Udce08 05GB

A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance
manual 2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminologi och Index

A Foreword 1
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the maintenance manual .................................................................. 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About the machine version ................................................................................ 3
Copyright ........................................................................................................... 4
Reading instructions ................................................................................... 5
Warning information .......................................................................................... 5
Important information ........................................................................................ 5
Read operator’s manual .................................................................................... 5
Read maintenance manual ............................................................................... 5
Maintenance manual’s content .......................................................................... 6
Function group structure ................................................................................... 7
Product alternatives and optional equipment .................................................... 8
Machine card ..................................................................................................... 9
Function descriptions ...................................................................................... 10
About the documentation ......................................................................... 13
The documentation’s parts .............................................................................. 13
Ordering of documentation .............................................................................. 13
Feedback .................................................................................................. 14
Form for copying ............................................................................................. 14
Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

2 A Foreword
UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

A Foreword – Foreword 3
Foreword
mm mm mm mm mm mm
About the maintenance manual

General
page
–
Thank you for choosing Kalmar Industries as your machine supplier.

We hope that we’ll meet your expectations.
The maintenance manual contains information about how the machine
should be maintained for maximal operating reliability and service life
as well as troubleshooting information for fast correction of any
malfunctions.
Conditions
page
–
The instructions are based on the use of generally available standard

tools. All lifting devices, for example, slings, straps, ratchet blocks,
etc., must meet governing national standards and regulations for lifting
devices.
Kalmar Industries will not accept any responsibility for modifications
performed without permission from Kalmar Industries or if other lifting
devices, tools or work methods are used other than those described in
this manual.
Storage
page
–
NOTE
The maintenance manual shall be accessible to service
personnel.
About the machine version

page
–
The information in this publication corresponds to the machine’s de-

sign and appearance at the time of delivery from Kalmar Industries.
Due to customisations, there may be deviations.
Kalmar Industries reserves the right to modify specifications and
equipment without prior notice. All information and data in this manual
are valid at the time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Only used equipment approved by Cargotec.

4 A Foreword – About the maintenance manual
Copyright
page
–
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Duplication by any means such as copying, printing, etc., is prohibited.

A Foreword – Reading instructions 5
Reading instructions
Warning information
page
–
Warnings inform of potential hazards that, if warnings are not heeded,

may result in personal injury or product damage.
DANGER
Situation that may lead to severe personal injury or fa-
tality if the rule is not followed.
WARNING
Situation that may lead to personal injury if the rule is
not followed.
CAUTION
Situation that may lead to product damage if the rule
is not followed.
Important information
page
–
Important information is indicated by NOTE, and is provided to facili-

tate the work process, handling or increase understanding of the
information.
NOTE
Information that is important without being related to safety.
Read operator’s manual

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s manual.
000262
Read the operator’s manual
Read maintenance manual

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the maintenance manual.
001128
Read the maintenance manual

6 A Foreword – Reading instructions
Maintenance manual’s content

page
–
The information in the maintenance manual is divided in function

groups (0-12) to facilitate information searches. The manual is divided
in 20 sections A-C, 0-12, D-G. The sections with letters contain specif-
ic information that applies to several function groups and is not bound
to a function, e.g., section "F Technical data". This is described in
greater detail in the table below.
For more information about function groups, see Function group struc-
ture page 7.
A Foreword General information about the maintenance manual’s purpose, content and read-
ing instructions as well as survey for feedback of views and eventual inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
Technical description, description of the machine’s functions with schematic
5 Steering
drawings and explanatory texts for the included components.
6 Suspension Overviews with the components’ position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
9 Frame, body, cab and

accessories
11 Common electrics
12 Common pneumatics
D Error codes Error code information can be found in the Workshop Manual and the Operator’s
Manual.
E Diagrams Wiring diagrams and hydraulic diagrams are found in the Workshop manual
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations
that may appear in the manual, index for headings in the manual.

Function group structure

page
–
The information in the manual is divided in a structure of functions at

different levels, based on the machine’s design and use, called func-
tion groups.
The upper level (called main group) determines area, e.g.,
group 7 Load handling. The second level (called two-digit) determines
function, e.g., 7.2 Lift and lower. The third and fourth levels are used
to break down functions in smaller parts (components).
The function groups’ structure for main group and two-digit group level
is common for all machines from Cargotec, e.g. 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
made at the third and fourth group level, e.g. 4.3.9 Wheel brake and
4.3.9.1 Disc assembly. This means that certain function groups (head-
ings) will be left out in the documentation for certain machines since
the machine is missing that specific function or component. In turn, this
means that there may be jumps in the function groups’ numbering (e.g.
the three-digit heading level 4.8.7 Oil cooler may be included for some
machines, but is missing for others).
The function groups are intended to be used as search terms to find
different types of information between different sections and manuals.
The information in a function group is divided in smaller sections ac-
cording to the type of content, e.g., description or change.
The maintenance manual and Workshop manual contain different in-
formation. The maintenance manual contains only the information
needed for preventive maintenance and simpler troubleshooting. The
Workshop manual contains more in-depth information and repair
instructions.
References between sections in the same manual are indicated with
section and group number, e.g., "see section 4 Brakes,
group 4.3.9 Wheel brake". References within a section are indicated
with a page number, e.g., "see Sensor fuel level, description page 24".
References between Maintenance manual and Workshop manual are
not given. If more information is desired for a function group, the pri-
mary recommendation is to search under the same function group in
the other manual.

