is too close to
objects it will stop movement immediately.
Maintenance manual
208 001 EN
12 3 Driveline/axle – 3.6 Electrical drive
Function description (diesel generator power

supply)
PLC PLC
8
9, 18
14
15 17
16
600 - 625 VDC
-
2 G 6 ~
3 5 7 7
- - U U
19 19
~ ~
4
300 - 425 VAC

11 11 11 11
M~ °C 12 M~ °C 12 M~ °C 12 M~ °C 12
3 3 3 3
10, 21 10, 21 10, 21 10, 21 20 20
PG PG
13 13
Item numbers in parentheses refer to the circuit diagram.
Maintenance manual
208 001 EN
Pos Function Signal description Reference
1 The diesel engine generates

electrical power required by the
AC-generator.
2 The AC-generator (G01) produces 400 – 440 VAC, 50 – 60 Hz

electrical power to the system.
3 Main circuit breaker (F01) protects 400 – 440 VAC, 50 – 60 Hz

the system from overload and
short-circuit currents.
4 Generator supply contactor (K51) 400 – 440 VAC, 50 – 60 Hz

connects AC-generator´s output to
the RTG electrical system.
5 Main fuses (F2) protect the rectifier 400 – 440 VAC, 50 – 60 Hz

from short-circuit currents.
6 Rectifier (U5) converts alternating 400 – 440 VAC / 540 – 600 VDC
current into direct current for the
direct current intermediate circuit
(DC-link).
7 Inverters (U1 and U2 or U2 and 540 – 600 VDC / 400 – 440 VAC, 0
U3) receive the electric power from – 58 Hz
the DClink and convert DC power
into adjustable frequency AC
power.
8 PLC verifies wheel positions by Proximity switch – PLC: 24 VDC

proximity switches (S106,S107,
S108, S109, S110, S111,
S206,S207, S208, S209, S210 and
S211).
9 Gantry joystick (S701 or S731) Joystick – PLC: 24 VDC

sends setpoint signal to inverters PLC – inverter: Profibus
via Profibus.
10 Brakes (Y101, Y102, Y203 and PLC – brake contactor: 24VDC

Y204) will open when inverters 230 VAC, 50 – 60 Hz (8 wheels)
start to control the motors. 400 VAC, 50 – 60 Hz (16 wheels)
11 Inverters control the direction of ~ 0-400 VAC, 0 – 58 Hz

rotation and speed of the drive
motors (M101, M102, M203 and
M204).
12 PLC monitors the temperature of Inverter – PLC: Profibus

the drive motors with temperature
sensors.
Maintenance manual
208 001 EN
13 PLC monitors the speed of the Inverter – PLC: Profibus

motors with the pulse encoders
(B101 and B203) on the motors.
14 PLC monitors anti-collision by Whisker-switch – PLC: 24 VDC

catwhisker switches .
15 PLC monitors anti-collision by Ultrasonic sensor – PLC: 24 VDC

ultrasonic sensors .
16 PLC monitors anti-collision by laser Laser sensor – PLC: 24 VDC

sensors .
17 Manual steering switch (S702) Joystick – PLC: 24 VDC

gives steering command to PLC, PLC – inverter: Profibus
which slows down the setpoint
signal for Inner wheel side.
18 When braking, gantry motors are Joystick – PLC: 24 VDC

acting as electrical brakes, PLC – inverter: Profibus
command of braking comes when
gantry joystick goes to neutral
position.
19 Regenerative energy generated ~680 VDC

during braking is fed via DC-link to
braking units (A1 and A2)
20 Braking units feed excess energy ~680 VDC

to braking resistors (R91), which
are transferring braking energy to
heat.
21 When motors are stopped (rotation PLC – Brake contactor 24 VDC

speed zero), brakes (Y101, Y102, Brake contactor – Brake 400 VAC,
Y203 and Y204) close. 50 – 60 Hz
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Function description (zero emission power supply)
PLC PLC
9
10, 19
15
16 18
17
1, 21 540 - 600 VDC
-
2 7 ~
20
3
6 8 8
- -
~ ~
4 5
400 - 440 VAC

12 12 12 12
M~ °C 13 M~ °C 13 M~ °C 13 M~ °C 13
3 3 3 3
11, 22 11, 22 11, 22 11, 22
PG PG
14 14
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Pos Function Signal description
1 Electrical power is supplied from external power See chapter F Technical data for supply voltage
source through a cable.
2 Electrical power is led through a power supply See chapter F Technical data for supply voltage
connection box.
3 Medium voltage transformer transforms the supply See chapter F Technical data for supply voltage
voltage into a lower voltage. Transformer is
applicable only when the power supply from
external power source over 1 kV.
4 Main circuit breaker (F150) protects the system 400 – 440 VAC, 50 – 60Hz
from overload and shortcircuit currents.
5 Main supply contactor (K50) connects external 400 – 440 VAC, 50 – 60Hz
power supply to the RTG electical system.
6 Main fuses (F2) protect the rectifier from short- 400 – 440 VAC, 50 – 60Hz
circuit currents.
7 Rectifier (U5) converts alternating current into direct 400 – 440 VAC / 540 – 600 VDC
current for the direct current intermediate circuit
(DC-link).
8 Inverters (U1 and U2 or U2 and U3) receive the 540 – 600 VDC / 400 – 440 VAC, 0 – 58 Hz
electric power from the DC-link and convert DC
power into adjustable frequency AC power.
9 PLC verifies wheel positions by proximity switches Proximity switch – PLC: 24 VDC
(S106,S107, S108, S109, S110, S111, S206,S207,
S208, S209, S210 and S211).
10 Gantry joystick (S701 or S731) sends setpoint Joystick – PLC: 24 VDC

signal to inverters via Profibus. PLC – inverter: Profibus
11 Brakes (Y101, Y102, Y203 and Y204) will open PLC – brake contactor: 24VDC
when inverters start to control the motors. Brake contactor – brake: 230 VAC, 50 – 60 Hz (8
wheels)
400 VAC, 50 – 60 Hz (16 wheels)
12 Inverters control the direction of rotation and speed ~ 0-400 VAC, 0 – 58 Hz

of the drive motors (M101, M102, M203 and M204).
13 PLC monitors the temperature of the drive motors Inverter – PLC: Profibus
with temperature sensors.
14 PLC monitors the speed of the motors with the Inverter – PLC: Profibus
pulse encoders (B101 and B203) on the motors.
15 PLC monitors anti-collision by catwhisker switches Whisker-switch – PLC: 24 VDC

.
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Pos Function Signal description
16 PLC monitors anti-collision by ultrasonic sensors Ultrasonic sensor – PLC: 24 VDC

.
17 PLC monitors anti-collision by laser sensors . Laser sensor – PLC: 24 VDC
18 Manual steering switch (S702) gives steering Joystick – PLC: 24 VDC

command to PLC, which slows down the setpoint PLC – inverter: Profibus
signal for Inner wheel side.
19 When braking, gantry motors are acting as Joystick – PLC: 24 VDC

electrical brakes, command of braking comes when PLC – inverter: Profibus
gantry joystick goes to neutral position.
20 Regenerative energy generated during braking is ~680 VDC

fed via DC-link to Active Interface Module (AIM)
(U7).
21 AIM unit feeds all excess energy to electricity

distribution network.
22 When motors are stopped (rotation speed zero), PLC – Brake contactor 24 VDC
brakes (Y101, Y102, Y203 and Y204) close. Brake contactor – Brake 400 VAC, 50 – 60 Hz
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3.6.1 Component position

Overview
4
2
1. Diesel Engine/Generator
2. Electric centre, EE-house
3. Wheel turning motors
4. Drive motors
For component positions of Zero Emission RTG; see chapter11
Common electrics.
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1
Table of content
4 Brakes 3
4.3 Service brake system 3
4.3.1 Checking and adjusting the gantry brake 4
4.3.2 Checking and adjusting the steering brake 5
4.3.3 Checking and adjusting the trolley brake 6
4.3.4 Checking and adjusting the hoist brake 8
4.3.5 Checking and adjusting the skew brake 15
4.3.6 Checking and adjusting the cable reel brake (Zero Emission RTG) 17
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2
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4 Brakes – 4.3 Service brake system 3
4 Brakes
Description
Gantry,steering, trolley, skew and trim travel braking are done
eletrically by brake motor.
Hoist brake is of spring loaded / electro hydraulic released type
operated disk brake type.
Component position
6
5 6
5
4
1
2
1. Gantry brake
2. Steering brake
3. Trolley brake
4. Hoist brake
5. Skew brake
6. Trim brake
7. Cable reel brake (Zero Emission RTG)
4.3 Service brake system
Description
The hoisting system is equipped with one or two operational hoist
brakes and optionally with emergency hoist brakes. The brakes are
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4 4 Brakes – 4.3 Service brake system
spring-loaded, fail-safe disc brakes. The operational hoist brake and

the emergency hoist brake are both applied in case of an emer‐
gency stop.
The operational hoist brake acts on the input shaft of the gearbox.
The brake is applied when hoisting or lowering is not activated. The
brake is released by an electro-hydraulic thruster when hoisting or
lowering is activated. The brake is equipped with a manual releas‐
ing.
Optional emergency hoist brake acts directly on the hoist drum. The
brake prevents the load from falling in case of emergency. The
brake is released by a hydraulic pressure produced by a hydraulic
unit. The hydraulic unit is equipped with a hand pump with which the
brake can be released manually.
Gantry brakes, steering brakes, trolley brakes, skew brakes, and
trim brake (option) are springoperated single disc brakes with two
friction surfaces. The brake torque is generated by several compres‐
sion springs by friction. The brakes are released electromagneti‐
cally.
4.3.1 Checking and adjusting the gantry brake

Instructions
For instructions, see Appendixes, section Gantry brake.
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4.3.2 Checking and adjusting the steering

brake
Instructions
NOTE
Air gap (a + 0,1 mm) needs not to be readjusted
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a + 0,1mm
4.3.3 Checking and adjusting the trolley brake

Instructions
CAUTION
Do not leave lever in the brake. Tripping hazard.
In normal application, the brake is practically maintenance-free.

Only in applications that involve extremely high frictional work, the
air gap S1 has to be checked at defined intervals and readjusted to
the nominal value S1n before the maximum air-gap S1m is excee‐
ded (see figure).
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NOTE
Before commissioning, it must be checked in the de-energized state
that the air-gap is uniform and equal to the nominal size using a feeler
gauge between the armature disk and magnetic section at 3 points on
the circumference.
NOTE
When the motor is recommissioned, the brake must be checked for
correct operation!
3 2
5
1
S2 = 2,5mm
S1 = 0,5mm
(S1n) (min 0,5mm)
(S1m) (max 1,5mm)
h = min 15,5mm
The air gap is adjusted as follows:
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1 Remove fan cover 1.

2 Loosen fixing screws 2, screw adjustment bushes 3 into the‐
magnetic section 4 using a fixed spanner and tighten the fix‐
ing screws again.
3 Then check the air-gap again.
NOTE
Frictional surfaces must not come into contact with oil or grease!
Replacing the friction coating has been consumed, the rotor 5 must
be replaced. See figure for minimum rotor thickness h.
NOTE
Dimensional S2 must be observed!
4.3.4 Checking and adjusting the hoist brake

Safety
DANGER
Immediate risk of crushing. Always use the safety switch with a lock
when servicing the hoist brake. The safety switch prevents the hoist
brake from releasing during the service.
4.3.4.1 Checking brake alignment
General
Misalignment of the brake can cause weak contact pressure
between brake pads and disc and lead to lowered braking torque.
For that reason, it's very important that the brake is correctly
aligned.
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Instructions
1
2 4
3
7
6
1 Check that the linkage of the brake works properly, e.g. that
there is no bending in the brake arms or top levers when the
brake is releasing. Misalignment of the brake can also be rec‐
ognized from uneven wear of the disc and the brake pad lin‐
ings. If necessary, adjust with following steps.
In case of unevenly worn brake pad linings, the brake pads
must be replaced before alignment. For instructions, see
Appendixes, section Hoist brake.
2 Remove the wedge (1).
3 Release the brake spring completely by turning the adjust‐
ment nut (2) counterclockwise.
4 Remove the catch (3) by unscrewing the fastening screw (4).
NOTE
Turning the reserve stroke adjustment nut (5) in following step may
damage the AWC (automatic wear compensator) if the catch is in its
place.
5 Turn the adjustment nut (5) counterclockwise to move brake

pads away from disc.
6 Loosen the brake mounting bolts (6).
7 Rotate the adjustment nut (2) clockwise until the upper edge
of the torque indicator (7) shows about 1/3 of the nominal
braking torque (see brake’s type plate for braking torque).
8 Turn the adjustment nut (5) clockwise to press the brake pads
against the disc. Brake aligns itself to the brake disc.
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9 Check that the brake disc's (8) edge exceeds the brake pads
A (9) by 5 mm (A). Measure from the outer edge of the brake
pad, not from the brake pad carrier. If necessary, adjust by
moving the brake.
10 Check brake alignment.
11 Insert wedge (1) loosely and without force into the guide way.
12 Reinstall the catch (3).
13 Tighten the brake mounting bolts (6) with tightening torque of
655 Nm.
9 14 Adjust braking torque and thruster’s reserve stroke, see chap‐
ters Checking the braking torque and Checking the reserve
stroke of the thruster.
8
4.3.4.2 Checking the air gap between brake pad and brake disc
General
The brake is equipped with a centering device, which centers the
brake automatically when the brake pads are wearing down. In case
of considerably unequal brake pad lift-off, an adjustment is neces‐
sary.
Instructions
1 Release the brake with thruster.

2 Check the air gap between brake pads and brake disc. If the
gaps are considerably unequal, adjust with following steps.
3 Remove the cover (1).
4 Remove the adjusting screws (2) and clean the threads from
any adhesive agent.
5 Tighten the adjusting screws (2) evenly with a screwdriver (air
gap = 0), afterwards loosen the screws one quarter rotation.
7 Actuate and release the brake several times until the wedge
(3) doesn’t move further down.
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8 Check that the air gap is equal on both sides of the brake
disc.
If the air gap is too large on the stop side of the brake, turn
both adjusting screws (2) clockwise. “Stop side” means the
side of the brake which is equipped with the wedge (3).
If the air gap is too large on the opposite side, turn both
adjusting screws (2) counterclockwise.
Adjust by turning the adjusting screws with very small steps.
9 Activate the self centering device with following steps.
10 Release the brake.
12 Actuate and release the brake several times until the wedge
(3) doesn’t move further down.
13 Reinstall the cover (1).
4.3.4.3 Checking the lining wear / lining thickness
General
IMPORTANT
The sintered lining will tend to accumulate dust particles which can
reduce the friction factor and thus the available braking torque. These
dust particles in the brake pad surface can be removed by carrying
out the annual dynamic brake test. If it is not possible to carry out
dynamic load tests at regular intervals, it is recommended to change
brake pads every 2 years. If brake pads removed from the brake are
in otherwise good condition i.e. free from oil contamination, even
wear pattern, no visible cracks or deformation and well above mini‐
mum residual pad thickness, they can be reconditioned by grinding or
machining approximately 0,5 mm off the surface.
Instructions
Minimum allowable thickness of the linings:
• Glued linings: 3 mm
• Riveted linings / Glued and riveted linings: 5 mm
When the minimum thickness has been reached, the brake pads
must be replaced and run in properly. For instructions, see Appen‐
dixes, section Hoist brake.
4.3.4.4 Checking the condition of the brake disc
Instructions
Check the disc for:
• Grease and rust. Clean the disc if necessary.

• Uneven grooves and crack. If considerably uneven grooves or
cracks are found, please contact Cargotec service personnel.
4.3.4.5 Checking the reserve stroke of the thruster
General
Thruster ‘s stroke requires certain reserve to generate proper con‐
tact pressure between brake pads and disc. Without reserve stroke
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the spring force is guided to the thruster itself and not to the brake
pads. For that reason is very important that the reserve stroke is
correctly adjusted to achieve maximum braking torque.
Instructions
4
1
1 Release the brake with thruster.

2 Measure the distance (A) between thruster frame and piston
rod as shown in the figure. Correct distance is 155 mm (+3 /
-1 mm). The lower edge of the cap has to be at the center of
the notch “10” (1). If necessary, adjust with following steps.
3 Remove the catch (2) by unscrewing the fastening screw (3).
NOTE
Adjusting the reserve stroke may damage the AWC (automatic wear
compensator) if the catch is in its place during procedure.
4 Adjust the distance A to 155 mm with the adjustment nut (4).

5 Apply the brake.
6 Reinstall the catch (2). Ensure that the catch pin (5) is within
the catch.
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4.3.4.6 Checking the braking torque
Instructions
Check the braking torque from the scale (1) while the brake is
1 applied. Torque is correctly adjusted when the upper edge of the
indicator shows approximately 90% of the rated maximum braking
torque. For braking torque, see chapter F, Technical data. If neces‐
sary, adjust by turning the adjusting nut (2).
NOTE
The permissible minimum braking torque is 50% of the rated maxi‐
mum braking torque.
If the whole brake is replaced, ensure that the braking torque marked
on new brake’s type plate corresponds to old one.
4.3.4.7 Checking the adjustment of limit switches and manual

release devices
Safety
CAUTION
Limit switches must not be put out of service, overridden or blocked
in any other way. Otherwise the safe use of the brake is no longer
given.
Control for brake status (released/applied)

The limit switch (1) is mounted to the spring tube. For the limit
switch there is an actuating roll (2) screwed onto a threaded rod.
Figure shows the brake applied. When the brake releases, the
threaded rod moves upwards. The actuating roll activates the limit
1 switch when the brake is released.
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Wear control
The limit switch (1) is mounted into the crosspiece (2) of the AWC.
When the brake is set correctly, the switch is not activated. With
growing wear, the spindle (3) moves into the crosspiece. As soon as
the wear reaches the critical value, the limit switch is actuated.
2
3
Manual release device

Check the function and condition of the manual release device.
4.3.4.8 Checking the AWC (Automatic Wear Compensator) for

wear
Instructions
The catch (1) and the freewheel (2) may be objects to wear. Wear‐
ing can be recognized from constant reduction of the reserve stroke
1 in case of lining wear, although the AWC is actuated. In case of
wear, proceed as follows:
1 Rotate nut (3) clockwise to compensate lining wear and thus

the reduced reserve stroke, see section Checking the reserve
stroke of the thruster.
3 2 Replace worn parts respectively and the complete AWC unit
as soon as possible. For instructions, see Appendixes, sec‐
tion Hoist brake.
2
4.3.4.9 Checking the operation of the hoist brake / brake

system
Instructions
Check visually the operation of the brake system for braking dis‐
tance etc. If necessary, check and repeat brake adjustment.
4.3.4.10 Dynamic brake test
Instructions
Carry out 3 – 4 braking cycles at maximum lowering speed with no
load attached to the spreader.
4.3.4.11 Static brake test for system with two hoist brakes
(option)
Instructions
1 Attach a test load (SWL) to the spreader.
2 Lift the load approximately 30 cm off the base.
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3 Release one brake at a time using a manual release. The

second brake must hold the load safely. If necessary, check
and repeat brake adjustment.
4.3.5 Checking and adjusting the skew brake

Instructions
DANGER
Immediate risk of crushing. Always use the emergency switch on the
trolley when servicing the skew gear. The emergency switch prevents
the skew gear from operating during the service.
In normal application, the brake is practically maintenance-free.

Only in applications that involve extremely high frictional work, the
air gap S1 has to be checked at defined intervals and readjusted to
the nominal value S1n before the maximum air-gap S1m is excee‐
ded (see figure).
NOTE
Before commissioning, it must be checked in the de-energized state
that the air-gap is uniform and equal to the nominal size using a feeler
gauge between the armature disk and magnetic section at 3 points on
the circumference.
NOTE
When the motor is recommissioned, the brake must be checked for
correct operation!
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3 2
5
1
S2 = 2mm
S1 = 0,25mm
(S1n) (min 0,25mm)
(S1m) (max 0,6mm)
h = min 5,6mm
The air gap is adjusted as follows:

1 Remove fan cover 1.
2 Loosen fixing screws 2, screw adjustment bushes 3 into the‐
magnetic section 4 using a fixed spanner and tighten the fix‐
ing screws again.
3 Then check the air-gap again.
NOTE
Frictional surfaces must not come into contact with oil or grease!
Replacing the friction coating has been consumed, the rotor 5 must
be replaced. See figure for minimum rotor thickness h.
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NOTE
Dimensional S2 must be observed!
4.3.6 Checking and adjusting the cable reel

brake (Zero Emission RTG)
Instructions
For instructions, see Appendixes, section Cable reel.
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1
Table of content
5 Steering 3
5.2 Power assisted brake system 5
5.2.2 SmartRail (option) 5
5.2.3 Filling / Changing planetary gear oil 6
5.2.4 Checking the wheel alignment 7
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2
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5 Steering – Wheel turning sensors 3
5 Steering
General
The wheel turning is performed by an electric motor without sepa‐
rate wheel position locking mechanisms.
Multiple steering modes, controlled from the cabin:
• normal container mode

• 90° turning of wheels
• wheels in parking position
• carousel drive around RTG’s centre
Wheel turning sensors

Gantry travelling is possible only if PLC gets correct signal from
steering sensors.
If correct position doesn’t come during set time, Fault message
appears in operator’s display.
B C Steering modes:
A
A) Traverse 0° (Normal travelling mode)
B) Carousel ~23° (turning around RTG’s center point)

C) Longitudinal 90° (Cross-travel mode)
A FRONT SILL BEAM
B C S121A Limit switch A Corner 1
S121B Limit switch B Corner 1
S121C Limit switch C Corner 1
S122A Limit switch A Corner 2
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4 5 Steering – Cat-whiskers
REAR SILL BEAM
Cat-whiskers
Cat-whiskers (1) are located in front of side frames.
Lubricate cat-whiskers by using aerosol spray.Lubrication interval
2000 hours or at least 4 Months. Turn cat-whiskers left and right a
1 couple of times.
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5 Steering – 5.2 Power assisted brake system 5
5.2 Power assisted brake system

Steering
3
1. Steering motor
2. Planetary gear
3. Oil tank
4. Inductive switches
5. Tie rod
5.2.2 SmartRail (option)

Description
Smartrail is:
1. An automatic steering system for RTG. The automatic steering

will keep the RTG on a virtual rail with an accuracy greater
than +/- 10 cm.
2. An automatic container position indication system. When a
container is picked or placed, Smartrail sends a message to
the Yard Management System and tells the location where the
container is.
Smartrail is based on the latest Global Positioning System (GPS)

technology. Advanced GPS equipment in combination with RTG
onboard sensors allows real time positioning of the RTG within an
accuracy of one centimeter
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6 5 Steering – 5.2 Power assisted brake system
NOTE
Please view the appendix section in this manual for complete informa‐
tion on Smartrail.
5.2.3 Filling / Changing planetary gear oil

Instructions
1 Unscrew the plug (1).
2 Fill the gearbox with oil through the filling hole (2) until it flows
2 out from the hole (1).
3 Plug the hole (1).
4 Complete the oil filling up to the proper oil level. Check the oil
1 level through the glass eye (3).
3
Changing oil
Remove the planetary gear in order to drain oil. The drain plug is at
the bottom of the gear.
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5.2.4 Checking the wheel alignment

Instructions
6 6
B
A 7 C
B C
790
Ld
Lb
La
Lc
La
Lb
Ld
Lc
10 E
10
8
8
4 5
9
11 3
11
1
22mm
D-D D1
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NOTE
These instructions apply to both 8- and 16-wheeled RTGs.
Before checking the wheel alignment, drive the crane gantry direc‐
tion several times. Perform the wheel alignment on two supports
(10) by following steps 1-11. You need two alignment pins (6) and a
wire (7).
1 Unscrew the wheel nuts at the wheel hub’s centreline level

(position A).
2 Fasten the alignment pins (7) and the wire (8) into positions B
and C.
3 Remove paint from the head of the end stop screws (1) (4
pieces).
4 Turn the outer wheels so that La – Lb =±1mm.
5 Screw the nuts of the outer end stop screws (1) (under the
bogie beam) onto the fork’s support (see view D1).
6 Tighten the nuts of the outer end stop screws.
7 Check that the inner inductive switch (2) is halfway (9mm)
over the steering plate (3), if not, loosen the screws (5) in
order to move the switch bracket (4).
8 Align the inner wheels by adjusting the length of the tie rod (8)
so that Lc – Ld = ±1mm.
9 Pre-adjust the inner end stop screws (1) to a distance of 22
mm from the end of the bogie beam’s bottom plate (see sec‐
tion view D-D).
10 Turn the wheels (90º) electrically against the end of the pread‐
justed end stop screw.
11 Check that the inner inductive switch (2) is halfway (9mm)
over the steering plate (3). If not, you have to adjust the end
stop screw and turn the wheels electrically again until a 90°
position is reached.
You can also check this by looking from the top (see section
view E). The back plate (9) of the inductive switch bracket
should be at the same position as the groove (11) on the
outer edge of the steering plates (see the arrow).
12 Tighten the nuts of the inner end stop screws.
13 Remove the alignment pins and the wire from positions B and
C. Screw the wheel nuts back on.
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Steering linkage
Bogie
A-A B-B
A A B B
NOTE
Uncsrew the plug (1) for the duration of lubrication
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1
Table of content
6 Suspension 3
6.3 Tyres and rims 3
6.3.1 Tyre pressures 3
6.3.2 Checking a rim 4
6.3.3 Tightening torques of the wheel nuts 6
6.3.4 Cleaning wheel hub and rim before installation 7
6.3.5 Tyre pressure monitoring system (option) 8
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2
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6 Suspension – 6.3 Tyres and rims 3
6 Suspension
6.3 Tyres and rims
6.3.1 Tyre pressures

Safety
DANGER
The machine must not be able to move during maintenance. Before
>3m lifting and changing the wheels, always place wheel chocks in front
of the jack and the machine wheels.
Always deflate the tyres to 1 bar or less before handling them. Com‐
ponents of a wheel under pressure can be thrown off when the
wheel is handled.
Do not deflate a tyre through the valve if the tyre or rim is damaged.
A damaged tyre can explode.
Never stand directly in front of a tyre that is being inflated or defla‐
ted. Components of a wheel can be thrown off when the tyre pres‐
sure is changed.
Never install damaged tyres or rims.
Repairing rims by welding is prohibited.
The machine is not to be used if any of the tyres is deflated.
WARNING
The tyre installation work may only be performed by trained person‐
nel using appropriate tools.
Suddenly deflating tyres can cause severe injuries during installation.
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4 6 Suspension – 6.3 Tyres and rims
CAUTION
The mounting nuts of the changed wheels must be retightened after
4-5 hours of operation.
Always follow the tyre manufacturer´s instructions or similar instruc‐
tions when changing the tyres.
Never use a steel hammer for installing or removing rim components.
Use alloy or plastic hammers.
Keep the tyre pressures at the specified level. Improperly inflated
tyres decrease stability and machine capacity.
Remove any items which can cut the tyre, for example, splinters of
glass or wood and metal chips, from the tyres.
Pay attention to abnormal tyre wear which can be caused by a fault,
such as brakes that operate unevenly. Repair any faults immediately.
IMPORTANT
Use a protective screen, hearing protection and safety glasses.
Tyre pressure recommendation

The tyre pressure is checked when the tyre is cold.
Keep the tyre pressures at the specified level by utilizing the air
compressor and accessories supplied with the RTG cranes.
The tyre pressures, see Chapter F Technical data
Fig. : Protective screen

6.3.1.1 Air compressor (option)
Instructions
For further information regarding the air compressor, please refer to
the appendix section of this manual for complete air compressor
manual.
6.3.2 Checking a rim

General
DANGER
Before starting to work on a tyre, the tyre must always be deflated
entirely or to about 1 bar (15 psi).
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CAUTION
Use appropriate lifting equipment for handling the removed compo‐
nents.
IMPORTANT
It is recommended that any inspection work on the rims including
non-destructive testing (NDT) methods be performed by an appropri‐
ate expert.
Hairline cracks or larger cracks may be formed on the rims over a

long period of time. We recommend checking the rims annually with
the magnetic particle testing method.
The inspection can be performed on one rim at a time in conjunction
with other tyre service procedures. The checked rims are easy to
identify if they are marked with, for example, a colour that is
changed each year.
Component position
Rim structure
2 1 3 5 4 6 7 8 9 1. Flange
2. Lock ring driver
3. Lock ring
4. Gutter band
5. O-ring
6. Bead seat band
7. Center band
8. Back band
9. Rimbase and disc
Alternative 1
2 1 3 5 4 6 7 8 9
Alternative 2
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Checking a rim
1 Deflate the tyre.

2 Remove the wheel.
4 3 Remove the tyre from the rim, and disassemble the rim; see
paragraph Rim structure. Remove loose items 1 and 6.
4 Clean the areas of the rim that are marked with a dash line in
8
the figure, removing all paint.
5 Check the marked areas with magnetic particles. If there are
no cracks, accept the rim for use.
6 If there are cracks, grind the cracked sections until they are
smooth, do not grind deeper than 0.5 mm. Perform a pene‐
trant test with a solvent-based penetrant liquid.
If there are no cracks, accept the rim for use.
If there are cracks, discard the rim.
7 Protect the rim from rust by, for example, painting it.
8 Reassemble the rim, and install the wheel.
NOTE
Ensure that the rim components are properly in place.
9 Mark the rim, and record the procedures in the service log.
6.3.3 Tightening torques of the wheel nuts

Instructions
Check the condition of the threads of the wheel mounting scews
and nuts when installing the wheel. The threads must be intact and
clean. Lubricate the threads lightly.
Use the right order when tightening wheel nuts. Tightening order for
12 and 20 nut wheels are shown in the illustrations.
1 5
12 Check tightening torques from Chapter F Technical data.
9
8
CAUTION
4 3
10 7
If any of the bolts are broken, all bolts of that joint must be replaced.
6 2 11
NOTE
Check the wheel nuts visually every day and the tightening torque
Fig. : Tightening order for wheels with 12 nuts every 500 hours.
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24 1 9
16 17
5
8
13
20
12 21
4 3
11
22
19
14
6 7
18 10 2 23 15
Fig. : Tightening order for wheels with 20 nuts

6.3.4 Cleaning wheel hub and rim before
installation
General
All excessive grease and other impurities must be cleaned from the
contact surfaces of the wheel hub and rim before installing the
wheel. Use grease removing chemical, for example, white spirit.
Cleaning a wheel rim

Clean both sides of a rim on contact surfaces indicated in the figure.
The contact surfaces should only have primer paint on the surface.
Cleaning a wheel hub

Clean a wheel hub on contact surface indicated in the figure.
Instruction applies to both driving and running wheel.
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6.3.5 Tyre pressure monitoring system (option)

Description
WARNING
• The system does not prevent low tyre pressure, it only alerts of
a low tyre pressure.
• The system does not prevent tyre or wheel overload. Overload‐
ing any tyre is extremely dangerous and can cause failure of
suspension components, not just tires.
• Tyres can fail for other reasons besides low pressure or over‐
loading. Always be on the alert for other tyre problems as indica‐
ted by unusual noises, vibration, uneven tread wear or bulges
on the tire.
The system monitors the pressure in tyres via electronic sensors

that read pressures and transmit a Radio Frequency (RF) signal to a
monitor. The sensors read the tyre pressure in every seven seconds
and send an updated pressure reading every five minutes to the
monitor in the cabin.
Monitor modes
• Normal mode
The Vehicle LEDs next to the “Tractor display” and the trailer
LED(s), flashes every four seconds either green for OK or red
for alarm. The display remains blank.
• Program mode
The program mode is used for programming the sensors to
show data on the monitor. The selected vehicle LED flashes
on/off every second. For any wheel position with a sensor pro‐
grammed, the "Tyre location selected" LED blinks and the dis‐
play shows three dashes ("- - -").
Nonprogrammed locations flashes when selected and scrolls a
“No sensor" -message.
1 3 4 Button functions
5 6
1. Vehicle selection LEDs

2. SEL button
3. SEL button
4. PROG button
5. Sensor low-battery indicator
6. UP & DOWN buttons
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• SET button (3)

When in Normal mode, pushing and holding the SET button
lights up all tyre locations that have been programmed.
When in Program mode, pushing the SET button exits the Pro‐
gram mode.
• PROG button (4)
Hold the PROG button (approximately for five seconds) until
the LED for the selected group blinks ‘off’ as part of the on/off
alternations denoting Program mode.
Deleting a single sensor/location: With a tyre location selected,
hold the PROG button for approximately. 10 seconds to delete
a single sensor location.
To delete all sensor locations: Hold the PROG button for 30
seconds. After five seconds, the Group LED begins to flash;
hold for another five seconds and “DEL” appears on the moni‐
tor.
NOTE
If the selected group LED begins to flash after being in Normal
mode for approximately five seconds, continue to hold the
PROG button until the group LED returns to solid and "DEL"
appears on the display (approximately 10 seconds). The
selected tyre location is deleted and the next wheel location
flashes after the PROG button is released.
• UP & DOWN buttons (6)

In both Normal and Program mode, push the UP button to
rotate the tyre locations clockwise. Push the DOWN button to
rotate the selected tyre location counterclockwise.
• SEL button (2)
The SEL button displays the pressures on the unit that is lit
solid the remaining groups are flashing).
6.3.5.1 Setting upper pressure alerts
Instructions
1 Unplug the power cord from the monitor (the mini-USB con‐
nector).
2 While holding down the UP button, plug the power cord back
into the monitor. A new alert level percentage is displayed on
the screen.
3 Release the UP button.
4 If the monitor displays the upper alert pressure you desire,
continue to step 5. If it is not the upper alert you desire, repeat
steps 1 and 2 until you see the desired alert level.
5 The high alert function can be turned OFF by repeating the
steps 1 and 2 after the 45% level is reached.
6 To turn the high alert function back ON, repeat the steps 1
and 2 to get the 10% alert level.
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6.3.5.2 Sensor alerts
Description
• FIRST STAGE LOW PRESSURE ALERT

Alerts at 12.5% pressure loss from the initial pressure at instal‐
lation. The first alert level gives an audible beep, flashes the
tyre location and displays the low pressure until the low pres‐
sure is corrected the SET button is pressed putting the monitor
into reminder mode, or the monitor is unplugged.
If no button is pressed to mute the system continues to alert.
• SECOND STAGE LOW PRESSURE ALERT
Alerts at 25% pressure loss from the initial pressure at installa‐
tion with an audible beep.
Displays the low pressure and flashes the tyre location.
If no button is pressed to mute the system, the system contin‐
ues to alert until the pressure is corrected.
• REMINDER MODE
To mute the audible alert, set into reminder mode by pressing
the SET button. The system gives a periodical audible alert.
• “SIGNAL CHECK IN” FEATURE
Sensors send “check-in” signal bursts regularly. If a signal is
repeatedly lost, the monitor lights the selected wheel location
with a solid light (no beeping alert except when the location is
selected – it displays dashes “_ _ _” ).
• MULTIPLE LOW PRESSURE ALERTS
The monitor flashes all locations with low pressures. When a
tyre location is selected, the system flashes the pressure and
position of the selected tyre location and gives an audible alert.
• HIGH PRESSURE ALERTS (VARIABLE)
Alerts at 25% high pressure. The level of the alert can be set
by end user from 10%, 15%, 19%, 24%, 28%, 33%, 40% and
45% over the set level. High alert can be turned OFF.
6.3.5.3 Testing signal strength in diagnostic mode
Sensor packet counts
1 Set the monitor into the Program mode by holding the PROG
button (for approximately five seconds). Release when the
Tractor or Trailer light begins flashing.
2 Use the UP or DOWN buttons to select a tyre location. The
monitor displays three dashes (---).
3 Hold the SET button down until a number appears on the dis‐
play (for approximately five seconds), then release the button.
The display goes blank when the SET button is released and
the unit changes to diagnostic display mode.
4 Scroll to tyre locations with UP & DOWN buttons. The number
displayed for each location is the current transmission count
for that selected tyre (00 to 255).
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NOTE
When in diagnostic mode, the Program mode and delete functions are
disabled.
Signal strength testing
1 Press and hold the PROG button to change the diagnostic

display contents from the packet counts to the background
“signal” level.
While holding the PROG button, three digits appears. The first
two digits indicate the RF ‘noise level’ the monitor is experi‐
encing at that time, and the last digit is always "A" meaning
Ambient Temperature. The RF noise level tells how much RF
interference is present. Levels over 8 makes receiving sensor
packets more difficult. The lower the number, the less interfer‐
ence.
When the PROG button is released, the display continues
showing the signal level status of the selected sensor.
2 In the signal level status display mode, the first two digits give
an indication of the RF signal strength level above the RF
level - measured during the latest packet. The last digit is the
temperature code received from the sensor.
Indication Sensor melting range
0 -40C
1 -20C
2 0C
3 20C
4 40C
5 60C
6 80C
7 100C
Signal strength of 1 or 2 is marginal reception; some signals will

not be received. Signal strength above 4 is good. Average signal
strength is in 4 to 6 range.
3 To toggle between packet counts and signal level, press the
PROG button repeatedly. Toggle sequence is:
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a) Packet count (last decimal point).

b) Background noise level while PROG held.
c) Sensor signal strength (no decimal point) or repeater sig‐
nal strength (second decimal point) depending which
was the last signal to be received for that programmed
sensor.
d) Background noise level while PROG held.
e) Cycle repeats.
NOTE
Pressing the SET button at any time cancels the diagnostic mode and
blanks the display, returning the monitor to normal operation and dis‐
play. Receiving an alarm packet from a sensor also cancels the diag‐
nostic mode.
6.3.5.4 Checking the tyre pressures manually
Instructions
1 Remove the sensor.
NOTE
The monitor shows "00" for that sensor and gives an audible alert.
2 Check the pressure, and inflate if necessary.
NOTE
To reset a sensor´s baseline pressure, remove the sensor for 60 sec‐
onds, then reinstall. Removing and replacing a sensor on the valve
stem after driving can result in "false" alerts. Allow tyres to cool to
ambient temperature before installing sensors. If it is not possible to
wait for the tyre to cool, remove the sensor when the tyre is warm, wait
60 seconds and screw back on.
6.3.5.5 Muting the audible alert
Instructions
1 Press the SET button after the alert sounds. This puts the
monitor alert in "reminder" mode. An “alert” beep will continue
periodically as a reminder of a low-pressure situation.
6.3.5.6 Removing sensors to rotate or replace tyres
Description
When the sensors are installed, they are programmed to a specific
tyre position. If rotating tyres or installing new tires or if you have to
remove the sensors, do one of the following:
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Marking sensors
By marking the sensors, you eliminate the need to reprogram the

sensor to the monitor.
1 Mark each sensor to identify its wheel location.