Product alternatives and optional equipment

page
–
The information in the manual is divided in modules. For product alter-

natives and optional equipment, handling of the modules differs de-
pending on if it is the one or the other that is described, see below.
Special equipment is not described in the manual. If you’re uncertain
about what equipment the machine should have, use the machine
card to decide which information applies, see Machine card page 9.
Product alternatives
Product alternatives are such options that exclude certain standard
equipment (e.g., engine alternative).
Equivalent information for different product alternatives is described in
separate sections following each other under the same function group.
To indicate that there are different alternatives, the supplement "Prod-
uct alternative" is used in the heading together with a simple descrip-
tion of which alternative is described, e.g., "(Product alternative
Climate control unit ECC)".
Optional equipment
000264
Optional equipment comprises options that can be added to the stand-

ard equipment to obtain additional or improved functions.
Symbol indicating optional equipment
Information for optional equipment is described in separate sections
with standard equipment as the starting point. The description of the
optional equipment describes how the standard function is affected by
the option as well as which components are added.

Machine card
page
–
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
IMPORTANT
Changes made on the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
The machine card indicates of which drawings the machine consists,

in many cases these can be associated options and product alterna-
tives. For more information about the handling of product alternatives
and optional equipment, see Product alternatives and optional equip-
ment page 8. The machine card is delivered with the parts catalogue
and can be found in the cab.
The machine card is divided in the same functions groups as the parts
catalogue, maintenance and Workshop manual. For practical reasons,
the machine card uses only the first and second level in the function
group register. The function groups are written in groups of four char-
acters, e.g. group 0107 matches group 1.7 Cooling system in the
manual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue’s foreword.
If the information on the machine card does not help, contact
Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.

Function descriptions
page
–
Function descriptions are schematic overviews that describe how a

function works as well as which components and signals work
together.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
8
2
B
4
007942
Example of function description

1. Hydraulic force (solid double line)

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

Symbol explanation function descriptions

The following symbols are used in function descriptions, the symbols
1 2 are based on standard symbols used in wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7
7 88 M
7. Hydraulic oil pump with fixed displacement
8. Electric motor
9
9 10
10 9. Accumulator
10. Disc brake
11. Filter
11
11 12
12 12. Radiator
D790-1 13. Bulb

ECU795
13 14 14. Control and monitoring system, two control units with CAN-bus
13 14
D797-F
ECU796 15. Restriction
16. Adjustable restriction
15
15 16
16 17. Inductive position sensor
17
17 18
18 18. Electrically controlled servo valve
19. Thermal bypass valve
˚C
19 ˚C 20 ˚C
19 20 ˚C 20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 ˚C
21 22
22 Pa
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
23 Pa 24
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
25
26. Spring brake cylinder
27. Valve block
26 27
26 27 28. Shuttle valve
29. Non-return valve
28 29 30. Hydraulic oil pump (transmission)
007991
28 29
010587
30

A Foreword – About the documentation 13
About the documentation

The documentation’s parts
page
–
The documentation for the machine consists of the following parts:
Operator’s manual
The operator’s manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
delivered to the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual
• Supplier documentation for e.g. engine, transmission, and drive
axle, etc.
Ordering of documentation
page
–
The documentation is ordered from the dealer for Cargotec.

Always specify publication number when ordering.
For publication number, see the machine card.

14 A Foreword – Feedback
Feedback
Form for copying
page
–
Cargotec’s ambition is that you who work with maintenance of Kalmar

machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To: Cargotec Sweden AB

SE-341 81 Ljungby
SWEDEN
Fax: +46 372 263 90
From:
Company / Sender: ........................................................................................................................................
Telephone: ....................................................................................................................................................
E-mail: ...........................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
information Name / Publication number: ...........................................................................................................................
Section / page number: ..................................................................................................................................
Suggestions,
views, .......................................................................................................................................................................
remarks, etc.
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

B Safety 1
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic system, depressurising ...................................................................... 6
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 9
Working under machine .................................................................................... 9
Lifting heavy components ............................................................................... 10
Vibrations ........................................................................................................ 11
Noise ............................................................................................................... 11
Solvents .......................................................................................................... 12
Fire and explosion risks ................................................................................... 13
Fluid or gas under pressure ............................................................................ 15
Coolant ............................................................................................................ 16
Refrigerant ...................................................................................................... 17
Air pollution ..................................................................................................... 18
Tensioned springs ........................................................................................... 19
Electric motors ................................................................................................. 19
Rotating components and tools ....................................................................... 20
Tyres and rims ................................................................................................. 21
Lifting equipment ............................................................................................. 21
Welding ........................................................................................................... 22
Spare parts ...................................................................................................... 23
Non-ionised radiation ...................................................................................... 24
Environment ............................................................................................. 25
General ........................................................................................................... 25

2 B Safety

B Safety – Safety 3
Safety
mm mm mm mm mm mm
General safety information

Safety concerns everyone!
page
–
The safety information concerns everyone who works with the ma-
chine! Persons who do not follow the safety instructions given in this
manual must make absolutely sure that the work is performed without
risks of personal injury, without risks of machine damage, or property
damage!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully. Do not take any risks!
In this publication Cargotec has documented and warned for situations
and risks that may occur in connection with the use of, as well as serv-
ice/repairs of, the machine during normal circumstances.
That’s why it’s important that all who work with the machine, or repair/
service the machine read and follow the information in the Mainte-
nance manual and Operator’s manual.
A near accident is a warning!

page
–
A near accident is an unanticipated event where neither any person is

injured, nor machine or property is damaged. However, near accidents
show that there is an injury/damage risk and that actions must be tak-
en to avoid the risk of damage and injury.

4 B Safety – Safety instructions
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic system, depressurising page 6
• Oils page 6
• Fuel system page 7
• Clothing, etc. page 8
• Several mechanics on the same machine page 9
• Working under machine page 9
• Lifting heavy components page 10
• Vibrations page 11
• Noise page 11
• Solvents page 12
• Fire and explosion risks page 13
• Fluid or gas under pressure page 15
• Coolant page 16
• Refrigerant page 17
• Air pollution page 18
• Tensioned springs page 19
• Electric motors page 19
• Rotating components and tools page 20
• Tyres and rims page 21
• Lifting equipment page 21
• Welding page 22
• Spare parts page 23
• Non-ionised radiation page 24
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:

B Safety – Safety instructions 5
• Machine parked, that is, applied parking brake.

• Forks and trolley in completely lowered position.
• Engine off.
• Main electric power off (with battery disconnector).
007944
Machine with forks and trolley in completely lowered
position

Hydraulic system, depressurising

page
–
1 Machine in service position.

2 Depressurise the hydraulic system by opening the accumulator
drain valve.
DANGER
Fatal danger!
Extreme danger exists when working with hydraulics

when the hydraulic system is pressurised.
Depressurise the hydraulic system. Open the accu-

mulator drain valve.
3 Verify that the accumulator pressure has been released, meas-

ure with a pressure gauge at the pressure test outlet for the ac-
008845
cumulator charging valve (see section 10 Common hydraulics,

group 10.5.2 Main valve).
Accumulator drain valve’s controls
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
Oils
page
–
The following safety instructions shall be followed for work when han-
dling oils.
WARNING
Warm and pressurised oil.
Always depressurise the hydraulic system before

work in the system is started. The hydraulic system is
pressurised and its oil can cause personal injury.
Avoid skin contact with the oil, use protective gloves.

Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat

IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Always take action to avoid spills. In places where

drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs seal tight before collection

containers are moved.
Handle all oil as environmentally hazardous waste.

Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall al-
ways be handled by an authorised company.
Fuel system
page
–
The following safety instructions shall be followed for work when han-
dling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the

engine is warm since fuel can spill on hot surfaces
and may ignite.
Ensure that naked flames, sparks or red-hot/glowing

objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when

work on the fuel system is in progress.

WARNING
The engine’s fuel system operates at very high pres-
sure. The pressure is so high that the jet can damage
the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles.

If a component is to be loosened, hold a rag over the
coupling as protection and collect the fuel.
CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.
IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections seal tight

before moving collection containers.
Handle the fuel as environmentally hazardous waste.

Fuel freely released causes damage to the environ-
ment and may also cause fires. Fuel shall always be
handled by an authorised company.
Clothing, etc.
page
–
Clothes should be in good repair. Remove loosely hanging garments

(e.g., tie, scarf). Do not wear clothes with wide sleeves, wide pant
legs, etc.
Remove jewellery as it may conduct electricity and get caught in mov-
ing parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Be careful when working with welding or an open
flame since hair easily catches on fire.

Several mechanics on the same machine

page
–
WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental move-
ments do not injure any other person. Communicate
so that everyone knows where everyone is, and what
they are doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
Movements performed from the operator’s station, e.g., all movement
of lifting equipment, may cause severe personal injuries.
Safety actions
• Make sure that the machine’s lifting equipment is completely low-
ered or secured in another way.
• Move the battery disconnector to position zero and remove
the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine’s both sides at the
same time.
Working under machine

page
–
Working under the cab

Loose objects must not be present in cabs that are to be tilted.
The cab must always be tipped to its end position and secured with the
stop device.
When the work does not allow the cab to be tilted to its end position,
or for work with cab suspension, the cab must always be secured with
the stop device.
On machines with vertically adjustable cab the cab must be secured
in the raised position with the intended lock.
Working under frame

A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or drive axle.

Risks
Mechanical or hydraulic tools and lifting devices can fall over or acci-
dentally be lowered due to malfunctions or incorrect use.
Safety actions
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.
Lifting heavy components

page
–
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other tools to move

heavy components. Make sure that the device is ro-
bust and intact.
Risks
Unsuitable lift slings, straps, etc. may break or slide.
The centre of gravity of the component can change during the course
of the work, and the component may then make unexpected move-
ments which may cause severe personal injuries and material
damage.
A component lifted with lifting equipment can start to turn if the centre
of gravity changes.
A component lifted using an overhead crane may start to swing back
and forth, which can cause severe crushing injuries or material
damage.
Safety actions
Lifting with lifting device. Use lifting tool or other tools, especially
when there are such adapted for certain work. See workshop manual
for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Lift and lower with legs and arms, not
your back. Do not rotate the body during the lift. Ask for help be-
fore you lift.
• Use gloves. They’re often good protection to reduce crushing and
cutting injuries to fingers.
• Always use protective shoes.

Vibrations
page
–
Use of vibrating tools, e.g., impact nut runner or grinder, for an extend-
ed period of time may cause injuries as vibrations are transmitted from
the tool to hands. Primarily when fingers are cold.
Safety actions
Use heavy gloves to protect against cold and somewhat against
vibrations.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.
Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered to damage hearing. (Limit values may differ between different
countries.) High pitches (high frequencies) do more damage than low
pitches at the same sound level. Noise in the form of impulse sounds
may also be damaging, e.g., hammer strikes.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety actions
Use hearing protection. Make sure that it’s tested and protects against
the right noise level.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.

Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, glue, rubber, etc. are called organic solvents. Example: Petroleum
spirits, gasoline, thinner, alcohols, diesel, xylene, trichloroethylene,
toluene. Many solvents are flammable.
Risks
Products with solvents give off fumes that may cause dizziness, head-
ache and nausea. It may also irritate mucous membranes in the throat
and bronchi.
If the solvent ends up directly on the skin it may dry out and crack. Risk
of skin allergies increases. Solvents may also cause injury if they pen-
etrate through the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, there may be injury to
the central nervous system. This manifests itself in sleeping problems,
depressions, nervousness, poor memory and general tiredness. Con-
tinuous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety actions
Avoid inhaling solvent fumes by providing good ventilation, or wearing
a fresh-air mask or respiratory device with a suitable filter for the toxic
gases.
Never leave a solvent container without tight-sealing lid.
Use solvents with a low content of aromatic substances. It reduces the
risk of injury.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.

Fire and explosion risks

page
–
DANGER
The operator’s safety may not be jeopardised in case
of fire.
If possible, take the following actions at the slightest

sign of fire:
1. Stop the machine and turn the start key to stop

position.
2. Leave the cab.
3. Turn off the system voltage with the battery

disconnector.
4. Call the fire department.
5. Try to put out the fire.
If this is not possible, leave the machine and the

danger area.
DANGER
Smoke from a fire may be very toxic.
Smoke anaesthetises, suffocates, and can kill people!

Even small quantities of smoke can cause damage to
the lungs and respiratory organs.
Avoid breathing in fumes, do not stand in the smoke.

Use breathing apparatus for fire fighting and work
with burnt material.
DANGER
Tyres are flammable and cause explosive fires.
Fatal danger!
Always seek safety if tyres catch fire.
Examples of fire and explosion prone substances are oils, petrol, die-
sel fuel oil, organic solvents (paint, plastics, detergents), rust preven-
tive agents, welding gas, gas for heating (acetylene), high
concentrations of dust particles consisting of combustible materials.
Rubber tires are flammable and cause explosive fires.

Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette glow may cause an explosion. Evaporated
gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and
explosive fires.
When a battery is charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
On today’s machines there is a lot of electronic equipment. When
welding, the control units must be disconnected and the electric power
must be turned off with the battery disconnector. Powerful welding cur-
rents may otherwise short-circuit the electronics, destroy expensive
equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least
10 cm around the welding or cutting point). Use gloves, breathing pro-
tection and protective glasses. Also, welding work may not be done
near plastic or rubber materials without first protecting them from the
heat. Paints, plastics, and rubber develop a number of substances that
may be hazardous to health when heated. Be careful with machines
that have been exposed to intense heat or fire.

Safety actions
DANGER
Remains of fuel, oils, grease, and other flammable
materials on the engine or in the engine compartment
are fire hazards.
Risk of fire!
Remove combustible material residue from the en-

gine compartment as soon it is discovered, be espe-
cially careful on hot surfaces such as exhaust
systems, manifolds or turbos. If oil, fuel or coolant
leakage is detected, establish the cause and rectify
the fault before starting the engine.
• Make a habit of visually inspecting the engine and engine com-

partment before starting the engine and after operation, when the
engine has stopped. This helps to quickly detect if anything abnor-
mal has happened or is about to happen. Look particularly closely
for oil, fuel or coolant leakage, loose bolts, worn or poorly tight-
ened drive belts, loose connections, damaged hoses and electri-
cal cables. The inspection only takes a few minutes and can
prevent serious faults and costly repairs.
• Store hazardous substance in approved and sealed container.
• Make sure that there is no ignition source near flammable or ex-
plosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.
• Always have a fire extinguisher available.
Fluid or gas under pressure

page
–
Lines with high pressure may be damaged during work and fluid or gas
may jet out.
There may be high pressure in a line even if the pump has stopped,
therefore gas or fluid may leak out when the connection for the hose
is loosened.
A gas container that is subjected to external forces may explode, e.g.,
if it falls against a hard surface. Gas may jet out from damaged valves.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
• Cooling system.

Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer’s recommendations.
• A hydraulic hose that swells at a connection shows that it is about
to rupture. Change as soon as possible! Check the connections
carefully.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulator shall first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands to check for any leaks. A fine jet from a hy-
draulic hose may have such high pressure that it easily cuts
through, e.g., a hand and causes very severe injuries.
• First open the cooling system’s cap for the filling point, so that the
high pressure is released. Be careful. Hot steam and coolant may
jet out.
Coolant
page
–
The coolant in the machine’s cooling system consists of water, anti-

corrosion compound and (when needed) anti-freeze fluid, for example,
ethylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the filling point, so that the high pressure is
released. Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.

Refrigerant
page
–
Refrigerant is used in the machine’s air conditioning system.

Work on the air conditioning system must be performed by accredited/
authorised and trained personnel according to national legislation and
local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Refer to the importer for further regulations.
Safety actions
• Use special instructions and equipment for refrigerant according
to the Workshop manual when working on the air conditioning
system. Special certification and authorisation is often required of
the person who may do the work. (Follow national legislation and
local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).

Air pollution
page
–
Air pollutants are the compounds in the air around us and are regarded
as hazardous to health. Certain compounds are more prevalent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon dioxide is found in exhausts. Has no odour and is there-
fore extra dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or be found in
aerosol) when cutting, grinding or welding. May give mucous mem-
brane irritation with asthma-like symptoms as well as impaired lung
function. Even brief exposure to high concentrations can give prob-
lems with permanent sensitisation.
Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when
there is a risk of oil mist. Make sure that the protection is oil-proof.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary driving with the machine in the workshop.
Connect extraction to the exhaust pipe so that exhausts are rout-
ed out from the workshop.

Tensioned springs
page
–
Examples of tensioned springs:

1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before start-
ing any work on the machine.

Rotating components and tools

page
–
Examples of rotating components and tools:

• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinders
Risks
Rotating components, e.g., fans or shafts, can cause severe injuries if
touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety actions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or pant legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms
and neck.