2 When putting the sensors back onto the valve stem, screw the
sensors back onto the sensor’s original wheel location.
Deleting the sensors
1 Delete each sensor from the monitor.

2 When reinstalling sensors, reprogram them.
To delete a sensor or all sensors in a group, see section Button
functions.
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1
Table of content
7 Load handling 3
7.2 Lifting/lowering 3
7.2.2 Hoist ropes 16
7.2.3 Replacing hoist ropes using the mini-hoist 18
7.2.4 Replacing the hoist ropes using the service lift 28
7.2.5 Performing the trim maintenance (option) 36
7.2.6 Tightening torques of the most important screws and bolts 38
7.2.7 Alignment of the hoist machinery 40
7.2.8 Load cell calibration using the touch panel (if E-One2) 43
7.4 Side movement 45
7.4.1 Description 45
7.4.3 Adjustment of the trolley chains 57
7.4.4 Installation of the skew pulling device 58
7.4.5 Removing the skew motor 59
7.4.6 Jacking and wheel change of trolley 63
7.4.7 Changing the lubrication oil of the hoist, trolley and skew gears 64
7.9 Load carrying Bromma 71
7.9.1 Inspection of headblock (if using) twistlocks 73
7.9.2 Spreader stabilizer 73
7.9.3 Load sensing system (option) 78
7.9.4 Spreader cable 79
7.9.5 Lift hook (option) 79
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2
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7 Load handling – 7.2 Lifting/lowering 3
7 Load handling
7.2 Lifting/lowering
Description
General
Hoist machinery is equipped with disc-brakes that prevent move‐
ment when engine is not running or hoisting / lowering command is
not active. Disc-brakes are spring-loaded and land immediately if
the control circuit is broken. An electro-hydraulic thrusters open the
brakes. The brakes have a manual release lever that enables lower‐
ing when normal lowering is not possible.
Hoist gear is a three stage reduction gear mounted on the hoist
drum shaft with a coupling. Hoist drum operates four separate
ropes. Rope ends are fixed to the hoist drum by clamps.
Driving speed is adjusted by the hoist joystick located at the opera‐
tor’s cabin; Inverter is adjusting the speed of the motor on the basis
of joystick position. When the joystick is moved, the hoist brake
opens. The brake stays open until the motor speed goes back to
zero. Then the brake closes. During lowering, the hoist motor acts
as an electrical brake. The command to brake is triggered when the
motor speed exceeds the setpoint speed or the joystick returns the
neutral position.
Overspeed supervising is done by an absolute encoder that is con‐
nected to the hoist drum. In some machines the overspeed protec‐
tion is done by “the fail-safe overspeed" -switch.
PLC-system monitors the hoist position by an absolute-encoder.
When closing the end-stop positions, PLC starts automatically slow‐
down sequence according to PLC-program parameters. If the hoist
position is wrong and there is a possibility that headblock / spreader
rises too high, the overtravel switch activates and closes the hoist
brake immediately.
The hoist is guided by a smart slowdown system that controls the
speed of the hoisting or lowering when closing to the end stop limit.
The hoisting or lowering movement is stopped automatically at the
end stop limit.
Hoisting is limited with an overtravel limit that protects the hoist
machinery from damage in case of PLC malfunction. In case of
overtravel, the emergency stop is activated and the hoisting is stop‐
ped immediately.
When the "emergency stop" -fault is triggered or the height position
of the spreader is lost, the hoist system is synchronized by lifting the
spreader to the overtravel limit switch.
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4 7 Load handling – 7.2 Lifting/lowering
1. Overtravel limit up (hardware)

Stops hoisting motion immediately and the Crane Off state is
initiated. Hoist movement is possible only with bypass function.
2. End stop limit up (software)
1
2 Stops hoisting movement.
3 3. Slowdown checkpoint up (software)
4
PLC checks the hoisting speed at the checkpoint. If the speed
is too high for controlled slowdown, the PLC executes an emer‐
gency stop.
4. Slowdown start point up (software)
Slowdown ramp begins. Location of slowdown start point var‐
5
ies depending on hoisting speed.
6
5. Slowdown start point down (software)
Fig. : Hoist limits Slowdown ramp begins. Location of slowdown start point var‐
ies depending on lowering speed.
6. End stop limit down (software)
Stops hoisting movement.
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Hoist position, speed curves and limits

hw = hardware limit
sw = software limit
1
2 1. overtravel up, synchronization. point (hw)
2. end stop up (sw)
3. slowdown check up (sw)
3
10 4. slowdown up (sw)
5. slowdown down (sw)
6. end stop down (sw)
7. ground level
8. max speed
4 9. speed curve
10. position curve
8
6
7
52
Diesel generator power supply

Hoist movement consists of AC-Generator, rectifier, inverter and
electric hoist motor. The system is powered by an AC-generator that
is run by a diesel engine.
Re-generative power from the motor is fed to the DC-link, where the
braking units feed all excess energy to the braking resistors that
transfer the braking energy into heat.
Zero emission power supply (option)

Hoist movement consists of rectifier, inverter and electric hoist
motor. The system is powered by external power source through a
cable. The crane is equipped with medium voltage transformer if the
power supply voltage is more than 1 kV.
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Re-generative power from the motor is fed to the DC-link where the
Active Interface Module (AIM) feeds all excess energy to the elec‐
tricity distribution network.
Function description of hoist (diesel generator

power supply)
PLC PLC
11
8, 17
16
15
540 - 600 VDC

-
2 G 6 ~
3 5 7
- U U
18 18
~
4
400 - 440 VAC
10 M~ °C 12
3
9, 20 19 19
13 PG
14 n
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1 The diesel engine generates the

power required by the AC-
generator.
2 The AC-generator (G01) produces 400 – 440 VAC, 50 – 60Hz

electric power to the system.
3 Main circuit breaker (F01) protects 400 – 440 VAC, 50 – 60Hz

the system from overload and
short-circuit currents.
4 Main contactor (K0) connects AC- 400 – 440 VAC, 50 – 60Hz

generator ´s output to the RTG
electical system.
5 Main fuses (F2) protect the rectifier 400 – 440 VAC, 50 – 60Hz
6 Rectifier (U5) converts the 400 – 440 VAC / 540 – 600 VDC
alternating current into direct
current for the direct current
intermediate circuit. (DC-link)
7 Inverter (U1) receives electric 540 – 600 VDC / 400 – 440 VAC, 0
power from the DC-link and – 51 Hz
converts the DC power into AC
power operating on adjustable
frequency.
8 the hoist joystick (S731) sends a Joystick – PLC: 24 VDC

setpoint signal to the inverter via PLC – inverter: Profibus
Profibus.
9 Brake (M603) opens when the PLC – Brake Contactor: 24 VDC

inverter starts to control the motor Brake Contactor – Brake: 400
and the motor is producing torque. VAC, 50 – 60Hz
10 The inverter controls the direction ~ 400 VAC, 0 – 51 Hz

of rotation and the speed of the
hoist motor (M601).
11 PLC monitors the overload by Inductive switches - PLC

inductive switches (S612-S615).

the hoist motor with temperature
sensors.

motor with the pulse encoder
(B601) on the motor.
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14 PLC monitors the overspeed of the Overspeed switch – PLC: 24 VDC

hoist motor with an overspeed
switch (S601).
15 PLC monitors the position of the Absolute-encoder – PLC: Profibus

spreader with the absolut-encoder
(B603) attached to the hoist drum.
16 PLC monitors the overtravel of the Overtravel switch – PLC: 24 VDC

hoist with an overtravel switch
(S603).
17 When braking, the hoist motor is Joystick – PLC: 24 VDC

acting as an electrical brake. When PLC – inverter: Profibus
the hoist joystick returns to the
neutral position, the hoist motor
starts to brake.
18 Re-generative power produced by ~680 VDC

inverter is fed via DC-link to
braking units (A1 - A2)
19 Braking units feed all excess ~680 VDC

energy to braking resistors (R91 –
R92), which are transferring
braking energy to heat.
20 When motor rotation speed is zero PLC – Brake contactor: 24 VDC

(motor stopped), the brake (M603) Brake contactor – Brake: 400 VAC,
closes. 50 – 60Hz
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Function description of hoist (zero emission power

supply)
PLC PLC
12
17 9, 18
16
1, 20
540 - 600 VDC
-
2 7 ~
19
3
6 8
-
~
4 5
400 - 440 VAC
11 M~ °C 13
3
10, 21
14 PG
15 n
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1 Electrical power is supplied from See chapter F Technical data for

an external power source through supply voltage
a cable.
2 Electrical power is led through slip See chapter F Technical data for
ring box of the cable ree (X160). supply voltage
3 Medium voltage transformer See chapter F Technical data for

transforms the supply voltage into supply voltage
a lower voltage. The transformer is
applicable only when the power
supply from an external power
source of over 1 kV.
4 Main circuit breaker (F150) 400 – 440 VAC, 50 – 60Hz

protects the system from overload
and shortcircuit currents.
5 Main supply contactor (K50) 400 – 440 VAC, 50 – 60Hz

connects the external power
supply to the RTG electrical
system.
6 Main fuses (F2) protect the rectifier 400 – 440 VAC, 50 – 60Hz
7 Rectifier (U5) converts alternating 400 – 440 VAC / 540 – 600 VDC
current into direct current for the
direct current intermediate circuit.
(DC-link).
8 Inverter (U1) receives the electric 540 – 600 VDC / 400 – 440 VAC, 0
power from the DC-link and – 51 Hz
converts the DC power into AC
power operating on adjustable
frequency.
9 Hoist joystick (S731) sends a Joystick – PLC: 24 VDC

Profibus.
10 Brake (M603) opens when the PLC – Brake Contactor: 24 VDC

inverter starts to control the motor Brake Contactor – Brake: 400
and the motor is producing torque. VAC, 50 – 60Hz
11 Inverter controls the direction of ~ 400 VAC, 0 – 51 Hz

rotation and the speed of the hoist
motor (M601).
12 PLC monitors the overload by Inductive switches - PLC

inductive switches (S612-S615).
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the hoist motor with temperature
sensors.

15 PLC monitors the overspeed of the Overspeed switch – PLC: 24 VDC

hoist motor with an overspeed
switch (S601).
16 PLC monitors the position of the Absolute-encoder – PLC: Profibus

spreader with the absolut-encoder
(B603) attached to the hoist drum.
17 PLC monitors the overtravel of the Overtravel switch – PLC: 24 VDC

hoist with an overtravel switch
(S603).
18 When braking, the hoist motor is Joystick – PLC: 24 VDC

acting as an electrical brake. When PLC – inverter: Profibus
the hoist joystick returns to the
neutral position, the hoist motor
starts to brake.

during braking is fed via a DC-link
to the Active Interface Module
(AIM) (U7).
20 AIM unit feeds all excess energy to

the electricity distribution network.
21 When motor rotation speed is zero PLC – Brake contactor: 24 VDC

(motor stopped), the brake (M603) Brake contactor – Brake: 400 VAC,
closes. 50 – 60Hz
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Hoist equipment
4
5
3
2
1
6
1. Hoist motor
2. Coupling
3. Hoist brake
4. Hoist gear
5. Hoist drum
6. Emergency hoist brake
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Hoist overtravel switch

The overtravel is protected by an overtravel switch that closes the
hoist brake. The crane goes off if the spreader is too high.
7.2.1.1 Overload / eccentric overload protection sensors on

skew trollies
Instructions
IMPORTANT
Before the adjustments of the sensors, check the lifting capacity of
the machine. See chapter F Technical data
1 Hoist a container with a 10 % overload.

2 If the hoist overload fault appears in the cabin display, use the
"Prevent Bypass" -switch in the cabin and lower the container.
NOTE
The torque measurement of the hoist inverter is used for calculating
the load. Overload is detected on PLC by comparing the calculated
value to a 3 % limit value.
The weighing result of the container is not displayed in the cabin,
because the overload sensors stop the weighing of the container when
there is overload.
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Faults in cabin display
Fault Indication
F-7 Hoist overload
F-25 Hoist eccentric load
3 To adjust the overload sensors, move the sensors in the

required direction (up/down) just enough to trigger the "hoist
overload" -fault (the sensor goes OFF).
4 Adjust the eccentric overload sensors first at the same height
than the overload sensors and then lower the sensors four (4)
millimeters.
NOTE
Only in machines with hoist capacity of 35 tons, 40 tons or 41 tons.
5 Adjust the eccentric overload sensors first at the same height

than the overload sensors and then lower the sensors five (5)
millimeters.
NOTE
Only in machines with hoist capacity of 45 tons.
Overload sensors
Capacity Test load (adjusting Setting

overload 10 %)
35 t ca. 38 t Setting at 19 t/side
41 t ca. 45 t Setting at 22.5 t/side
Almost overload sensors (option)

The adjustment height depends on the container weight for which
you want the "Almost overload" -fault to be triggered.
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Almost overload sensors
Capacity Test load (adjusting Setting

underload 5 %)
35 t ca. 33.5 t Setting at 16.75 t/side
Load sensors
S661 (2) Left side Overload
S662 (1) Left side Eccentric
S663 (2) Right side Overload
S664 (1) Right side Eccentric
3 S665 (3) Left side Almost overload

1
S666 (3) Right side Almost overload
2
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Load cell sensors (option)

The machine with a rated hoist capacity of 50 t or more is equipped
with load cell sensors that detect overload. The load cells are moun‐
ted on the axles of two sheaves out of four.
Fig. : Load cells on the headblock

Slack rope sensors
The indicator switches (1) detect a hanging slack rope. They are
1
located next to each intermediate sheave.
1
1
1
7.2.2 Hoist ropes

7.2.2.1 Checking the condition of the hoist ropes
General
IMPORTANT
Any changes noticed in the condition of the hoist ropes must be
reported to a supervisor or service personnel responsible for servic‐
ing the machine.
The condition of the hoist ropes is one of the key factors affecting
the reliability and safety of lifting devices.
The hoist ropes must be visually checked daily for any damage and
deformations. Pay special attention to the point at which the rope
meets the pulley when the spreader is at the container transporta‐
tion height.
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Pay particular attention to the condition and operation of the ropes

during the first 50 hours of operation after replacing the cable. Most
deformations occur during this time.
Rope structure
The hoist rope is a steel wire.
A) General structure
1. Rope core
2. Cord
3. Strand core
4. Rope strand
B) Cross-section
1 2 3 4
When to discard
CAUTION
If the rope damage was caused by a malfunction of the lifting device,
the device must be repaired before replacing the rope.
CAUTION
The rope must be discarded if the number of broken cords is more
than 14 on a section of 132 mm or 29 on a section of 660 mm.
These limits are based on the ISO 4309 and DIN 15020 standards. If
broken cords are found but there are fewer of them than this, the
ropes must be checked every 500 hours of operation.
Fig. : Examples of wires that must be discarded

immediately.
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The operational safety of a hoist rope is determined by the following
• Number and type of wire fractures

• Wire fractures near terminals
• Many wire fractures within a short section
• Accumulation of wire fractures
• Broken strands
• Reduced diameter caused by a damaged core
• Reduced elasticity
• Internal and external wear
• Corrosion
• Deformations
• Damage caused by heat or electricity
7.2.3 Replacing hoist ropes using the mini-hoist

General
These instructions apply to machines both with a trim and without it.
Preparatory procedures
Lower the spreader on planks or some other stand on the ground so
that the weight is not on the twist locks or flippers.
Remove the rain covers from the top of the hoisting drum and idlers.
Place the covers on the service platform in the middle of the trolley.
CAUTION
Always use a safety harness when working on the crane outside the
safety rails.
7.2.3.1 Detaching the rope-ends of old ropes
Detaching the ropes that go to the hoisting drum through the idlers
1 Use a lifting sling to fasten the top of the mini-hoist to the rail
(A) next to the idler.
2 Attach a hook to the mini-lift wire rope.
3 Use a rope lock and a lifting sling to fasten the hoist hook to
the hoist rope to the point (B).
4 Lift the rope with the hoist. The rope-end on the drum
becomes loose.
5 Remove all fasteners holding the rope-end on the hoisting
drum.
6 Lower the rope to the ground with the mini-hoist.
A 7 Repeat steps 1-6 to the other rope coming to the drum
through the idler.
Fig. : Fastening points for the top of the mini-hoist (A)
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B B
A A
A-A
Fig. : Fastening points for mini-hoist hook (B)

Detaching the ropes that go straight to the drum
B
(B) behind the hoisting drum.
3 Use a rope lock and a lifting sling to fasten the hoist hook to
the hoist rope to point (C).
4 Lift the rope with the hoist. The rope-end on the drum
becomes loose.
drum.
7 Repeat steps 1-6 to the other rope coming straight to the
drum.
Fig. : Fastening points for and the top of the mini hoist
(B)
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Fig. : Fastening points for mini-hoist hook (C)

Detaching ropes from the skew
To detach the rope fastened to the skew, remove the rope length
adjustment screw from the skew. Remove also the pocket and hoist
rope-end.
1
3
6
7
1. idler
2. adjustment screw
3. installation bar
4. shackle
5. mini-hoist wire
6. mounting nut
7. skew
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1 Fasten the top of the mini-hoist with a lifting sling to the rail
(H) next to the idler (1).
2 Remove the mini-hoist hook.
3 Screw the installation bar (3) to the end of the adjustment
screw (2) on the skew (7).
4 Fasten the bar to the mini-hoist wire (5) with the shackle (4).
5 Lift the adjustment screw (2) and rope slightly with the mini-
hoist.
6 Open the locking of the mounting nut (6) and screw it open.
Remove the nut.
H 7 Lower the rope to the ground with the mini-hoist.
8 Repeat steps 1-7 to the other rope fastened to the skew and
to both ropes fastened to the other skew.
Fig. : Fastening points for the top of the mini-hoist (H)

NOTE
If the machine is equipped with a trim, perform also the following
steps.
9 Put the trim locking pin through the trim wheel and to the point
A B
(B). This way the trim does not move during the installation.
CAUTION
If the locking pin is not used, the trim may move and cause injury.
After the replacement of the ropes, the locking pin must be detached
from the center hole. Otherwise it is possible to damage the trim
motor by driving into the locking pin.
A. locking pin storage

B. locking hole
10 Tie the top end of the mini-hoist with a lifting sling to the posi‐
tion (D).
Fig. : Fastening points for the top of the mini hoist (D)
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12 Use a rope lock and a lifting sling to fasten the mini-hoist wire
and hook to the hoist rope point (E). The fastening point is at
the service platform level.
13 Move the skew so that the mini-hoist wire rope is straight
down.
14 Slightly lift the hoist rope with the mini-hoist.
15 When the rope on the trim is loose, remove the locking pin
E and the mounting bolt.
16 Dismantle the pocket at the rope-end so that the rope can fit
through the trim.
18 Repeat steps 9-17 to the other rope on the trim.
Fig. : Fastening points for mini-hoist hook (E)

7.2.3.2 Installing new ropes
Instructions
IMPORTANT
Before you start installing the ropes, note that the ropes are not all
the same length. The length of the hoist ropes varies depending on
whether the ropes go straight to the drum or through an idler and
whether the machine is equipped with a trim or not. Also the two
ropes coming to the trim are of different length.
A There are two types of hoist ropes. The lays of rope are different, the
lay can be left- or right-handed. These different types are marked as
B follows: SZ = righthanded lay and ZS = left-handed lay.
A Keep the new ropes as clean as possible during the installation.