Tyres and rims

page
–
DANGER
Tyres shall be regarded as pressure reservoirs. If han-
dled incorrectly, they constitute a fatal danger
Parts can be thrown with explosive force and may

cause severe injuries.
Never repair damaged tyres, rims or lock rings. Tyre

changes shall be performed by authorised personnel.
Risks
Dismantling of wheels: tyres, rims and lock rings may be ejected.
Inflating of wheels: tyres, rims or lock rings may be ejected.
Safety actions
• Deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the machine’s lift-
ing equipment in particular, the greatest care must be taken with re-
gard to securing the mast and carriage.
Get into the habit of always keeping the carriage lowered to the lowest
position when working on the machine.
Risks
If the machine’s lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is extra high when depressurising the hydraulic sys-
tem, see Hydraulic system, depressurising page 6.
Safety actions
Do not begin work until the carriage is completely lowered. If the na-
ture of the work requires the carriage to be raised, it must be secured
in some way.

Welding
page
–
DANGER
Contact Cargotec Support before welding is carried
out on the machine.
CAUTION
Nowadays there is a lot of electronics in machines.
Control units must be disconnected and the current
switched off using the battery disconnector during all
welding work on the machine.
Powerful welding currents may otherwise short-cir-

cuit the electronics, destroy expensive equipment,
and may cause an explosion or fire.
page
–

Spare parts
WARNING
For safety reasons, the following spare parts may
only be replaced by genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Lift boom
• Boom nose extension
• Lift cylinder
• Valve block lift
• Extension cylinder
• Valve block extension
• Rotation motor unit
• Tilt cylinder
• Twistlocks, lift shoe
• Control breaker (for hydraulic function)
• Emergency switch
• Frame
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

Non-ionised radiation
page
–
WARNING
Optional equipment such as two-way radio, remote
control door opener, etc. may emit non-ionising radi-
ation. Such equipment transmits within the frequency
band 100 - 500 MHz.
Danger of interference to active medical devices (e.g.

pacemakers).
Do not use two-way radios, remote control door open-

er, etc. when someone with an implanted active med-
ical device is in the cab.
NOTE
Do not use two-way radios, remote control door opener, etc.
when someone with an implanted active medical device
(e.g. pacemaker) is in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for equipment not
installed by Cargotec or according to installation instructions ap-
proved by Cargotec.

B Safety – Environment 25
Environment
General
page
–
Our global environment is severely affected by ever-increasing indus-

trialisation of the world. Nature, animals, and human beings are ex-
posed daily to great risks in connection with chemical handling in
different forms.
There are still no environmentally safe chemicals such as oils or cool-
ants on the market. All who handle, perform service or repairs on ma-
chines must therefore use the necessary tools and methods to spare
the environment in an environmentally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well thought-out recycling of the machine is the cornerstone of ending
the life cycle and being able to retain materials for re-use in new prod-
ucts. According to calculations by Cargotec, the machine is recyclable
to more than 90% by weight.
Environmentally hazardous waste

Components such as batteries, plastics and other items that may con-
stitute environmentally hazardous waste must be handled and taken
care of in an environmentally safe and sound manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause damage to the environment and can also
cause fires. Therefore, when emptying and draining oils, take action to
avoid unnecessary spills.
Waste oils and fluids must always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning system

The refrigerant in the air conditioning system for the cab accelerates
the greenhouse effect and may not be intentionally released into the
open air. Special training is required for all service work on the air con-
ditioning system. Many countries also require certification by national
authority for such work.
Working in a contaminated area

The machine shall be equipped for work within a contaminated area
(polluted or health-hazardous area) before starting to work. Also, spe-
cial local rules apply when handling and servicing such a machine.

26 B Safety – Environment
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In cer-
tain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, refrigerant of the type
R134a and an amount between 1-3 kg is used.

C Preventive maintenance 1
C Preventive maintenance
Table of Contents C Preventive maintenance

mm mm mm mm mm mm
Preventive maintenance ................................................................................ 3

Preventive maintenance, general ........................................................................... 3
Preventive maintenance, work instructions ............................................................ 3
Check and service log ............................................................................................ 4
Service schedule .................................................................................................... 5
Washing ............................................................................................................... 17
Lubricating 500h ................................................................................................... 18
Lubricating 1000h ................................................................................................. 28
Checking for cracks ............................................................................................. 32

2 C Preventive maintenance

C Preventive maintenance – Preventive maintenance 3
Preventive maintenance
mm mm mm mm mm mm
Preventive maintenance, general

page
–
It’s very important that preventive maintenance is performed accord-

ing to recommended intervals.
Preventive maintenance should be performed by Cargotec, or by a
service organisation authorised by Cargotec.
WARNING
Service intervals shall be followed.
This is to maintain the machine’s safety and to fulfil

warranty and service agreements!
Use spare parts and fluids approved by Cargotec to

fulfil the warranty.
Preventive maintenance, work

page
–
instructions
1 For a new machine it is of great importance during the first work-
ing week to check-tighten the wheel nuts until properly seated.
This should be performed at intervals of 4–5 hours (up to approx.
40–50 hours).
2 Regular service shall be performed according to service sched-
ule, see Service schedule page 5. The service schedule shall be
followed to ensure high machine reliability.
Note completed service in the service log, see Check and service
log page 4.

4 C Preventive maintenance – Preventive maintenance
Check and service log

page
–
Model:
Serial number:
Completed maintenance
Operating Actions Operating Date Signature

hours hours
500h 500h service
1000h 1000 service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000 service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000 service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000 service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000 service
9500h 500h service
10000h 2000h service

Service schedule
page
–
Service shall be performed every 500h. Actions are divided into 500h,
1000h and 2000h service.
Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.
Actions for 1000h service are performed at odd thousands of operat-
ing hours: 1000h, 3000h, 5000h, etc.
Actions for 2000h service are performed at even thousands of oper-
ating hours: 2000h, 4000h, 6000h, etc.
After service is performed, make a note in the check and service log,
see Check and service log page 4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hour
CAUTION
Lubrication intervals are based on normal handling
and environment and are subject to the use of the rec-
ommended grades and quantities.
In other conditions, e.g. cold, hot, dusty, we recom-

mend halving the intervals.
The lubrication interval must never exceed

12 months.

Object, action Service Comment Reference
500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
0 complete machine
Checking cleanliness and C C C Check for and remove trac- Section B Safety
leakage es of combustible materi-
als in the engine
compartment.
Take extra care on hot sur-
faces such as exhaust sys-
tems, manifolds or turbo.
If leaks of oil, fuel, or cool-
ant are detected, find the
cause and solve the
problem.
Attachments (stub axles) C C Visual check in connection

with greasing.
Lubricating 500h L L L Lubricating 500h page 18
Lubricating 1000h L L Lubricating 1000h page 28
Checking for cracks C* * Check every 4000h or Checking for cracks

every year. page 32
1 Engine (engine option Volvo)

Bolted joints, attachments, C C C
mountings, etc.
Fuel tank C C Clean if necessary. Section 1 Engine,

group 1.2.1 Fuel tank
Fuel filter R R Section 1 Engine,

group 1.2.2 Fuel filter
Fuel prefilter C C/R C/R Drain water/impurities. Section 1 Engine,

group 1.2.3 Fuel pre-filter
C C C Cleaning the filter in con- Section 1 Engine,

Particle filter
nection with clean-burning group 1.3.1 Particle filter.
every 1500h.
Valve clearance C Checking/adjusting NOTE

For newly overhauled en- Performed by service
gine, adjust valve clear- shop authorised by
ance after 250h. Volvo Penta.
Injector C
Turbo C

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Air filter main cartridge C/R C/R C/R Checking indicators, filter Section 1 Engine,
change when indicated. group 1.6.1 Air cleaning
system
Air filter safety cartridge C C/R C/R Changed every other time
main cartridge is changed.
Exhaust system C C C Sealing check. Section 1 Engine,

group 1.6.3 Exhaust
system
Charge air hoses C C C Sealing check. Section 1 Engine,

group 1.6.4 Intercooler
Radiator C C C External check and Section 1 Engine,

cleaning. group 1.7.4 Radiator and
expansion tank
NOTE
Do not use high pres-
sure wash.
Drive belts C C/R C/R Change when needed. Section 1 Engine,

group 1.7.5 Cooling fan
Coolant C C/R C Level check. Section 1 Engine,

Coolant should be re- group 1.7.7 Coolant
placed after 5000h. When
changing, check/clean the
cooling system.
For volume, see
section F Technical data
Coolant freezing point C C C
Engine oil R R R For volume and quality, Section 1 Engine,

see section F F Technical group 1.8 Lubrication
data system
Engine oil filter R R R At every oil change Section 1 Engine,

group 1.8.4 Oil filter
Lubrication and cooling C C C Sealing check.

system
1 Engine (engine option Cummins)

mountings, etc.


500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Fuel filter R R Section 1 Engine,
Fuel prefilter C C/R C/R Drain water/impurities. Section 1 Engine,


Particle filter
every 1500 h.
Valve clearance C Valve clearance checked/ Section 1 Engine,

adjusted after 5000h / eve- group 1.5.4 Valve
ry 4th year. mechanism
Air filter main cartridge C/R C/R C/R Checking indicators, filter Section 1 Engine,
change when indicated. group 1.6.1 Air cleaning
system
Air filter safety cartridge R C/R C/R Changed every other time
main cartridge is changed.

group 1.6.3 Exhaust
system


cleaning. group 1.7.4 Radiator and
expansion tank
NOTE
Do not use high pres-
sure wash.
Drive belts C/R C/R C/R Change when needed. Section 1 Engine,
group 1.7.5 Cooling fan
Drive belt tensioner C/R C/R Check every 1000h or eve-
ry year. Change if needed.
Fan hub C C * Check every 1000h or

every year.
Vibration damper, rubber C * Check every 2000h or

every 2 years.

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Coolant C C C Level check. Section 1 Engine,
Coolant should be re- group 1.7.7 Coolant
placed after 2000h. When
changing, check/clean the
cooling system.
For volume, see
section F Technical data
Coolant freezing point C C C
Engine oil R R R For volume and quality, Section 1 Engine,

see section F F Technical group 1.8 Lubrication
data system

1 Engine (engine alternative Caterpillar)

mountings, etc.

Fuel filter R R R Section 1 Engine,

Fuel prefilter R R R Incl. draining of water. Section 1 Engine,


Particle filter
every 1500h.
Valve clearance C C Checking/adjusting first NOTE

checking/adjusting after
Checking/adjusting
500 operating hours.
must be performed by
a service technician
authorised by Kalmar
Industries.
Air filter safety cartridge C C/R C/R Changed every other time Section 1 Engine,
main cartridge is changed. group 1.6.1 Air cleaning
system
Air filter main cartridge C/R C/R C/R Checking indicators, filter
change when indicated.
Turbo C Check Section 1 Engine,

group 1.6.2 Turbo

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
group 1.6.3 Exhaust
system


cleaning. group 1.6.4 Intercooler and
group 1.7.4 Radiator and
expansion tank and
Coolant pump C Check Section 1 Engine,

group 1.7.1 Coolant pump
Drive belts R R R Change after 500h or eve- Section 1 Engine,

ry year. group 1.7.5 Cooling fan
Coolant C C/R C Check freezing point, Section 1 Engine,

change the coolant after group 1.7.7 Coolant
3000h or every other year.
Engine oil R R R Section 1 Engine,

group 1.8 Lubrication
system

Starter motor C Check Section 1 Engine,

group 1.11.1 Starter motor
Alternator C Section 11 Common

electrical,
group 11.4.4 Alternator
Lubrication and cooling C C C Sealing check.