It is easier to balance the spreader later if the pocket of each rope is
placed at the same distance (A and B) from the rope-end.
Check the diameter of the hoist ropes. The correct diameter can be
found from the technical data.
A. 50 mm (2 in)
B. 100 mm (4 in) Make sure that the rope lengths and places for each rope are cor‐
rect. The correct lengths can be found from the technical data.
CAUTION
When a hoist rope is pulled up from a reel on the ground, the reel
must be rotated so that the rope does not become twisted. The twists
can bend the rope so that it is damaged.
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Fig. : Positions of the hoist ropes (1-4)

Installing the rope-ends to the skew
1 Install the pocket at the end of a new rope on the ground and
tighten it.
2 Fasten the adjustment screw detached from the skew to the
pocket.
3 Fasten the top end of the mini-hoist to the trolley rail.
4 Remove the mini-hoist hook.
Fig. : Installation bar coming through the skew

5 Lower the hoist wire rope end to the ground through the hole
1 on the skew (5).
6 Use the installation bar (2) and the shackle (3) to fasten the
2 assembly prepared on the ground to the wire rope.
7 Lift the adjustment screw (3) up through the skew hole.
Fig. : Mounting nut in its place

1. shackle
2. installation bar
3. adjustment screw
4. mounting nut
5. skew
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8 Make sure that the twist-prevention pin (8) goes to a slot on

the adjustment screw (9) to prevent the hoist rope from twist‐
ing.
Fig. : Threading the mounting nut in its place

9 Thread the mounting nut (6) in its place on the adjustment
8
6 screw and lock it.
7 10 Check the mounting of the twist-prevention pin (8). There
must be a spring washer (7) under the mounting nut (6), and
some of the pin’s threads must be visible. Tighten with care if
necessary.
11 Repeat steps 1-10 to the other rope-ends that will be fastened
to the skews.
NOTE
9 If the machine is equipped with a trim, perform also the following

steps.
12 Thread the rope end through the trim, pull it all the way to the
ground and then install the pocket on the ground.
Fig. : The mounting of the twist-prevention pin.
6. mounting nut NOTE
7. washer
8. twist-prevention pin The rope is installed to the trim with the same kind of pocket as to the
9. adjustment screw (includes a slot for a pin) skew. The fastener must not be fastened to the rope on the ground
beforehand because then the rope would not fit to its place through
the trim.
13 Tie the top end of the mini-hoist with a lifting sling to the posi‐
tion (D).
14 Fasten the mini-hoist wire rope to the hoist rope with a
shackle, rope lock and a lifting sling, leave 5 metres of the
rope free on the rope-end.
15 Lift the hoist rope with the mini-hoist.
16 Thread the rope through the trim.
17 Use a rope lock and a lifting sling to fasten an auxiliary rope to
the end of the hoist rope that comes through the trim. Leave
D enough rope free after the fastening point to attach the
pocket.
18 Lock the other end of the hoist rope to a fixed object on the
ground to prevent it from rising to the trim during the installa‐
Fig. : Fastening points for the top of the mini hoist (D) tion.
19 Detach the mini-hoist wire rope from the hoist rope.
20 Use the auxiliary rope to pull the hoist rope-end to the ground.
21 Install the pocket to the rope-end.
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22 Pull the free end of the rope by hand so that the other rope-
end and the pocket installed to it rise to the trim. At the same
time, slow down with the auxiliary rope so that the rope-end
does not rise to the trim too fast.
23 When the pocket is in its place in the trim, put the mounting
bolt and locking pin in their places.
24 Detach the auxiliary rope.
25 Repeat steps 12-24 to the other rope that will be on the trim.
Threading the ropes
Fig. : Rope lay-out

Thread the ropes through the idlers of the spreader or the head‐
block. The idlers are on the headblock, if the machine has one. If
there is no headblock on the machine, the idlers are on the
spreader.
Thread the ropes as shown in the figure.
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Installing the rope-ends to the drum

The rope installation method varies depending on whether the ropes
come to the drum straight from the headblock or through the rope
idlers.
A 1 Fasten all the four rope-ends to the drum with one small fas‐
tener (B).
2 Check the balance.
3 Rotate the drum three rounds and then fasten the ropes per‐
B manently with larger fasteners (A).
A. large fastener
B. small fastener
Installing the rope-ends that come straight to the drum
Ropes that come straight to the drum are fastened with the fasten‐
ers in the middle of the drum.
behind the hoisting drum..
2 Use a shackle, a rope lock and a lifting sling to fasten the min‐
ihoist wire rope on the ground to the hoist rope. Leave 1.5
metres of the rope-end free.
3 Lift the rope up to the drum.
4 Use a small fastener to fasten the end of the rope to the drum.
NOTE
Do not tighten the first small single-rope-fastener too much. Avoid
bending of bolt.
5 Detach the mini-hoist

6 Repeat steps 1-5 to the other hoist rope that comes straight to
the drum.
Installing the rope-ends that come through the idler to the drum
Ropes that come through the idlers to the drum are fastened with
the fasteners at the end of the drum.
behind the hoisting drum.
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2 Attach a cable stocking (B) to the hoist rope-end (A).

3 Attach the mini-hoist wire rope to the cable stocking with a
A shackle.
4 Pull the rope with the mini-hoist through the idler to the drum.
You must pull the rope slightly past the drum so that the cable
stocking does not remain between the fasteners.
5 Fasten the rope with a large fastener to the last fastening
point on the drum.
6 Detach the mini-hoist and cable stocking from the hoist rope-
end.
A. Hoist rope-end
B. Cable stocking
7 Fasten the rope-end with a small fastener to the correct posi‐
tion on the drum (at this point the rope is bent so that it is
upraised on the drum).
584 Nm
NOTE
A
Do not tighten the first small single-rope-fastener (A) too much. Avoid
bending of bolt.
8 Remove the large fastener from the drum. The rope takes its
correct place on the drum.
9 Repeat steps 1-8 to the other rope that comes to the drum
Fig. : Correct torque for double-rope-fastener through the idler.
Balancing the spreader

When the ropes are fastened with one small fastener, you can
check if the spreader is balanced when lifted. All ropes must carry
an equal amount of the load. If rough adjustment is needed (10 cm
or more), the adjustment is done by moving the fastening point of
the rope forward on the drum. Move the rope end with the minihoist
the same way as before. Fine adjustment is done later with the rope
length adjustment screws that are attached to the skews.
Final fastening of the hoist rope-ends on the drum

When the spreader is roughly balanced, the ropes can be fastened
more permanently. Use a weight to make sure that the ropes are
straight and tight on the drum.
1 Rotate the hoisting drum three rounds.

2 When rotating the hoisting drum, make sure that the ropes are
in line on the drum.
3 Fasten the double-rope-fasteners to the correct torque (Tight‐
ening torque 584 Nm).
Procedures after the installation
1 Fine-adjust the spreader balance with the adjustment screws

on the skews.
2 Lubricate the ropes.
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7.2.4 Replacing the hoist ropes using the

service lift
General
These instructions apply to the machines both with a trim and with‐
out it.
Preparatory procedures
CAUTION
Always use a safety harness when working on the machine outside
the safety rails.
1 Lower the spreader on planks or some other stand on the

ground so that the weight is not on the twist locks or flippers.
2 Remove the rain covers from the top of the hoisting drum and
idlers.
3 Place the covers on the service platform in the middle of the
trolley.
7.2.4.1 Detaching the rope-ends of old ropes
Detaching the ropes that go to the hoisting drum through the idlers
B B
A A
A-A
1 Use a rope lock and a lifting sling to fasten the service lift
chain to the hoist rope to the point (B).
2 Lift the rope with the lift. The rope-end on the drum becomes
loose.
drum and lower the rope to the ground with the service lift.
4 Repeat steps 1-3 to the other rope that come to the drum
through the idler.
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NOTE
steps.
5 Lock the trim with the locking pin (B) through the trim wheel.
A B
This way the trim does not move during the installation.
CAUTION
If the locking pin is not used, the trim may move and cause injury.
WARNING
A. Locking pin storage After the replacement of the ropes, the locking pin must be detached
B. Locking hole from the center hole. Otherwise it is possible to damage the trim
motor by driving into the locking pin.
6 Attach a hook to the end of the service lift chain.

7 Thread the lift chain at a point (A) through the trolley next to
A the other trim rope.
Fig. : Threading points for the lift chain (A)
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chain to the hoist rope. A suitable fastening height is at the
trim service platform level (D).
9 Lift the hoist rope a few inches with the service lift.
10 When the rope on the trim is loose, remove the locking pin
and the mounting pin from the pocket.
11 Dismantle the pocket at the rope-end so that the rope can fit
through the trim.
12 Lower the old rope to the ground with the service lift.
13 Repeat steps 5-12 to the other rope on the trim.
D
Fig. : fastening points for the lift hook (D)
Detaching the ropes that go straight to the drum
A A
C
A- A
chain to the hoist rope to the point (C).
2 Lift the rope with the lift. The rope-end on the drum becomes
loose.
3 Remove all fasteners on the hoisting drum and lower the rope
to the ground with the lift.
4 Repeat steps 1-3 to the other rope coming straight to the
drum.
Detaching the rope-ends fastened to the skew

To detach the rope fastened to the skew, remove the adjustment
screw of the rope length from the skew. The pocket and hoist
ropeend are also removed.
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1 Screw the installation bar (2) to the end of the adjusting screw
6
1 (3) on the skew and lock it with the mounting nut (4).
2 Remove the hook from the end of the service lift chain (6).
2
3 Attach the service lift chain to the installation bar with the
shackle (1).
4 Lift the adjusting screw and rope slightly with the lift.
5 Open the locking of the nut and screw it open.
3 6 Lower the rope to the ground with the lift (the lift chain goes
through the skew and the nut).
4 7 Repeat steps 1-6 to the other rope fastened to the skew and
to both ropes fastened to the other skew.
5
1. shackle
2. installation bar
3. adjusting screw
4. mounting nut
5. skew
6. service lift chain
7.2.4.2 Installing new ropes
Instructions
NOTE
Before you start installing the ropes, note that the ropes are not all the
same length. The length of the hoist ropes varies depending on
whether the ropes go straight to the drum or through an idler and
whether the machine is equipped with a trim. Also the two ropes com‐
ing to the trim are of different length.
A There are two types of hoist ropes. The lays of rope are different, the
lay can be left- or right-handed. These different types are marked as
B follows: SZ = right-handed lay and ZS = left-handed lay.
A Keep the new ropes as clean as possible during the installation.

It is easier to balance the spreader later if the pocket of each rope is
placed at the same distance (A and B) from the rope-end.
Check the diameter of the hoist ropes. The correct diameter can be
found from the technical data.
A. 50 mm (2 in)
B. 100 mm (4 in)
Make sure that the rope lengths and places for each rope are correct.
The correct lengths can be found from the technical data.
CAUTION
When a hoist rope is pulled up from a reel on the ground, the reel
must be rotated so that the rope does not become twisted. The twists
can bend the rope so that it is damaged.
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Fig. : Positions of the hoist ropes (1-4)

Installing the rope-ends to the skew
1 Install the pocket at the end of a new rope on the ground and
3
1 tighten it.
2 2 Fasten the adjustment screw (4) detached from the skew to
the pocket.
3 Remove the hook from the end of the chain.
4 Lower the service lift chain to the ground through the hole on
the skew and the mounting nut (1). (The nut cannot be instal‐
led later, it must be taken into consideration at this point.)
5 Fasten the assembly prepared on the ground to the chain with
the installation bar and the shackle
6 Lift the adjustment screw (4) up through the skew hole and
adjustment screw nut. When the rope is nearly up, it is impor‐
4 tant to check that the pin (3) goes to the slot on the adjust‐
ment screw (4).
7 Thread the mounting nut (1) in its place on the adjustment
screw (4) and lock it.
8 Check the mounting of the twist-prevention pin. There must be
Fig. : The mounting of the twist-prevention pin. a spring washer (2) under the mounting nut (1), and some of
1. mounting nut the pin’s threads (3) must be visible. Tighten with care if nec‐
2. washer essary.
3. twist-prevention pin 9 Repeat steps 1-8 to the other rope-ends that will be fastened
4. adjustment screw (includes a slot for a pin) to the skews.
NOTE
steps.
10 Thread the rope end through the trim, pull it all the way to the
ground and then install the pocket on the ground.
NOTE
The rope is installed to the trim with the same kind of pocket as to the
skew. The pocket must not be attached on the ground beforehand
because then the rope would not fit to its place through the trim.
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11 Lower the service lift chain to the ground through a point (A).
A 12 Use a rope lock and a lifting sling to fasten the lift chain to the
hoist rope. Leave 5 metres of the rope free.
13 Lift the hoist rope with the lift.
14 Thread the rope through the trim.
15 Use a rope lock and a lifting sling to fasten an auxiliary rope to
the end of the hoist rope. Leave enough rope free after the
fastening point to attach the pocket.
16 Lock the other end of the hoist rope to a fixed object on the
ground. This prevents it from rising to the trim during the
installation of pocket on the other end.
17 Detach the service lift chain from the hoist rope (keep the
hoist rope in its place with the auxiliary rope).
18 Pull the rope-end to the ground with the auxiliary rope and
install the pocket to the rope-end.
19 Pull the other end of the rope by hand so that the rope-end
with the pocket attached to it rises to the trim. At the same
time, slow down with the auxiliary rope so that the rope end
does not rise to the trim too fast.
20 When the pocket is in its place in the trim, put the mounting
A pin and locking pin in their places
21 Repeat steps 10-20 to the other rope that is on the trim.
Fig. : Chain lay-out (A)
Threading the ropes
Fig. : Rope lay-out
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1 Thread the ropes through the idlers of the spreader or the

headblock. The idlers are on the headblock, if the machine
has one. If there is no headblock on the machine, the idlers
are on the spreader.
Thread the ropes as shown in the figure.
Installing the rope-ends to the drum

The rope installation method varies depending on whether the ropes
come to the drum straight from the headblock or through the rope
idlers.
1 Fasten all the four rope-ends to the drum with one small fas‐
tener (B).
2 Check the balance.
3 Rotate the drum three rounds and then fasten the ropes per‐
A manently with larger fasteners (A).
A. large fastener
B. small fastener
Installing the rope-ends that come straight to the drum
Ropes that come straight to the drum are fastened with the fasten‐
ers in the middle of the drum.
1 Lower the service lift chain through the trolley at the point (A).
2 Use a rope lock and a lifting sling to fasten the chain on the
ground to the hoist rope. Leave 1.5 metres of the rope-end
free.
3 Lift the rope up to the drum.
4 Fasten the end of the rope to the drum with a small fastener.
A
NOTE
Do not tighten the first small single-rope-fastener too much. Avoid
bending of bolt.
5 Repeat steps 1-4 to the other rope that comes straight to the
drum.
Fig. : Lowering point (A)

Installing the rope-ends that come through the idler to the drum
Ropes that come through the idlers to the drum are fastened with
the fasteners at the end of the drum.
Before lifting the rope to the idler, fasten an auxiliary rope to the
hoist rope in addition to the chain. Use the auxiliary rope to guide
Maintenance manual
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the rope-end first up from the idler groove (this is the only way to
make the rope fit through the hole).
1 Lower the service lift chain next to the groove (A) of the other
A idler.
2 Use a rope lock and a lifting sling to attach the lift chain to the
hoist rope. Leave 7 metres of the rope end free so that it rea‐
ches through the idler to the drum.
3 Attach an auxiliary rope that reaches from the trolley to the
ground.
4 Lift the hoist rope with the service lift. Stop the rope before it
reaches the trolley.
5 Pull the rope-end with the auxiliary rope up through the idler
groove.
6 Lift the rope more with the service lift.
Fig. : Lowering point (A)

7 Thread the rope through the idler to the drum and use one
small fastener to fasten the rope-end to the hoisting drum.
584 Nm
NOTE
A Do not tighten the first small single-rope-fastener (A) too much. Avoid
bending of bolt.
8 Detach the service lift chain from the hoist rope.

9 Repeat steps 1-8 to the other rope that comes to the drum
through the idler.
Fig. : Correct torque for double-rope-fastener

Balancing the spreader
When the ropes are fastened with one small fastener, you can
check if the spreader swings when lifted. All ropes must carry an
equal amount of the load. If rough adjustment is needed (10 cm or
more), the adjustment is done by moving the fastening point of the
rope forward on the drum. Move the rope-end with the service lift.
Fine adjustment is done later with the adjustment screws of the rope
length that are attached to the skews.
Final fastening of the hoist rope-ends on the drum

When the spreader is roughly balanced, the ropes can be fastened
more permanently. Use a weight to make sure that the ropes are
straight and tight on the drum.
1 Rotate the hoisting drum three rounds.