system
2 Transmission
Transmission oil C R R Change transmission oil Section 2 Transmission,
every 1000h or every year. group 2.6 Lubrication
On indication from the filter system
monitor (only applies to
machines with ZF
transmission).
Transmission oil filter R* R R At each transmission oil Section 2 Transmission,

change. group 2.6.4 Oil filter
* Only during 500h service

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Transmission, calibration C C Calibration of the transmis- Section 2 Transmission,
sion is recommended eve- group 2.8 Control system
ry 1000 hours.
3 Driveline/Axle
Propeller shaft C C C Section 3 Driveline/Axle,
group 3.2 Propeller shaft
Drive axle C C Section 3 Driveline/Axle,

group 3.3 Drive axle
Drive axle oil C R R Section 3 Driveline/Axle,

group 3.3 Drive axle
4 Brake system
Power-assisted brake C C C Function check.
Brake pedal and pedal C C C Section 4 Brakes,

assembly group 4.1.1 Brake pedal
Brake pressure, checking C C C Section 4 Brakes,

group 4.3.6 Distribution
block
Parking brake C/R C/R C/R Check pad thickness, Section 4 Brakes,
change when needed. group 4.5.4.2 Parking
brake pads
5 Steering
Link arms C C C Checking the bearings and Section 5 Steering,
lock iron for the shafts. group 5.2.6 Link arm
Sensor wheel angle, feed- C C C Check the wheel angle Section 5 Steering,
sensor with regard to play. group 5.2.9 Sensor wheel
back joystick control
Check the wiring. angle
Sensor steering wheel read- C C C Section 5 Steering,

ing mini-wheel/joystick group 5.2.11 Sensor steer-
ing wheel reading
control
6 Suspension
Steering axle suspension C C Suspension in the frame. Section 6 Wheel suspen-
sion, group 6.2.1 Steering
axle cradle
Wheel spindle, check C C Check the play in the wheel Section 6 Wheel suspen-
suspension. Max. sion, group 6.2.2 Wheel
0.25 mm. spindle

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Wheel hub, checking *) C Check bearing pre-load. Section 6 Wheel suspen-
*) Check the first time after sion, group 6.2.3 Wheel
1000h, then every 2000h. hub
Tyres and rims C C C Damage, wear and pres- Section 6 Wheel suspen-
sure, change as needed. sion, group 6.3 Tyre
system
Wheel nuts C C C Check-tighten. Section 6 Wheel suspen-

sion, group 6.3 Tyre
system
Rim C* C* * In connection with tyre Section 6 Wheel suspen-

change or once a year. sion, group 6.3.2 Rim
7 Load handling
Mast suspension C C Check that the welds are Section 7 Load handling,
intact and check the group 7.2.6 Mast
bearings.
Side support C C C Section 7 Load handling,

group 7.2.6 Mast
Lifting chains C C C Check for damage. Section 7 Load handling,

Tension chain when group 7.2.8 Chains
needed.
Side shift cylinder C C C Section 7 Load handling,

group 7.4.4 Side shift
cylinder
Tilt cylinder C C C Check that the welds are Section 7 Load handling,
intact and check the group 7.7.5 Tilt cylinder
bearings.
Lifting forks C C C Section 7 Load handling,

group 7.9.1 Lifting forks
C C Calibrating the scales Section 7 Load handling,

Scales
Group 7.10.1 Electric
scales
C C Damage Section 7 Load handling,

Attachment
group 7.10.5 Side lift
attachment

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
C C C/R Checking that the parts are Section 7 Load handling,
Twistlocks
properly tightened every group 7.10.5 Side lift
500 hours. attachment
Check of float position eve-
ry 500 hours.
Check of vertical move-
ment every 2000 hours.
Check for cracks every
other year or every
Replacement every
Reset the hour counter for
twistlocks after
replacement.
C C C Section 7 Load handling,

Sensors
group 7.10.5 Side lift
attachment
8 Control system
Service indicator, reset C C C A special code is required Section 8 Control and mon-
in addition to the service itoring system,
code. group 8.2.4 Service
indicator

Instrument and control C C C Function check
C C C Checking function. Section 9 Frame, body,

Air conditioning unit
cab, and accessories,
group 9.4 Air conditioning.
Function check of drive Section 1 Engine,

belt. group 1.7.5 Cooling fan
Fresh air filter (only applies C/R R R Depending on the external Section 9 Frame, body,
to Spirit Delta) environment. cab and accessories,
Some models have washa- Group 9.4.4 Fresh air filter
ble prefilters. The fine-filter
is changed when
necessary.
C C C Clean when needed. Section 9 Frame, body,

Condenser
NOTE! Not high-pressure cab and accessories,
washer. Group 9.4.9 Condenser
unit