2 When rotating the hoisting drum, make sure that the ropes go
to the grooves on the drum.
3 Fasten the double-rope-fasteners to the correct torque (Tight‐
ening torque 584 Nm).
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Procedures after the installation
1 Fine-adjust the spreader balance with the adjustment screws

on the skews.
2 Lubricate the ropes.
7.2.5 Performing the trim maintenance (option)

General
The trim may be used only when it is required for handling the con‐
tainer. The trim can be used for lowering and lifting one side of the
5°° spreader through 3 or 5 degrees. Normally, the trim idler should be
in the middle position. Unnecessary running of the trim causes
5°° needless wear and may result in premature need for maintenance.
The faultless operation of the trim requires regular maintenance in
1 accordance with the manual. Neglecting the maintenance instruc‐
tions can lead to, for example, falling of the container.
Instructions
WARNING
If the lift or trim mechanism shows any sign of malfunction during
operation - for example, the load does not remain at the set height -
stop working immediately and contact service personnel.
Neglecting the maintenance of the trim will cause falling of the load
which can result in injury.
Only two people are allowed to be on trim service platform at the
same time.
The crane functions must not be used during the maintenance.
CAUTION
• Prior to maintenance, the load must always be lowered.
• You must insert the trim locking pin (1) in the locating hole
before commencing maintenance. This is to prevent the trim
from tilting +/-3° or +/-5°.
• When installing the hoist ropes, make sure that you also secure
the trim with a locking pin.
• Be sure to remove the locking pin when the maintenance is fin‐
ished.
NOTE
The electric brake is equipped with a microswitch that prevents the
use of the trim if brake maintenance is neglected. If use of the trim is
prevented, neglecting proper brake maintenance has caused the
brake to wear past the permitted level.
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Maintenance points
• Observing the operation of the device while working

• Adjusting the end and middle limits when necessary
• Checking the gear oil level
• Changing the gear oil
• Cleaning the gear breather
• Checking the electric brake according to the instructions
• Adjusting the electric brake when necessary
• Lubricating the idler slide bearing with grease
• Inspecting the general condition of the structures during main‐
tenance
• Checking the tightness of the bolts
Changing the oil
2
1
4 A
3 7
6
5 7
5
The trim gear oil change has to be made from the service platform
installed for this purpose. Remove the grille (1) and go down the
ladder (2) to the service platform (3).
1 Move the trim with the skew-sideshift to the middle of the

service platform (point A), so that the trim also functions as a
wall for the service platform.
2 Lower the spreader to the ground.
3 Lock the trim to the middle position with the locking pin (4).
4 Place an oil receiver under the trim gear.
5 Open the oil drain plugs (5) and let the oil drain into the
receiver.
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NOTE
Oil volumes are 17 litres and 2 litres
6 Open the filling plugs (6).

7 After the oil has drained, close the drain plugs (5).
8 Fill new oil to the level of the level plugs (7) and close the fill‐
ing plugs (6).
7.2.6 Tightening torques of the most important

screws and bolts
Hoist equipment
B B B
6 6
7 7
B A
1
2 2 5
3
3
A 3
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Pos Hoist equipment
Fixing bolts of hoist ropes: Screws M24 x 90 mm.

1
Tightening torque 584 Nm (433 ft-lbf)4 x 6 = 24 pcs
Fixing bolts of the coupling:Screws M16 x 50 mm.

2
Tightening torque 280 Nm (207 ft-lbf)
Fixing bolts of the hoist drum: Screws M30 x 120 mm.

3
Fixing bolts of the hoist drum to flange: Screws M24 x 70

4
mm. Tightening torque 655 Nm (485 ft-lbf)
Fixing bolts of the coupling to flange: Screws M12 x 45

5
mm. Tightening torque 120 Nm (89ft-lbf)
Fixing bolts of the electric motor: Screws M24 x 130 mm.

6
Fixing bolts of the hoist brake: Screws M24 x 50 mm.

7
NOTE
Check and tighten the bolt and screw connections
The maintenance interval is 3000 main diesel hours, or at least once a
year.
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Trim (option)
1 239 N m
NOTE
You must insert the trim locking pin (1) in the locating hole before you
start the maintenance. This is to prevent the trim from tilting +/-3° or
+/-5°.
Check and tighten the screw connection to 239 Nm (177 ft-lbf).
7.2.7 Alignment of the hoist machinery

Instructions
A
NOTE
D All adjustments related to the hoist machinery coupling are made by
moving the electric motor longitudinally, laterally, or vertically.
E
B C
A. Motor mounting bolt (4 pcs)

B. Lateral motor adjustment screw (4 pcs)
C. Motor adjustment screw lock nut (8 pcs)
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D. Longitudinal motor adjustment screw (4 pcs)

E. Shim
1 Adjust the correct distance (250 ±0.25 mm) between the
H
sleeves with the motor adjustment screws (D) by measuring
the distance between the measurement points (H) using, for
F G
example, a tape measure and micrometer.
250 ±0,25mm
60
60
F= Axle of the hoist gear

G= Axle of the electric motor
H= Measuring point from center line
0.5mm
2 Adjust the alignment of the sleeves using a square tool (max.

0.5 mm).
• Perform lateral adjustment with the motor adjust‐
a)
ment screws (B).
b) Perform vertical adjustment by placing shims (E)
under the motor, at the mounting bolts.
3 Check the alignment of the sleeves with a dial gauge .
• a) Rotate the transmission shaft via the brake plate to
view the measurement result on the dial gauge.
b) If necessary, use the motor adjustment screws (B)
and shims (E) to adjust.
Maintenance manual
208 001 EN
0.1°
0.1°
Ø120
max. 0,4mm
4 Check the alignment (max. 0.4 mm) of the sleeves with the
dial gauge.
• a)Rotate the transmission shaft via the brake plate to
view the measurement result on the dial gauge.
b) If necessary, use the motor adjustment screws to
adjust (D).
5 After all adjustments are performed, tighten the motor mount‐
A ing bolts (A) (tightening torque: 629 Nm).
6 Lock the motor adjustment screw lock nuts (C) with Loctite
641 thread-locking compound.
D
E
B C
7 Install the shaft tube (I) and the transmission-side lamella (J)
between the sleeves.
I J
NOTE
The direction of installation of the mounting bolts (L).
Maintenance manual
208 001 EN
8 Install the motor-side lamella (K) between the sleeve and the
shaft tube.
K
NOTE
The direction of installation of the mounting bolts (L).
9 Tighten the mounting bolts of the coupling (tightening torque:

280 Nm).
7.2.8 Load cell calibration using the touch panel

(if E-One2)
Instructions
Calibrating force sensors
NOTE
RTG with rated hoist capacity of 50 ton or more is equipped with load
cells (B902, B903) detecting overload.
NOTE
Use a test container that gives equal load for all ropes (not an unbal‐
anced test container). The weight should be as close as possible to
the rated load.
1 Press the calibration button in the RTG status display. It

opens the calibration screen of the force sensors.
2 Lower the spreader on the test container until the ropes are
loose. You may have to use the bypass switch. The sensors
zeroed indicator turns to green when the ropes are loose
enough.
3 Fill the weight of the test container in the related field in the
force censors calibration screen.
4 Close the twistlocks.
5 Hoist up the test container.
6 Wait until the raw signal value is unchangeable in the calibra‐
tion screen of the force sensors
7 Press the Calibration button.
Maintenance manual
208 001 EN
8 Check the weight with empty spreader. The left and right val‐
ues should be equal (±1.0T).

7.2.9.1 Headblock
Instructions
A. Intermediate sheaves for hoist ropes
Maintenance manual
208 001 EN
7 Load handling – 7.4 Side movement 45
7.4 Side movement
7.4.1 Description
General
The trolley frame assembly is made of welded steel. The operator
cabin is bolted on the trolley and travels with it across the crane
span width.
The hoist drum is attached at the other end of the trolley frame and
two hoist cable pulleys at the opposite sides of trolley frame.
The driving speed is adjusted by a trolley joystick located at the
operator’s cabin. An inverter adjusts the speed of the motor on the
basis of joystick position.
When joystick is moved, trolley brake is opened and it will stay open
until driving speed goes back to zero, then brake will close. When
braking (decelerating), the trolley motor acts as an electrical brake.
When the trolley joystick is returned to the neutral position, the trol‐
ley motor starts to brake.
During the trolley movement, the PLC system monitors the position
by a speed signal. When the trolley is near the end stop, the PLC
starts to slow down the trolley according to predefined parameters.
When the trolley bypasses the slowdown check point (3), the PLC
checks that the speed does not exceed the given limits. In case the
software end stop limit (2) is bypassed, the overtravel limit switch (1)
send a signal which activates an E-stop. The E-stop stops trolley by
closing the trolley brake immediately.
There are proximity sensors at the software synchronization points
(4) in both driving directions. When the proximity sensor is activated,
the PLC synchronizes the trolley position.
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46 7 Load handling – 7.4 Side movement
1. Overtravel limit switch (hardware)

The overtravel limit stops the trolley movement immediately.
The trolley movement is possible only with the bypass function.
2. End stop limit (software)
The end stop limit stops the trolley movement.
3. Slowdown checkpoint (hardware)
The PLC checks the trolley travel speed at the checkpoint. If
the speed is too high for controlled slowdown, the PLC exe‐
cutes an emergency stop.
4. Synchronization point (software)
The PLC verifies the trolley position at a synchronization point.
5. Slowdown start point (software)
The slowdown start point begins. The location of the slowdown
start point varies depending on the travelling speed.
Diesel generator power supply
The trolley movement is generated by the AC generator, rectifier,
inverters and electric drive motors. The system is powered by the
AC generator, which is run by a diesel engine.
The regenerative power from the motor is fed via the DC link to the
braking units. The braking units feed all excess energy to the brak‐
ing resistors. The braking resistors transfer the braking energy to
heat..
Zero emission power supply

The trolley movement is generated by the rectifier, inverters and
electric drive motors. The system is powered by an external power
source through a cable connection. When the power supply voltage
is more than 1 kV, the crane is equipped with a medium voltage
transformer.
The regenerative power from the motor is fed via DC link to the
Active Interface Module (AIM). The AIM unit feeds all excess energy
to the electricity distribution network.
Maintenance manual
208 001 EN
Trolley position, speed curves and limits
12
11
13
1 2 3 4 5 6 7 8 9 10
hw = hardware limit
sw = software limit
1. overtravel limit (hw)
2. end stop limit (sw)
3. slowdown checkpoint (hw)
4. synchronization point (hw)
5. slowdown start (sw)
6. slowdown start (sw)
7. synchronization point (hw)
8. slowdown checkpoint (hw)
9. end stop limit (sw)
10. overtravel limit (hw)
11. max speed
12. speed curve
13. position curve
Maintenance manual
208 001 EN
Function description of the trolley travel (diesel

generator power supply)
PLC PLC
13
14 8, 15
540 - 600 VDC

-
2 G 6 ~
3 5 7
- U U
16 16
~
4
400 - 440 VAC

10
M~ °C 11
3
9, 18 17 17
PG
12
The item numbers in parentheses refer to the circuit diagram.
Maintenance manual
208 001 EN
1 The diesel engine generates the

power required by the AC
generator.
2 The AC generator (G01) produces 400 – 440 VAC, 50 – 60Hz

electric power to the system.
3 The main circuit breaker (F01) 400 – 440 VAC, 50 – 60Hz

and shortcircuit currents.
4 The main contactor (K51) connects 400 – 440 VAC, 50 – 60Hz

the AC generator´s output to the
RTG electical system.
5 The main fuses (F2) protect the 400 – 440 VAC, 50 – 60Hz
rectifier from short-circuit currents.
6 The rectifier (U5) converts 400 – 440 VAC / 540 – 600 VDC
intermediate circuit. (DC link)
7 The inverter (U4) receives the 540 – 600 VDC / 400 – 440 VAC, 0
electric power from the DC link and – 51 Hz
convertsthe DC power into
adjustable frequency AC power.
8 The trolley joystick (S701) sends a Joystick – PLC: 24 VDC PLC –

setpoint signal to the inverter via inverter: Profibus
Profibus.
9 The brake (Y601) opens when the PLC – Brake contactor: 24 VDC
inverter starts to control the motor Brake contactor – brake: 400 VAC,
and the motor starts to produce 50 – 60Hz
torque.

of rotation and speed of the trolley
motor (M604).
11 The PLC monitors the temperature Inverter – PLC: Profibus

of the trolley motor with the
temperature sensors.
12 The PLC monitors the speed of the Inverter – PLC: Profibus

motors with the pulse encoder
13 The PLC resets trolley position by Proximity switch – PLC: 24 VDC

a proximity switch (S606).
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208 001 EN
14 The PLC uses a cam switch to Cam switch – PLC: 24 VDC

check the trolley overtravel at both
ends and the trolle speed at the
slowdown area (S605).
15 When braking, the trolley motor Joystick – PLC: 24 VDC PLC –

acts as an electrical brake. The inverter: Profibus
trolley motor starts to brake when
the trolley joystick goes to the
neutral position.
16 The regenerative power produced ~680 VDC

by an inverter is fed via the DC link
to the braking units (A1 - A2)
17 The braking units feed all excess ~680 VDC

energy to braking resistors. The
braking resistors (R91 – R92)
transfer the braking energy to heat.
18 When the motor rotation speed is PLC – Brake contactor: 24 VDC

zero (motor stopped), the brake Brake contactor – Brake: 400 VAC,
(Y601) closes. 50 – 60Hz
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208 001 EN
Function description of the trolley travel (zero

emission power supply)
PLC PLC
14
15 9, 16
1, 18
540 - 600 VDC
-
2 7 ~
17
3
6 8
-
~
4 5
400 - 440 VAC

11
M~ °C 12
3
10, 19
PG
13
The item numbers in parentheses refer to the circuit diagram.
Maintenance manual
208 001 EN
1 Electrical power is supplied from See chapter F Technical data for

an external power source through supply voltage
a cable.
2 Electrical power is led through a See chapter F Technical data for

cable reel slip ring box (X160). supply voltage
3 The medium voltage transformer See chapter F Technical data for

transforms the supply voltage into supply voltage
a lower voltage. The transformer is
supply from the external power
source is over 1 kV.
4 The main circuit breaker (F150) 400 – 440 VAC, 50 – 60Hz

and short-circuit currents.
5 The Main supply contactor (K50) 400 – 440 VAC, 50 – 60Hz

connects the external power
supply to the RTG electical
system.
6 The main fuses (F2) protect the 400 – 440 VAC, 50 – 60Hz
rectifier from short-circuit currents.
7 The rectifier (U5) converts 400 – 440 VAC / 540 – 600 VDC
intermediate circuit. (DC link)
8 The inverter (U4) receives the 540 – 600 VDC / 400 – 440 VAC, 0
electric power from the DC link and – 51 Hz
converts the DC power into
adjustable frequency AC power.
9 The trolley joystick (S701) sends a Joystick – PLC: 24 VDC

Profibus.
10 The brake (Y601) opens when the PLC – Brake contactor: 24 VDC
inverter starts to control the motor Brake contactor – brake: 400 VAC,
and the motor starts to produce 50 – 60Hz
torque.

of rotation and speed of the trolley
motor (M604).
12 The PLC uses the temperature Inverter – PLC: Profibus

sensors to monitor the temperature
of the trolley motor.
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208 001 EN
13 The PLC uses pulse encoder Inverter – PLC: Profibus

(B602) to monitor the speed of the
motors.
14 The PLC resets the trolley position Proximity switch – PLC: 24 VDC
by a proximity switch (S606).
15 The PLC uses a cam switch Cam switch – PLC: 24 VDC

(S605) to check the trolley
overtravel at both ends and the
trolley speed at the slowdown
area.
16 When braking, the trolley motor Joystick – PLC: 24 VDC

acts as an electrical brake. The PLC – inverter: Profibus
trolley motor starts to brake when
the trolley joystick goes to the
neutral position.
17 The regenerative energy ~680 VDC

generated during braking is fed via
DC link to the Active Interface
Module (AIM) (U7).
18 The AIM unit feeds all excess

energy to the electricity distribution
network.
19 When the motor rotation speed is PLC – Brake contactor: 24 VDC

zero (motor stopped), the brake Brake contactor – Brake: 400 VAC,
(Y601) closes. 50 – 60Hz
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Trolley drive motor and gear
1. Motor
2. Gear
Skew motor and gear
1
2
1. Motor
2. Gear
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208 001 EN
Cam limit switch

The cam limit switch (S605) is used for monitoring the overtravel
limits and slowdown checkpoints. The cam limit switch (1) has two
contacts to both trolley travel directions. The contacts give inputs
when the cam comes in contact with the limit bar (2).
A) Overtravel limit
Stops the trolley movement immediately. The trolley movement
is possible only with the bypass function.
A B) Slowdown checkpoint
The PLC checks the trolley travel speed at the checkpoint. If
the speed is too high for a controlled slowdown, the PLC exe‐
1 cutes an emergency stop.
B 2
A
A B
B
Synchronization proximity switches

The proximity switches (S606, S607) are installed to the trolley. The
sensing plates (1) are located on the left crossbeam.
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208 001 EN
Trolley skew proximity switches
S608 (1) Left side Forward
S609 (2) Left side Backward
1 S632 (3) Left side Stop

2
3 S610 (1) Right side Forward
S611 (2) Right side Backward
S633 (3) Right side Stop
Maintenance manual
208 001 EN
7.4.3 Adjustment of the trolley chains

Instructions
1
C
3 2
4
Tol e r a n c e ± 1c m
II TR O LLE Y
I
A
TR O LLE Y
II I
B
5
TR O LLE Y
II I
C
IMPORTANT
Adjust the chain so that the measurement between the bumpers and
the end plates are equal at both sides.
Maintenance manual
208 001 EN
1 Drive the trolley to the gate end (1).

2 Lock the trolley with the locking device (2).
3 Measure the distance between the trolley bumpers and end
stop plates. Make sure that the measurement is equal on both
sides. The tolerance for the margin is ±1 cm.
4 Open the trolley brake (3) manually.
5 Rotate the propeller shaft (4) by hand, until the chains are
tight (BI).
6 Hold the tension with the brake disk by closing the brake (3).
7 Tighten the nut (5) until the chain is tight (CII). Tighten the left
chain from the walking platform and the right chain from the
service hatch.
8 Open the locking device (2).
7.4.4 Installation of the skew pulling device

Instructions
2,3 1
E Left end
2,3 1
2,3
Section A--A
Left end
1
2,3
Right end
Maintenance manual
208 001 EN
Place the flange bearings (1) at the left end so that the dimension
(E) is as small as possible. After that the screws and nuts (2, 3) are
tightened thoroughly about 200 Nm.
Place the bearings in the right end so that required geometrical tol‐
erances are obtained.
NOTE
Remove the sprocket assembly of the skew device during mainte‐
nance, for example when changing the bearing unit.
If the sprocket assembly is not removed for maintenance, the bearing
units installation bolts cannot be tightened to the required torque.
7.4.5 Removing the skew motor

Preparations
Prepare the tools: sleeve (M24, M7), wrench and screw driver.
Safety
• Put wood block under the skew motor for protection. Do not lay
the skew motor directly to the ground without wood blocks.
• Obey the safety instructions all the time. Wear safety helmet,
safety shoes when work on site.
• Prepare a clean and safe work area.
• Make sure that you keep the disassembled parts in good con‐
dition to prevent rusting.
Removing the skew motor (under hoist drum)

1. Clean the skew motor.
2. Removing the wiring

1) Remove the cover with sleeve M7 or M8.
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208 001 EN
2) Remove the cover with sleeve M7 or M8.
3) Remove the cable M608
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208 001 EN
4) Remove the cable Y608.
3. Remove the cover
4. Unscrew the bolt.
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208 001 EN
1 Short retaining screw (standard components)
2 Lock washer
3 Washer
4 Circlip
6 Customer shaft
5. Unscrew the 4 bolts of the support one by one.
Fig. : Installation with standard components
6. Remove the motor.
WARNING
The falling down motor can cause personal injury and material dam‐
age.
Make sure that you take the motor safely.
Maintenance manual
208 001 EN
7.4.6 Jacking and wheel change of trolley

Instructions
2
284 mm
10-
20
ton 154 mm
1 6
5
1 Remove the falling prevention clamps (1).

2 Jack up the wheel below the trolley box-frame. Use the jack
(5). The lifting capacity is 10 - 20 ton.
3 When the wheel is lifted off the rail (4), place a support
between the rail and the trolley box-frame.
4 Remove the end plate and the buffer (2).
5 Remove the axle of the wheel (3).
NOTE
The axle weight is 40 kg (88 lbs).
6 Roll off the wheel along the rail (6).
NOTE
The wheel weight is 148 kg (326 lbs).
IMPORTANT
Make sure that there is no danger in the service environment that
could possibleendanger the personnel.
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208 001 EN
7.4.7 Changing the lubrication oil of the hoist,

trolley and skew gears
General
With every oil change, check the breathers for impurities and clean
if necessary.
Hoist gear
5
4
2
Pos Hoist gear
1 Drain hole
2 Fill hole
3 Sight glass
4 Breather
5 Breather
6 Temperature gauge
Maintenance manual
208 001 EN
Trolley gear
2
4
Pos Trolley gear
1 Drain hole
2 Fill hole
3 Sight glass
4 Breather
Skew gear
DANGER
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208 001 EN
Changing the oil
CAUTION
ate container and deliver the oil to a hazardous waste collection
point.
Take care to ensure absolute cleanliness. Impurities in oil cause
damage to the gear.
1 Place a suitable container below the draining plug (1).

2 Remove the draining plug (1).
3 Drain the oil into a container.
4 Close the draining plug (1) when the oil is flown out.
3
5 Remove the oil filling plug (3).
6 Add new oil through the oil filling plug (3).
The maximum oil level is the lower edge of the oil level sight
glass. The minimum oil level is 4 mm below the oil level sight
glass. For the oil type, see Chapter F Technical data.
1 2 Activating the vent plug
1. Draining plug
2. Oil level sight glass
3. Autovent plug / Oil filling plug
Remove the spring pin from the vent plug.

7.4.8.1 Component position
Central lubrication system

Some of the lubrication points of the trolley are centralized by pipes
to a location easier to access.
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208 001 EN
4,5 6 7 8,9 10
Pos Qty
1 Trolley wheel 1
2 Axles for the sheaves 4
3 Axles for the intermediate sheaves 1
4 Sprockets for the trolley moving 6
5 Trolley wheel 1
6 Axles for the trim (option) 3
7 Trolley gear unit bearing 2
8 Sprockets for the trolley moving 6
9 Trolley wheel 1
10 Trolley wheel 1
Maintenance manual
208 001 EN
Manual lubrication points
4
2
3
2
4
3
Maintenance manual
208 001 EN
Pos Qty
1 Intermediate sheaves for the hoist ropes 2
Hoist gear bearings and seal
NOTE
2 2
Grease through the grease nipple only when
the shaft is rotating.
3 Hoist drum bearings 2
4 Antisway drum (option) 2
5 Axle for the trolley gear 1
Bearings for the trolley motor (volume 40 g)
NOTE
6 Use specified grease for motor bearings. For 2
more information, see chapter F Technical data
in this manual and the information plate of the
motor.
Bearings for the hoist motor (volume 40 g)
NOTE
7 Use specified grease for motor bearings. For 2
more information, see chapter F Technical data
in this manual and the information plate of the
motor.
Manual lubrication points of the skew machineries
DANGER
Maintenance manual
208 001 EN
(2) (2)
(2)
1 1
(2)
Pos Qty
Skewing traveller, four wheels
NOTE
1 4
Keep grease out of the bearing travel surfaces
(3).
Transfer chain bearing, free from lubrication (can

(2) 4
be greased if necessary)
Maintenance manual
208 001 EN
7 Load handling – 7.9 Load carrying Bromma 71
7.9 Load carrying Bromma
Safety
DANGER
The spreader is equipped with automatic functions which may cause
a risk of injury. Observe the following functions when servicing or
repairing the spreader:
1. The twistlocks turn automatically to the closed position when all

the feelers are in the upper position.
2. The spreader extends and retracts automatically when the
length selection button is pressed in the cab. Do not put your
hands in the maintenance holes during the startup or when the
machine is running.
3. The hoist ropes move during the automatic functions. No per‐
sonnel are allowed in the operating range of the rope system
and the hoist ropes during the operation of the machine.
DANGER
Make sure that the engine and the main power are off before starting
the maintenance.
There is a risk of crushing on the spreader frame during the mainte‐
nance.
Be extremely cautious when performing any maintenance inside the
spreader frame.
The service personnel must be familiar with the risks related to
spreader function and movements.
In case of emergency, use the emergency switch on the trolley to
stop the machine.
Make sure that the person on the ground level stays a safe distance
from the spreader during maintenance.
General
The spreader consists of a center main frame and two pairs of tele‐
scopic beams. The outer end of the telescopic beams are connec‐
ted together by end beams.
The length of the spreader can be adjusted to fit different size con‐
tainers.
The ends of the telescopic beam units are equipped with guide
arms, used to position the spreader onto the container. The twist‐
lock system, that locks the spreader to the container, is fitted in the
corners of the end beams.
Maintenance manual
208 001 EN
72 7 Load handling – 7.9 Load carrying Bromma
Storage of the spreader

When detached from the crane, store the spreader on a mainte‐
nance rack or on a container and keep it’s twistlocks locked.
For long term storage instructions contact Cargotec.
Changing the spreader to the RTG with headblock
CAUTION
Always use an appropriate spreader with the RTG.
Always replace the broken spreader immediately.
NOTE
The spreader can be operated from any of the following three posi‐
tions.
1. Operator’s cabin
2. EE-House
3. Remote control
Only one control position can be active at a time and the control stand
selection from the main operator’s panel has to be selected to allow
remote control or control from the EE-house.
1 Lower the spreader on the container or a maintenance rack.

2 Secure the spreader in place by locking the twist locks.
3 Shut down the crane and cut off the main switch of the
machine to cut off power from the spreader.
4 Open the headblock twistlocks.
5 Disconnect spreader cables, pipes and other connection from
the headblock.
6 Position the headblock on the new spreader, reconnect
cables, close headblock twistlocks and open the spreader
twistlocks to detach it from the maintenance rack.
7 Power up the machine and test the spreader’s functions.
Maintenance manual
208 001 EN
7.9.1 Inspection of headblock (if using)

twistlocks
Description
NOTE
The twist-locks must be checked: FIRST TIME after 5000 operating
1 hours or 2 years whichever occurs first. After that they must be
checked once a year.
3
2
1. Locking device
2. Turning lever
3. Nut for catch
4. Twist-lock
Disassembly and assembly

4
1. Lower top-lift on the ground or over container.
2. Open locking device (1) of twist-lock’s turning lever by remov‐
ing screw from vertical pipe, and then removing locking piston.
3. Turn the lever (2) 90°.
4. Headblock is then separated from top-lift spreader.
5. Remove wedge from the top of twist-lock by untightening both
M8 screws.
6. Unscrew nut for catch (3). Turning lever can then be lifted off,
and twist-lock is released.
NOTE
Check the condition of twist-locks as explained in spreader twistlock
inspection instructions
Assembly of twist-lock is done in a reversed manner.
7.9.2 Spreader stabilizer

7.9.2.1 General
Description
Kalmar stabilizer system improves productivity of RTGs in difficult
wind conditions by damping swinging motion of a spreader.
Maintenance manual
208 001 EN
Stabilizer has practically no effect on the spreader movements in

other directions than rotation. That is why the stabilizer is a compli‐
mentary system for other electric spreader movement damping sys‐
tems.
When operator activates the stabilizer, the controller calculates the
best counter-motion against the rotating spreader and sends side
shift motor control commands to PLC. Based on controller com‐
mands PLC operates the electric motor contactors and trolley move‐
ment attenuates the spreader rotation.
Fig. : Spreader swinging motion.
Fig. : Simplified block diagram of the spreader stabilizer system

Troubleshooting
Stabilizer fault tracing table is shown in Table 1. It is good practice
to check communication between the stabilizer module A901 and
CAN/ Profibus gateway A650 using diagnostic LEDs, before replac‐
ing any hardware or doing more complicated troubleshooting.
Maintenance manual
208 001 EN
Table:Stabilizer fault tracing.
FAULT POSSIBLE CAUSE CORRECTIVE

ACTION
Stabilizer signal No power in A901 If LEDs are off,

light is always off or B650 check fuse
Broken lamp Check the lamp and

change if necessary
Error in CAN-bus Refer to attached

electrical drawings
Sensor error Sensor error If CAN

bus OK and A901
has healthy heart
beat, change
sensor B901
Stabilizer signal Error in CAN-bus Refer to attached

light is always on electrical drawings
Sensor error Sensor error If CAN

bus OK and A901
has healthy heart
beat, change
sensor B901
Stabilizer signal Wrong parameters Check the stabilizer

light is blinking 30 in PLC parameters on
seconds but rotation Operator’s panel
is not damping
Broken side shift Check motor

motor contactor contactors
Sensor error If CAN bus OK and

A901 has healthy
heart beat, change
sensor B901
A650 diagnose using LEDs

In normal operation the LEDs are never switched off, i.e. they either
flash or shine permanently. The flash sequences, which are listed in
the following table are repeated about every six seconds.
Maintenance manual
208 001 EN
Table:CAN and Profibus diagnostics using LEDs in A650.
Led# Function Status Meaning Corrective

action
LED1 CAN bus off no power Check 24 V

(red) status supply power
supply
1 x short CAN error Check CAN

flash bus wiring.
3 x short CAN off Check CAN

flash bus wiring.
short- CAN -
Fig. : Position of diagnostic LEDs. longlong warning
on CAN bus -
OK
LED 2 module off no power Check 24 V

(red) PROFIBU supply power
S status supply
1 x short looking for Check the

flash bit rate PROFIBUS
connection.
Fault in
wiring in
PROFIBUS
cable, short
circuit,
terminating
impedance
in wrong
position.
2 x short bit rate is Check the

flash monitored PROFIBUS
address
specified
3 x short waiting for Parameter

flash parameter telegram is
telegram faulty.
Diagnose via
SIMATIC-
Manager or
system
function
SFC13
(DPNRM_D
G)
Maintenance manual
208 001 EN
Led# Function Status Meaning Corrective

action
4 x short waiting for Configuratio

flash configuratio n telegram is
n telegram faulty.
Diagnose via
SIMATICMa
nager or
system
function
SFC13
(DPNRM_D
G)
on PROFIBUS -
OK
LED 3 PROFIBU off no data -

(red) S data exchange
exchange
on data -
exchange
via
PROFIBUS
A901 module on a spreader

A901 microcontroller module controls the operation of the stabilizer
( Figure). The essential part of smooth operation of the system is
the communication with PLC of a crane.
A simple diagnostic system has been implemented into the stabil‐
izer software to help fault tracing. There is a heart beat LED in a
module, which indicates if an error has been detected or status is
normal.
Fig. : A901 module

Normal operation
LED is flashing slowly at 2 seconds interval.
Maintenance manual
208 001 EN
Operation when error has been detected

LED is flashing fast. Three errors has been configured:
1. CAN bus error

2. no PLC error and
3. no parameters error.
You can conclude a source of the error by counting how many times
LED is blinking in one sequence.Table 3 shows the number of
blinks for each error type.
Table:Errors indicated by heart beat LED of MCC module.
Number of blinks Error Description
CAN bus error There is something

wrong with the
1
communication of
the CAN bus
no PLC detected No messages are

2
received from PLC
no parameters from PLC has not sent

7
PLC received parameters
7.9.3 Load sensing system (option)

Description
There is a logic display for maintenance personnel located on
spreader.
Display has the following information:
• total load under the spreader

• load under the spreader
• eccentricity of the load
Fig. : Bromma SCS3-PLC display for maintenance

personnel.
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7.9.4 Spreader cable

Instructions
CAUTION
If the rotation direction of the cable in the cable cage is clockwise, the
cable will be damaged.
The cable (A) must be installed to the cable cage (B) so that the
rotation direction is anticlockwise.
NOTE
B
Lubricate the cable with grease (e.g. Microlube GL 261 or similar) for
better sliding of the cable.
Fig. : View from top into cable basket

7.9.5 Lift hook (option)
Description
The lift hook is a special hoisting appliance used for non-container
loads. The hook is mounted on a hook frame. The hook frame is
directly connected to the headblock (instead of the spreader). The
crane must be run in hook mode to use the lift hook.
With only the headblock attached, the pretension in the ropes is
small. For this reason these safety limitations are automatically in
effect:
• The hoisting and veering speed are limited

• The hoisting height is limited
• The accelerations are limited
• The tension in the spreader cable (if present) is limited
Installing the lift hook
1 Put the crane to service position before any maintenance

work.
2 Place the spreader on the ground and keep on spreading until
slack rope appears at the sheaves of the headblock.
WARNING
The crane operator coordinates the activities of at least 2 persons.
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CAUTION
The hoist ropes can fall next to the hoisting sheave.
3 Turn off the spreader and the crane.

4 Disconnect the plug from the spreader and plug it in the
dummy socket on the headblock.
5 Unlock the 4 twistlocks of the headblock.
6 Hoist the headblock, but not higher than necessary.
DANGER
Clamping danger. Do not hoist the headblock higher than necessary.
CAUTION
When hoisting with empty headblock the ropes will sag too much. To
prevent this, the hoisting equipment should be installed between the
legs. When installing the hoisting equipment, move the trolley as little
as possible.
7 Place the headblock above the hook frame by moving the trol‐
ley and the crane.
WARNING
Do the crane movements with reduced speed.
CAUTION
With empty headblock the speeds and hoisting height are limited.
8 Lower the headblock safely on top of the hook frame, and

connect the frame to the headblock.
The crane is ready for production.
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1
Table of content
9 Frame, body, cab and accessories 3
9.2 Safety and emergency equipment 3
9.2.1 Emergency stop buttons 3
9.2.2 Safety switches 4
9.2.3 Service of the anemometer (option) 5
9.2.4 Removing covers of EE-house 7
9.12 Frame 8
9.12.1 Checking and tightening the frame joint bolts 8
9.12.2 Inspecting welded steel structures for fatigue cracks 9
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9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment 3
9 Frame, body, cab and

accessories
9.2 Safety and emergency
equipment
9.2.1 Emergency stop buttons

Description
B G
A 1
E
C
I D H
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4 9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment
Emergency stop buttons
Function A B C D E F G H I
Stopping all movements X X X X X X X X
Stopping the diesel engine (if equipped) X X
Stopping rotation of the cable reel (Zero

X
Emission RTG)
Cutting off power supply to the inverters by

opening main contactors in the EE-house X X
(Zero Emission RTG)
Emergency push button is released by turning the button’s knob

counterclockwise.
9.2.2 Safety switches

Description
CAUTION
Failure in using these safety equipment can result in death or serious
injury and/or damage to the crane and other property.
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Fig. : The locations of the safety switches

A. Service crane
B. Spreader
The safety switches are used to disconnect the actuators from the
main circuit.
The safety switch A stops the movements of the service crane.
The safety switch B stops the movements of the spreader.
9.2.3 Service of the anemometer (option)

Instructions
CAUTION
The anemometer is exposed to impurities such as sand and salt that
can get inside the rotating cup. Impurities cause friction that can
break the anemometer.
1 Use an allen wrench to loosen the setscrew on the side of the

wind cups.
2 Remove the wind cups and clean the exposed portion of the
shaft with a damp cloth or cotton swab.
3 Clean the wind cups with water and a mild liquid detergent.
4 Rinse thoroughly before replacing.
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6 9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment
NOTE
Do not use or add grease, oil or a spray lubricant of any kind.
5 When replacing the wind cups (1), slide them up the shaft (2)
as far as possible.
2 1
A. Incorrect
B. Correct
6 Tighten the setscrew (3).
7 Make sure that the wind cups spin freely. If they do not, the
bearings may be worn and need factory-replacement.
3
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9.2.4 Removing covers of EE-house

Instructions
DANGER
The electric systems must be serviced and repaired by trained serv‐
ice personnel.
Before commencing work, ensure the electric system is de-ener‐
gized.
For safety instructions, see Chapter B Safety, section Electric sys‐
tems.
1 Turn the main switch (A) to OFF-position.

A
2 Remove the screws (12 pcs) to remove the covers of the DC

bus bars (B).
B B 3 Remove the screws (10 pcs) to remove the inverter (C) cov‐
ers.
4 After maintenance, attach the covers in reverse order.
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8 9 Frame, body, cab and accessories – 9.12 Frame
9.12 Frame
9.12.1 Checking and tightening the frame joint

bolts
Instructions
A. Frame joint bolts
CAUTION
The frame joint bolts must always be checked for tightness and con‐
dition when the frame is placed under high stress, for example, when
the machine motion has been stopped with an exceptionally abrupt
emergency stop when carrying load or after collisions.
1 Check the bolt-nut an pairs visually for broken bolts. Bolts

without nut can be inspected by knocking them with hammer.
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9 Frame, body, cab and accessories – 9.12 Frame 9
If you detect any broken bolts, contact the Cargotec service

personnel.
2 Check the bolts for tightness. Use, for example, a drop of col‐
ourful paint as a seal at the contact surface of the frame and
bolt head to recognize loose bolts.
3 Tighten the loose bolt connections with tightening torque of
900 Nm (667 ft-lbf).
9.12.2 Inspecting welded steel structures for

fatigue cracks
General
All welded steel structures of the crane must be checked yearly for
fatigue cracks. Pay special attention to the objects pointed out in the
section Most critical welded joints on page 11.
Fatigue crack growth

The fatigue cracks will become large enough to be detectable by
means of nondestructive testing methods, i.e. MT, UT or DPT.
Some cracks are detectable by visual inspection before fracture
increase.
If the fatigue cracks occur, in many cases the remaining elements of
the structure will prevent serious damage so long as the crane is
immediately taken out of service and repaired.
Periodic inspection is required to detect fatigue cracks that have
growth to a significant size in order to avoid serious failure in the
crane structure.
When the crack is found, repair is necessary

Restoring the structure to its original condition is recommended.
Sometimes this is not practical, and a change in geometry by cutting
and grinding means is more economical.
Sometimes fatigue cracks are found with a frequency significantly
greater than would be expected considering the stress levels used
in the design. This may be caused by overload in the crane during
operation. If such cracks are found, a review of the operation must
be made to see if overload is occurring, and remedial measures
must be developed to avoid future overloading. The cracking may
be due to differences in geometry between the actual detail and the
tested detail. In this case, it may be economical to modify the geom‐
etry.
9.12.2.1 Test procedures
Abbreviations
Type of test Symbol
Magnetic Particle Test MT
Dye-Penetrant Test DPT
Visual Test VT
Ultrasonic Test UT
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Dye-penetrant
1 Clean and dry the test surface thoroughly. Use chemical sol‐
vents, vapour degreasing, or mechanical methods to cleaning.
NOTE
The mechanical cleaning, such as grinding, blasting or wire brushing,
may change the test results.
2 Use one of the following type penetrants in conjunction with

the proper procedure to get satisfactory results
• water soluble penetrant
• post emulsifiable penetrant
• solvent removable penetrant
Magnetic particle
1 Clean the test surface of loose rust scale and moisture.

2 Clean the painted surfaces at all points of welding rod contact.
NOTE
Grinding, brushing or blasting do not affect results of testing in most
instances.
3 A magnetic field can be applied to the test material with

• permanent magnet
• yoke which is an electromagnet type of device
• passing high amperage current through the part
Visual
1 Clean the dirt and grease from the surface by wiping with a
rag.
2 Look for cracked paint and rust showing through the paint.
Ultrasonic
1 Do the test in accordance with approved method.
Frequency of inspection
After the guarantee time a periodic inspection is required. The
inspection period is one year.
If anything unusual is observed by visual inspection the observation
should be confirmed with Magnetic Particle test. Ultrasonic test can
also be used to complete Magnetic Particle test. Dye-Penetrant test
can be used in such places where it is impossible to use MT or UT.
Reporting procedure
Photocopy the sketch, if available, or make your own sketch or pho‐
tograph, and indicate the following items on the defect:
Cargotec needs to receive report results of any structural inspection
to enable comparison with other similar structures throughout the
world.
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• Location
• Size
• Extent of defect
• In toe of weld
• Propagation into base metal
• Etc.
Cargotec needs to receive report results of any structural inspection

to enable comparison with other similar structures throughout the
world.
Testing and repairing

Please contact the Cargotec service personnel for assistance on
testing and for required repairing actions.
9.12.2.2 Most critical welded joints
Frame
Inspection objects
A) All welds of the main girders from the centre to distance of 3,5
m (11,5 ft) to both directions. Check also trolley rails.
B) All welds of the vertical columns to the height of 3 m (10 ft)
from the sill beam. Also check the area for any other possible
damages.
C) All welds of the wheel fork flanges.
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Trolley frame
Inspection objects
• All welds pointed out in the figures
• All welds at the cabin attachment points
9.12.2.3 Welding
General
Electrical characteristics:
The current used is DC-reversed polarity.
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Joint welding procedure

Before chipping, grinding and welding, carefully protect the equip‐
ment that are in danger of being damaged by heat and/or splashing,
especially the electric components and cables and so on.
The ground cable of the welding unit is joined as near as possible to
the welding area.
IMPORTANT
The following objects are either special material or a special struc‐
ture. Welding of these must be accepted by Cargotec Finland Oy:
• Wheel forks and all of their components

• Gearboxes
• Trolley wheels
• Trolley rails
• Electric motors
• Diesel motors
• Generators
• Brakes and all of their components
• Twistlocks (spreader and headblock)
Defects
Any cracks or blow holes that appear on the surface of any bead of
welding must be removed by chipping or grinding to a sound clean
metal before depositing the next successive bead of welding. The
next successive bead of welding must be deposited in accordance
with this procedure. The welds must be free from undercutting and
reasonably free of overlap, trapped slag and porosity.
Treatment of welding groove

Where sound back-welding from the opposite side is possible on
double- welded butt joints, the weld from the opposite side must not
be made until the joint has been backgouged (carbon arc gouging
with subsequent grinding to clean up the welding groove) or back-
chipped to sound clean metal.
Cleaning
All traces of slag, flux or foreign material must be removed before
laying down the successive welding bead.
Preheating and temperature control
• Preheat the welding area to 50ºC (122ºF) before any welding.

Dry the cracks and areas to weld.
Use gas torches to preheat the welding area and must be for
full length of the weld joint prior to starting the weld deposit.
• Preheat at least an area of 25 cm (10") in all directions from
the point of weld.
• Use only dried welding rods.
• Do not weld in the rain.
Heat treatment
Heat treatment after the repair welding is not necessary.
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1
Table of content
11 Common electrics 3
11.5 Distribution of electricity 3
11.5.1 Energy chain 3
11.5.2 Cable reel 7
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11 Common electrics – 11.5 Distribution of electricity 3
11 Common electrics
11.5 Distribution of electricity
11.5.1 Energy chain

Inspection points
Point Description Fault Corrective action
Checking the condition of cable carrier chains
1a Check of chain plates

a) One side worn more than a) Exchange chain plates.
other. b) Check channel width and
b) Chain plates broken or worn alignment. Adjust guiding
out. channel width if needed. See
adjusting of guiding channel.
1b Check of stays and dividers for

a) Stay bolting loose. a) Exchange stay and screws.
completeness and wear
b) Stay/dividers is missing or b) Replace stay/divider.
worn out.
1c Check of glide shoes a. and b. Replace with a glide shoe

a) Glide shoes worn out (see
with same thickness, check for root
wear mark).
cause.
b) Glide shoes missing. Replace
c. Check guiding channel width and
all glide shoes
alignment
c) One side worn more than
other.
Checking the energy chain for foreign particles and dirt
2 Check for obstructions. Ice, snow, dirt, forgotten tools or Remove before continuing
other foreign material present. operation. Install guards, shrouds
or protective grills as necessary.
Checking of connection elements
3
a) Check of connection elements a) Connection elements and/or a) Replace damaged parts;
at fixed point adjacent parts are damaged check for a possible
b) Check of connection elements b) Connection elements are exceeding of the travel
at moving end loose and/or noise while distance
driving b) Retighten connection
elements
Checking of cable length and condition and strain reliefs
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4 11 Common electrics – 11.5 Distribution of electricity
4a Check for sufficient cable length in Cables are tight to the inner stays Give additional cable length from
the chain: Stretch out the upper the spare cable loop at fixed point,
chain strand. Inside chain radius all retighten strain relief
cables should stay free in
longitudinal direction. Cables
should not stress the inner cross
stays of the chain
4b Check for an overlength of cables Cables rest on cross stays in Pull out cable length from inside
in the chain snakelike shape or are pressed out the chain at fixed point, retighten
between the stays strain relief
4c Check for wear or damages of Jacket is too thin, broken or cut Exchange cable. Do not repair!
cables
4d Check for completeness and Strain relief element is missing or Replace or retighten element,
fixation of strain relief elements loose check cable jacket
4e Check for twisting of core bundles Noticeable twisting of core bundles

a) Arrange exchange of the
("cork screw effect“) with overall cork screw-like shape
cable
of the cable
b) As a result a contraction of the
cable will be caused
NOTE
See checkpoint 4a
c) Execute frequent check of the

cable until exchange
Checking of moving arm and driver sledge
5a Check the current arm and middle

a) Current arm is deformed a) Reinforce current arm
arm for condition, fixation and
b) Current arm is loose, b) Retighten current arm; check
alignment
especially at change of for wear and adjustment of
direction contact plates of driver sledge
c) Current g arm axis and chain c) Check alignment of machine
longitudinal axis are d) Check crane rail and wheel
misaligned flange/guide rollers of the
d) Large lateral/vertical path trolley wheelset
deviations of current arm
5b
a) Middle arm piston has to a) Noise while driving, especially a) Check, if rear bracket is
move smooth between the when changing into opposite detached. Ensure that it is
contact plates while driving drive direction screwed down to the sledge
the chain b) Bigger clearance between b) Contact plates are worn out.
b) Check screw connections of moving arm and driver sledge Adjust or replace contact
driver sledge plates
5c Check the driver sledge for wear of Glide shoes, glide disc patches or Replace outworn parts
gliding parts contact plates are worn out
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Checking of guiding channel
6
a) Check alignment of guiding a) Misalignment a) New alignment of the guiding
channel to longitudinal axis of b) Inner width is too wide or too channel
crane rail narrow b) Adjust the guiding channelSee
b) Check compliance of the inner c) Boltings are loose adjusting of guiding channel.
width with specification d) Uneven joints and/or c) Retighten boltings
c) Check boltings of channel interfering edges d) New adjustment of channel
joints e) Channel parts are deformed holder and side walls
d) All channel joints have to be or damaged necessary
even and must not have any e) Straighten or replace
interfering edges deformed or damaged parts
e) Check guiding channel for
damages
A) Stay
B) Chain plate
C) Locking bolt
D) Screws
E) Glide shoe
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11.5.1.1 Adjusting of guiding channel
Instructions
Guiding channel and cable chain.
A) Inner width of guiding channel is 481 mm +2,00/-0,00 mm.

B) Outer width of cable chain is 475 mm.
C) Gap between guiding channel and cable chain is 3 mm +1,00
mm on both sides.
CAUTION
There must be a gap on both sides between the guiding channel and
chain.
Too small gap causes wearing on chain links. Too large gap causes
wearing on chain links and stays.
Admissable path deviation of guiding channel is +/- 12,5 mm.
Check the width and path deviation of guiding channel.
1 Measure the inner width (A) of guiding channel.

2 Loosen the adjusting screws on both sides of the channel (F).
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3 Move the channel (E) horizontally.

4 When the gap (C) on both sides is correct, tighten the adjust‐
ing screws.
11.5.1.2 Adjusting the cable length
Instructions
Check the cable lengths in the E-chain. The cables have to run
through the bending radius bow without stress.
A) Correct cable adjustment

B) Incorrect cable adjustment
1 Detach strain relief clamps.

2 Push or pull on the cables to reach the desired effect in the
chain.
3 Reattach the strain relief clamps.
11.5.2 Cable reel

Description
The power supply cable is connected to the crane with a cable reel
located on top of EE-house. The cable reel rolls the cable in accord-
ance with crane travelling. The cable reel is driven by electric motor
equipped with brake.
When gantry starts to move, cable reel brake opens and stays open
until driving speed goes back to zero then brake will close.
When braking (decelerating), cable reel motor is acting as electrical
brake, command of braking comes when gantry joystick goes to
neutral position. Re-generative power from the motor is fed to DC-
link where Active Interface Module (AIM) feeds all excess energy to
electricity distribution network.
The cable reel can be controlled manually from the control stand lo-
cated nearby the cable reel.
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To support the cable, the cable is led through a cable guide. Cable
slacking or overtensioning is prevented by monitoring the status of
the cable guide.
Function description
PLC
20 PLC
15 14
9, 16
1, 18
540 - 600 VDC
-
2 7 ~
17
3
6 8
-
~
4 5
400 - 440 VAC
11 M~ °C 13
3
10, 16
12 PG
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1 Electrical power is supplied from See chapter F Technical

external power source through a data for supply voltage
cable.
2 Electrical power is led through a See chapter F Technical

cable reel slip ring box (X160). data for supply voltage
3 Medium voltage transformer See chapter F Technical

transforms the supply voltage into a data for supply voltage
lower voltage. Transformer is
supply from external power source
over 1 kV.
4 Main circuit breaker (F150) protects 400 – 440 VAC, 50 –

the system from overload and short- 60Hz
circuit currents.
5 Main supply contactor (K50) 400 – 440 VAC, 50 –

connects external power supply to 60Hz
the RTG electical system.
6 Main fuses (F2) protect the rectifier 400 – 440 VAC, 50 –

from short-circuit currents. 60Hz
7 Rectifier (U5) converts alternating 400 – 440 VAC / 540 –

current into direct current for the 600 VDC
direct current intermediate circuit
(DC-link).
8 Inverter (U8) receives the electrical 540 – 600 VDC / 400 –

power from the DC-link and 440 VAC, 0 – 58 Hz
converts DC power into adjustable
frequency AC power.
9 Gantry movement is controlled by Joystick – PLC: 24 VDC

joystick. PLC – inverter: Profibus
10 Cable reel brake (Y160) on the PLC – brake contactor: 24

cable reel motor opens when VDC
inverter starts to control the motor. Brake contactor – brake:
400 VAC, 50 – 60 Hz
11 Inverter controls the direction of ~ 0-400 VAC, 0 – 58 Hz

rotation and speed of the cable reel
motor (M160) in accordance with
gantry travel.

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the cable reel motor with
temperature sensor (M160).
14 Gantry travel is guided by slowdown Cam limit switch – PLC:

system, which controls the speed Profibus
when closing to end stop limit.
Gantry movement is stopped
automatically at the end stop limit.
These limits are based on amount
of cable on the reel.
PLC monitors the gantry travel with
the geared limit switch (S160) on
the cable reel gear.
15 PLC monitors the tightness of the Proximity switch – PLC:

cable by proximity switches (S161 - 24 VDC
S164) on the cable guide.
16 When braking, cable reel motor is Joystick – PLC: 24 VDC

acting as electrical brake, command PLC – inverter: Profibus
of braking comes when gantry
joystick goes to neutral position.

during braking is fed via DC-link to
Active Interface Module (AIM) (U7).
18 AIM unit feeds all excess energy to

electricity distribution network.
19 When motor is stopped (rotation PLC – Brake contactor 24

speed zero), brake (Y160) closes. VDC
Brake contactor – Brake
400 VAC, 50 – 60 Hz
20 Cable reel can be monitored and Control stand – PLC: 24

controlled with a control stand on VDC
the cable guide. PLC – inverter: Profibus
Component position
Components on the front frame of Zero Emission RTG are shown in
the figure below. Component locations vary depending on crane’s
equipment.
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3 5 4 2
1. Cable reel
2. Cable guide
3. Main power supply transformer (only when the main power
supply voltage is over 1kV)
4. Power unit
5. Auxiliary power unit
5 6, 7 4
1. Proximity switches, cable tension monitoring

2. Geared limit switch
3. Gear
4. Motor
5. Brake
6. Pulse encoder
7. Temperature sensor
8. Slip ring box
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11.5.2.1 Changing lubrication oil of the gear
Instructions
2 Pos Cable reel gear
1 Drain hole
max
2 Fill hole
3
min 3 Sight glass
11.5.2.2 Lubrication points
Component position
Pos Lubrication points Qty
1 Motor bearings 2
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1
Table of content
F Technical data 3
Technical data and dimensional drawing 3
Engine fluid capacities, tightening torques and lubrication points 9
Tightening torques 10
Lubrication points 17
Tightening torques, units of measurement and conversation tables 25
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F Technical data – Technical data and dimensional drawing 3
F Technical data
Technical data and dimensional
drawing
Technical data
Engine
Make and model Cummins QSX 15 G6
Operating principle Turbocharged, low-emission direct-injection diesel engine with charge air cooler.
Power (ISO 8528) 455/ 414 kW
Number of cylinders 6
Alternator 24 V / 35 A
Starter and PLC batteries 24 VDC / 135 Ah (start) and 24 VDC / 135 Ah (PLC)
Exhaust emissions EPA Tier 2 TPEM
Generator
Make and model Stamford HCI 534 E2, insulation class H
Running speeds 1500 rpm / 50Hz
Zero emission power supply
Voltage 400 VAC, 3-phase, 60 Hz
Cable reel ZPMC (WEILONG)
Cable length 192 m
Power transmission
Operating principle Electric transmission.
Driven wheels Two driven wheels in both side-frames. Each driven wheel is equipped with an
electric drive motor.
Drive motors, left Siemens, 1LE1601-2BB03-4GB4-Z, 37 kW
Hubs, driven Kessler, D81VP489
Hubs, nondriven Kessler, S81
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4 F Technical data – Technical data and dimensional drawing
Brakes
Service brake Gantry travel braking is done electrically.
Parking brake Parking brake is operated by spring force, which is released electrically.
Steering
Steering system Turning is performed by an electric motor.
Steering motors 4 x Lönne, 1TZ9 A 112M-6 – 3/3,5kW-S2-10_H03 +L25+Q02+S03
Steering gears 4 x Brevini, SL3004/FE/1957,5/IEC110-112 with spline shaft
Steering brakes 4 x Precima, FDW 15.238.-005 with hand release
Tyres
Size 16.00-25 32PR E-3
Pressure 10 bar (145 psi) drive axle, 10 bar (145 psi) nondrive axle
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Hoisting device
Hoisting system Trolley located, electrically operated hoist motor/-gear assembly which rotates
the grooved-surface hoist drum.
Hoist motor Siemens, 1LE1601-3AB53-4AF4-Z, 200 kW
Hoist gear Kalmar, HG90V3
Hoist clutch KTR Shanghai, RADEX N90-NANA3-250-SBAN 470X30 NANA3 structure, with
brake disc
Hoist brake Bubenzer SB28, 60 Hz
Trolley motor Siemens, 1LG4 207-4AA91-Z, 30 kW
Trolley gear Nord, SK6282VX IEC200
Skew gear brake motor Nord, SK9022 1AZBK-100L8-2WU BRE20
Container lengths handled with the 20’, 40’ .

spreader Spreader type: YSX40E
Skew movements: ±5° / ±200 mm (±7.9”), switch for automatic centring in the
cabin
Hoist rope lengths Rope 1: 63,900 mm (+/- 50 mm)

Rope 2: 57,000 mm (+/- 50 mm)
Rope 3: 57,000 mm (+/- 50 mm)
Rope 4: 63,900 mm (+/- 50 mm)
Hoist rope diametre 26 mm
Cabin
General Reinforced steelprofile cabin is mounted to trolley via rubber vibration reducers.
Cabin travels across the span offering excellent visibility to all working areas.
Control and monitoring system
PLC system PLC ( Programmable Logic Controller )

Logic-controlled electric control and monitoring system.
Smartrail l Automatic gantry steering system and container position verification.
RMI system Kalmar RMI ( Remote Machine Interface ) is remote maintenance and
monitoring system.
Intercom Intercom system between rear frame, EE-house and operator’s cabin.
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Weight
Machine's total service weight 140,500 kg (309,800 lbs)
Performance
Lifting capacity 41,000 kg (90,200 lbs)
Driving speed Without load: SmartPower 130 m/min (426 ft/min)

With load: Speed depends on load under spreader
Lifting speed Without load: SmartPower 52 m/min (171 ft/min)

With rated load: SmartPower 26 m/min (85 ft/min)
Lowering speed Without load: SmartPower 52 m/min (171 ft/min)

With rated load: SmartPower 26 m/min (85 ft/min)
Trolley travel speed Without load/with load: 70 m/min (230 ft/min)
Climatic conditions
Ambient temperature -10°C (14°F) .... +45°C (113°F)
Humidity Max. 99%
Wind speed, operational 0....20 m/s (0....66 ft/s)
Wind speed, operational limited 20....25 m/s (66....82 ft/s)

performance
Wind speed, wheels in parking position 25....40 m/s (82....131 ft/s)
Wind speed, stowed condition > 40 m/s (> 131 ft/s)
Maintenance manual
208 001 EN
Dimensional drawing
trolley travel buffer to buffer 2193 0 71 11
41T
Bromma YSX40E
257 5 2143 0 70 4 257 5

8 5 8 5
2511 0 82 5 (21m level)
78 7
92 11
69 7
140 6
57
2396 0
2122 0
1737 5
2832 0
93 0
3 1
Removable
289 6
9 6
479 0 1917 0
685 0
22 6
15 9 62 11
243 8 35 0
8 1 2
179 0
5 10
83 0
83 0
2 9
2 9
2492 0 81 9
144 0 2658 0 87 2 185 0

4 9 6 1
2824 0 92 8
2987 0 98
Maintenance manual
208 001 EN
20' 40 '
Tyre size
16.00-25"
960 0 31 6
220 0 220 0
7 3 7 3
1349 0 44 3
Maintenance manual
208 001 EN
F Technical data – Engine fluid capacities, tightening torques and lubrication points 9
Engine fluid capacities, tightening

torques and lubrication points
Engine fluid capacities
Engine Sisu
Fuel tank 1935 l (439 Us gal)
Cooling system 40 l (9 Us gal)
Lubrication 46.5 l (10.6 Us gal)
Maintenance item Quality API/ASTM/SAE/ISO/Classification
Fuel tank High-quality diesel fuel EN590
Engine cooling system 50% high-quality monoethyleneglycol- BS6580 (1992) AFNOR (1991) ASTM
based coolant and 50% water. The D 3306
fluids must be mixed before they are
added to the cooling system.
Example: Shell GlycoShell
NOTE
We use and recommend only
glycol-based coolant that does not
contain nitrite. This kind of coolant
must not be mixed with nitrite-
based anti-corrosive agent
because it may create slag and the
cooling effect may be reduced.
Engine lubrication system

Ambient temperature:
-15 °C - +30 °C Diesel engine oil SAE 20W-30 E3
-10 °C - +30 °C Diesel engine oil SAE 30 CG-4
-5 °C - +45 °C Diesel engine oil SAE 40
0 °C - +45 °C Diesel engine oil SAE 50
-30 °C - +30 °C Diesel engine oil SAE 5W-30
Example: Shell Rimula Super
Maintenance manual
208 001 EN
10 F Technical data – Engine fluid capacities, tightening torques and lubrication points
Tightening torques
Gantry driveline/axle tightening torques
1 6
3
2
7
3
5 4
5
10
5 6
9
8
5 6
3 2
6 9
3
4 6
6
10
4
Maintenance manual
208 001 EN
Pos Torque Screw Grade Quantity
1 86 Nm M12 8.8 4
2 239 Nm M14 12.9 35
3 1176 Nm M30 10.9 20
4 200 Nm M16 8.8 4
5 380 Nm M20 8.8 48 (8 wheels)
650 Nm M22 40 (8 wheels)

6
48 (16 wheels)
7 67 Nm M10 10.9 16 (8 wheels)
8 650 Nm M24 8.8 24 (16 wheels)
9 120 Nm M16 8.8 2 (16 wheels)
200 Nm M16 8.8 12 (8 wheels)

10
8 (16 wheels)
Trolley tightening torques
1 1
2
5 3 2 2
6
9
8
11 10
7 5
8 11
10 11
9
2
Maintenance manual
208 001 EN
1 655Nm M24 8.8 12
2 127Nm M14 10.9 32
3 194Nm M16 8.8 4
4 379Nm M20 8.8 4
5 584Nm *) M24 8.8 24
6 655Nm M24 8.8 24
7 655Nm M24 8.8 4
8 655Nm M24 8.8 6 (1 brake)

12 (2 brakes)
9 1050Nm M24 10.9 16 (SF15)

2100Nm M30 16 (SF24)
10 1290Nm M30 8.8 8
11 655Nm M24 8.8 20
*) Single rope clamp / Do not tighten too much to avoid the bolt to
bend.
Maintenance manual
208 001 EN
Other trolley tightening torques
1
2
4
3
Maintenance manual
208 001 EN
1 239 Nm M14 12.9 35
2 200 Nm M16 8.8 8
3 See the following detail form
4 See the following detail form
Torque Screw Grade
10 Nm M6 8.8
23 Nm M8 8.8
35 Nm M10 8.8
70 Nm M12 8.8
Fastening of plastic slide bar
7 Nm M10 8.8
Maintenance manual
208 001 EN
Power unit tightening torques
1 1
1 379 Nm M20 8.8 32
3 380 Nm M20 8.8 16
Maintenance manual
208 001 EN
JIB hoist, trolley tightening torques
5 655 Nm M24 8.8 6
Maintenance manual
208 001 EN
Columns tightening torques
Pos Screw Grade Quantity
1 M24 10.9 112

2
2 M24 10.9 136
NOTE
For Geomet coated bolts, tightening torque need to be tested for
every bolt pacth.
Load on bolt 222 kN for 10.9 and 266 kN for 12.9.
1. lower end of the column

2. upper end of the column
Lubrication points
Gantry driveline/axle lubrication
7 7
2
1
A 1 7
7 1 A
7 7
1 B
B 1
7
1
B
B
A B-B
A-A A
7
9 7
10
7
10 7
3
7
9
7
5
7
7
4 7
4 7
6
8 7
7 6
Maintenance manual
208 001 EN
Pos Description Oil type Classification Quantity
1 Steering arm Shell Alvania Grease EP N/A

(LF) 1
2 Steering gear unit Shell Omala S2 G 320 ISO VG320EPPAO 11.5 L (15.5 L Actual)
3 Wheel hub (8 wheels) Shell Spirax S6 AXME N/A

75W-90
4 Wheel angle gear unit (8 Shell Spirax S6 AXME N/A

wheels) 75W-90
5 Wheel hub (16 wheels) Shell Spirax S6 AXME 2X2.4 L (2X2.4 L Actual)
75W-90
6 Wheel hub driven (16 Shell Spirax S6 AXME 2X2.7 L (2X3.6 L Actual)
wheels) 75W-90
7 Differential carrier (16 Shell Spirax S6 AXME 11.5 L (14.5 L Actual)

wheels) 75W-90
8 Angle gear (16 wheels) Shell Spirax S6 AXME 5.5 L (6.3 L Actual)
75W-90
9 Bearings for gantry motor Esso Unirex N3 40 g
10 Steering linkage Shell Alvania Grease EP N/A

(LF) 1
Maintenance manual
208 001 EN
Trolley and hoist equipment lubrication
6
4,5 7 8,9 10
14
12
11 15
21 19
16
18
15
17
13 20
Maintenance manual
208 001 EN
1 Trolley wheel Shell Alvania Grease EP N/A

(LF)1 *
2 Axles for sheave Shell Alvania Grease EP N/A

(LF)1 *
3 Axles for intermediate Shell Alvania Grease EP N/A

sheaves (LF)1 *
4 Sprockets for trolley Shell Alvania Grease EP N/A

moving (LF)1 *

(LF)1 *
6 Axles for trim (option) Shell Alvania Grease EP N/A

(LF)1 *
7 Trolley gear unit bearing Shell Alvania Grease EP N/A

(LF)1 *
8 Sprockets for trolley Shell Alvania Grease EP N/A

moving (LF)1 *

(LF)1 *

(LF)1 *
11 Hoist drum bearings Shell Alvania Grease EP N/A

(LF)1 *
12 Hoist gear unit bearings Shell Alvania Grease EP 30 g / nipple

(LF)1 *
13 Bearings for hoist motor Esso Unirex N3 40 g
14 Hoist gear unit Shell Omala S2 G 320 ISO VG320EPPAO 183 L (183 L Actual)
(320F)
15 Rollers for skews Shell Alvania Grease EP N/A

(LF)1 *
16 Bearings for trolley chain Shell Alvania Grease EP N/A

(LF)1 *
17 Skew gear unit Shell Omala S2 G 320 ISO VG320EPPAO 1.1 L (1.1 L Actual)
(320F)
18 Bearings for trolley motor Esso Unirex N3 40 g
19 Trolley gear unit Shell Omala S2 G 320 ISO VG320EPPAO 7 L (7.5 L Actual)
(320F)
Maintenance manual
208 001 EN
20 Hoist brake Shell Morlina 10 HL 10 DIN 51524 9.4 L
21 Skew chains Essolube D3 HP 10W/ N/A

Diesel CD 10W
*NOTE: Temperature dependence on below table
Temperature dependence of recommended grease
Oil type Ambient temperature Classification Quantity
Shell Alvania EP1 -10°C.... +45°C NLGI 1 N/A
Shell Alvania EP0 -15°C.... +10°C NLGI 0 N/A
Shell Centra W -30°C.... -5°C NLGI 00 N/A
Trim (option), emergency brake (option), automatic lubrication sys‐

tem (option)
Maintenance manual
208 001 EN
1 Trim high speed gear unit Shell Omala S2 G 320 ISO VG320EPPAO 2 L (2 L Actual)
(320F)
2 Trim slow speed gear unit Shell Omala S2 G 320 ISO VG320EPPAO 17 L (17 Actual )
(320F)
3 Emergency brake Shell TELLUS T46 ISO VG 46 31 L

hydraulic unit
4 Automatic lubrication Shell Rimula X W10 6 L (6 L Actual)

system (Option)
Head block (option) lubrication
1 Axles for intermediate Shell Alvania Grease EP N/A

sheaves (LF)1*
Maintenance manual
208 001 EN
Cable reel lubrication (Zero Emission RTG, option)
1 2
3
4
1 Reducer Shell Omala 220 N/A
Maintenance manual
208 001 EN
NOTE
The lubrication points 1- reducer is lubricated with lubricating oil, for
detail information refer to the above table. The other lubrication points
are lubricated with Grease
Maintenance manual
208 001 EN
F Technical data – Tightening torques, units of measurement and conversation tables 25
Tightening torques, units of

measurement and conversation tables
Tightening torques, recommendations
State Bolt Nut Lubrication
1 untreated untreated oil
2 bright-galvanized untreated or bright-galvanized oil or dry
3 hot-galvanized untreated oil or dry
Maintenance manual
208 001 EN
26 F Technical data – Tightening torques, units of measurement and conversation tables
Strength class / 8.8 10.9 12.9

Size
State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
Maintenance manual
208 001 EN
Strength class / 8.8 10.9 12.9

Size
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Units of measurement and their abbreviations
Unit Abbreviation
Newton-metre Nm
Kilopond-metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Foot ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km
Maintenance manual
208 001 EN
Conversion table, SI units
SI unit Conversion factor Other than 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/ m 2 )
kPa x 4.0 = in.H 2O 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/cm 2
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/s 2 x 0.305 = m/s 2
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
Maintenance manual
208 001 EN
SI unit Conversion factor Other than SI Conversion factor SI
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l / min (dm 3 / min) x 0.264 = US gal / min x 3.785 = l/min
Conversion table, length
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm, 1 mm = 0.001 m
Conversion table, area
Unit cm 2 m2 km2 a ft2 yd2 in 2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a , 1 mile2 = 259 ha = 2.59 km 2
Maintenance manual
208 001 EN
Conversion table, volume
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3(l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm 3 = 231 in3 = 0.83267 gal (UK)
Conversion table, weight
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table, pressure
Unit kp/cm2 bar Pa=N/m 2 kPa lbf/in2 lbf/ft2
kp /cm 2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/ m 2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm 2 = 735.56 Torr (mmHg) = 0.96784 atm
Maintenance manual
208 001 EN
31
Index
Adjusting the valve clearances and unit injector rocker Driven wheel 3 - 3
arms 1 - 8 Electrical drive 3 - 11
Adjustment of the trolley chains 7 - 57 Electrical transmission 2 - 3
Air intake / exhaust outlet 1 - 14 Electric systems B - 4
Air pollution B - 12 Emergency stop buttons 9 - 3
Alignment of the hoist machinery 7 - 40 Empty dust collector of air filter 1 - 16
Bleeding the fuel system 1 - 6 Energy chain 11 - 3
Brakes 4 - 3 Engine fluid capacities, tightening torques and
Cable reel 11 - 7 lubrication points F - 9
Changing a wheel 3 - 5 External cleaning of the radiator 1 - 21
Changing a wheel 3 - 9 Feedback A - 7
Changing oil 1 - 26 Filling / Changing planetary gear oil 5 - 6
Changing the coolant and flushing the cooling system Fire and explosion risks B - 10
1 - 20 Fluid or gas under pressure B - 11
Changing the coolant filter 1 - 19 Foreword A - 3
Changing the lubrication oil of the hoist, trolley and For the service personnel C - 3
skew gears 7 - 64 Frame 9 - 8
Checking / Changing the wheel hub, the differential Frame, body, cab and accessories 9 - 3
carrier and the angle gear lubrication oil 3 - 4 Fuel system 1 - 3
Checking / Changing the wheel hub lubrication oil 3 - 9 General safety instructions B - 3
Checking and adjusting the cable reel brake (Zero Hoist ropes 7 - 16
Emission RTG) 4 - 17 Inspecting welded steel structures for fatigue cracks 9
Checking and adjusting the gantry brake 4 - 4 -9
Checking and adjusting the hoist brake 4 - 8 Inspection of headblock (if using) twistlocks 7 - 73
Checking and adjusting the skew brake 4 - 15 Installation of the skew pulling device 7 - 58
Checking and adjusting the steering brake 4 - 5 Instructions for using shore supply (if equipped) B - 17
Checking and adjusting the trolley brake 4 - 6 Jacking and wheel change of trolley 7 - 63
Checking and tightening the frame joint bolts 9 - 8 Lift hook (option) 7 - 79
Checking a rim 6 - 4 Lifting/lowering 7 - 3
Checking the air filter indicator 1 - 15 Lifting heavy components B - 8
Checking the coolant level 1 - 19 Load carrying Bromma 7 - 71
Checking the generator mounting 2 - 4 Load cell calibration using the touch panel (if E-One2)
Checking the oil level 1 - 24 7 - 43
Checking the wheel alignment 5 - 7 Load handling 7 - 3
Check the fan hub bearing clearance 1 - 17 Load sensing system (option) 7 - 78
Check the vibration damper 1 - 16 Lubrication points 3 - 7
Clean and check the crankcase breather tube 1 - 16 Lubrication points 3 - 10
Cleaning the fuel tank 1 - 7 Lubrication points 5 - 9
Cleaning wheel hub and rim before installation 6 - 7 Lubrication points 7 - 44
Common electrics 11 - 3 Lubrication points 7 - 66
Complete machine 0 - 3 Lubrication points F - 17
Component position 3 - 18 Lubrication system 1 - 22
Component position 5 - 5 Maintenance manual A - 3
Component position 7 - 12 Maintenance tables C - 5
Component position 7 - 54 Mechanical parts 1 - 8
Concerning the maintenance and repair personnel B - Noise B - 9
16 Non-driven wheel 3 - 9
Coolant B - 12 Performing the trim maintenance (option) 7 - 36
Cooling system 1 - 18 Power assisted brake system 5 - 5
Cummins 1 - 3 Preventive maintenance C - 3
Description 7 - 45 Reading this manual A - 5
Distribution of electricity 11 - 3 Refrigerant B - 12
Driveline/axle 3 - 3 Regulations for safe maintenance work B - 15
32
Removing covers of EE-house 9 - 7

Removing the skew motor 7 - 59
Removing water from the water separator 1 - 4
Replacing hoist ropes using the mini-hoist 7 - 18
Replacing the air filter 1 - 15
Replacing the fuel filter 1 - 5
Replacing the fuel prefilter 1 - 4
Replacing the hoist ropes using the service lift 7 - 28
Replacing the oil filter 1 - 25
Rotating components and tools B - 14
Safety B - 3
Safety and emergency equipment 9 - 3
Safety instructions B - 4
Safety switches 9 - 4
Scheduled maintenance C - 12
Service brake system 4 - 3
Service of the anemometer (option) 9 - 5
Service Position B - 4
Several mechanics working on the machine B - 7
Side movement 7 - 45
SmartRail (option) 5 - 5
Solvents B - 9
Spreader cable 7 - 79
Spreader stabilizer 7 - 73
Steering 5 - 3
Suspension 6 - 3
Technical data F - 3
Technical data and dimensional drawing F - 3
Tensioned springs B - 13
Tightening torques F - 10
Tightening torques, units of measurement and
conversation tables F - 25
Tightening torques of the most important screws and
bolts 7 - 38
Tightening torques of the wheel nuts 6 - 6
Transmission 2 - 3
Tyre pressure monitoring system (option) 6 - 8
Tyre pressures 6 - 3
Tyres B - 14
Tyres and rims 6 - 3
Vibration B - 9
Working on top the machine B - 7
Working under the machine B - 8
Cargotec improves the efﬁciency of cargo ﬂows on land and at sea – wherever cargo is on the move. Cargotec’s
daughter brands Hiab, Kalmar and MacGregor are recognised leaders in cargo and load handling solutions around
the world. Cargotec’s global network is positioned close to customers and offers extensive services that ensure the Cargotec Finland Oy
continuous, reliable and sustainable performance of equipment. Ruskontie 55, P.O. Box 387
33101 Tampere, Finland
tel. +358 20 777 5000
Published by Cargotec Corporation. Copyright © Cargotec 2013. All rights reserved. No part of this publication may be fax +358 20 777 5001
reproduced, stored, photocopied, recorded or transmitted without permission of the copyright owner. www.cargotec.com
Rainbow-Cargotec Industries Co Ltd (RCI) is a joint venture of Cargotec and Jiangsu Rainbow Rainbow-Cargotec Industries Co., Ltd.
Heavy Industries Co., Ltd. (RHI) in China. Dangqian Gate, Taicang Port Economic
and Technological Development Zone,
RCI supports Cargotec's strategy of a strong local presence in China and other Asian area. Suzhou, Jiangsu, China

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Rubber Tyred Gantry Crane

Kalmar E-one 2 412621-16L-2040C-ZE

9 Frame, body, cab and accessories

B Safety Information regarding safety.

C Preventive maintenance Information about preventive maintenance. Maintenance tables.

9 Frame, body, cab and accessories

F Specifications Technical specifications, conversion tables, unit conversion factors.

Division into function groups

About the machine

Reading this manual

Information on possible safety hazards

Each manual can be ordered separately, in case extra copies of

Ordering the manuals

Form for copying

To: Cargotec Finland Oy

From: Company / sender: ...............................................................................................................................

Manual Name / publication number:..................................................................................................................

• Follow the safety instructions included in this manual.

In this publication, Cargotec Finland Oy. has documented and

• The machine is parked, and the parking brake is engaged.

Electric systems of the machine

• High-current system 400/440 VAC

• Before commencing work, ensure that the electric system is

• Over 1 kV (medium voltage), crane is equipped with medium

Refer to chapter F Technical data for the power supply voltage of

Protection against indirect contact of power supply

Several mechanics working on the machine

• Ensure that the spreader has been fully lowered or secured in

Working on top the machine

• Carefully clean all platforms, walkways, and ladders to prevent

Working under the machine

• Ensure that the spreader has been fully lowered or secured in

Lifting heavy components

Unsuitable lift slings, straps, etc. may break or slip.

Lift using a lifting device.

• Use lifting tools or equipment, especially when such equipment

If lifting must be performed without a lifting device:

• Lift near your body.

• Use heavy gloves to protect against cold and vibrations.

• Avoid inhaling solvent fumes and ensure good ventilation. If

Fire and explosion risks

Paints, plastics, and rubber generate various substances when

• Store explosive substances in approved and sealed containers.

Fluid or gas under pressure

• hydraulic and brake systems

• Use safety glasses and protective gloves.

• Use protective gloves and safety glasses if there is a risk of

• The air conditioning system must be serviced by authorized

• Carbon monoxide (fumes): Present in exhaust fumes. Odour‐

• Ensure adequate ventilation during welding, charging a battery,

• suspension elements in rubber suspension

• Use safety glasses.

Rotating components and tools

• See Clothing on page 6

• Deflate the tyre before starting to work on the wheel.

Regulations for safe maintenance work

1. Thoroughly acquaint yourself with the RTG structure and the

Concerning the maintenance and repair personnel