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Windshield wipers C C C Incl. flushing. Section 9 Frame, body,
cab and accessories,
Group 9.5 Wiping and
cleaning of windows
Lighting and audible signals C C C
Communication equipment C C C See separate subcontrac-

tor information
Roof window C C Check damage, change Section 9 Frame, body,

when needed. cab and accessories,
Group 9.9 Glass/windows/
mirrors
Cab frame C C Check rust damage, defor- Section 9 Frame, body,

mation or cracks. cab and accessories,
group 9.10 Cab frame
Hinges for doors and cover C C C Check doors’ mounting Section 9 Frame, body,
lids points. cab and accessories,
Group 9.10.2 Doors
Cab undercarriage C C Check mountings, isolators Section 9 Frame, body,

and bolted joints. cab and accessories,
group 9.10.3 Cab under-
carriage
Hydraulic tilting of the cab C C C Standard for the Spirit Del- Section 9 Frame, body,
ta cab. cab and accessories,
Check the pin for the cab group 9.10.3 Cab
and the lift cylinder’s undercarriage
mounting. Section 9 Frame, body,
Group 9.10.4 Cab tilting
Door stop with gas strut C C Checking the mounting Section 9 Frame, body,
points, joints and function. cab and accessories,
damping
Group 9.10.5 Door stop
Frame C C Check for any deformation

and rust damage as well as
cracks in welded joints
Non-slip plate for cab steps C C Check and replace non-

and on cab floor slip plate in poor condition.
Counterweight mounting C C Section 9 Frame, body,

Group 9.13.4
Counterweights

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Central lubrication C C C Section 9 Frame, body,
Group 9.14 Central
lubrication
Paint/coatings C Check the machine’s paint- Section 9 Frame, body,

ed surfaces for stone chips cab and accessories,
and scratches group 9.15 Paint/coatings
Repair damage immedi-
ately to avoid corrosion.
Safety decals C C C Check that safety decals See Operator’s manual

are legible, securely fas- DCF 90–180, section 3
tened and are not dam- Overview, group 3.2 Signs
aged. Clean very dirty
decals and replace decals
if needed.
Accumulator C C C Check the precharge Section 10 Common hy-
pressure. draulics Group
10.3.2 Accumulator
Hydraulic pressure, C C C Section 10 Common hy-

checking draulics, group 10.5.2 Main
valve
C C Section 10 Common hy-

Cooler for hydraulic oil
draulics, group 10.6.2 Hy-
draulic oil cooler
Breather filter C/R R R Section 10 Common hy-

draulics,
Group 10.6.7 Breather fil-
ter, hydraulic oil tank
Hydraulic oil filter R R Section 10 Common hy-

draulics,
Group 10.6.8 High-pres-
sure filter

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Hydraulic oil C/R Checked with oil sample. Section 10 Common hy-
• If oil sample OK after draulics, Group 10.6.9 Hy-
2000h, drive further draulic oil
1000h and take new
oil sample.
• If oil sample OK after
3000h, drive further
1000h and change oil.
Note: Max. 4000h change
interval.
Additive: Lubrizol should
be added when changing
hydraulic oil. Concentra-
tion 3%.
For volume, see
section F Technical data.
11 Common electrics
Position sensors C C C Should be free from grease
and dirt, clean as needed
Fuses C C C Check that fuses are intact, Section 11 Common elec-

change if needed. trical, group 11.2.2 Fuses
Batteries C C C Clean and wipe the bat- Section 11 Common elec-

tery, in particular the top at trical, group 11.3.1 Start
the terminal connections, battery
in order to avoid
self-discharge.
Check the state of charge
and electrolyte level and
add battery water as re-
quired. Charge the batter-
ies fully if the machine shall
be stored for a longer time
in order to avoid
sulphation.
Battery cable C C C Check that the positive ca-

ble from the batteries to the
electronic box and starter
motor does not display
signs of damage. Replace
if required.

500h, 1000h, 2000h,

1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
Test-run C C C Test-run the machine and

check the following:
• Instruments
• Brakes
• Gearshifting
• All load handling
functions
• Communication
equipment
• Steering
• Any noise
After test-run C C C Check the following after

test-run:
• Sealing (no leakage)
• Fluid levels
Washing
page
–
CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,

battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.

Lubricating 500h
page
–
1 Turn off the engine and turn off the main electric power.
2 Clean the area around each grease cup before greasing.
3 Lubricate the machine’s grease points with lubricant as recom-
mended, see section F Technical data. Also perform a visual
check of all lubricated mounts.
IMPORTANT
On machines with central lubrication, check that the
central lubrication’s grease points are lubricated, see
section 9 Frame, body, cab and accessories,
group 9.14 Central lubrication.

9
6 15 15
3 4 5
2 2
7
4 2 8
16 16
9
11, 13
10
12
9
10
014017
1 14 11
Lubrication points, lubricating grease
Pos. Lubrication point Reference

1 Cab lock Cab lock page 20
2 Hinges doors Hinges doors page 20
3 Door stop with gas strut damping Door stop with gas strut damping page 20
4 Key lock door/engine cover Key lock door/engine cover page 20
5 Pedal assembly, brake pedal Brake pedal page 20

6 Chain wheel Chain wheel page 21
7 Lifting chains Lifting chains page 21
8 Mast beam, outer. Internal. Mast beam, outer, internal page 21
9 Support rollers, mast page 23

Support rollers, mast
9 Support rollers, mast page 23

Support rollers, trolley
10 Support rollers and fork wheels, forks Support rollers, forks page 24
11 Side shift cylinder Side shift cylinder page 24
12
Side shift frame Side shift frame page 25
13 Mast mount Mast mount page 25
14 Link arm Link arms page 26
15 Tilt cylinders Tilt cylinders page 26
16 Side lift attachment Side lift attachment page 27

Cab lock
1 Tilt the cab.
2 Lubricate the cab locks with lubricating grease.
009496
Hinges doors
3 Lubricate the door hinges with lubricating grease. Lift the door to
facilitate lubrication.
Lubricate the mechanism in the hood.
Door stop with gas strut damping

4 Lubricate the door stop’s joints with lubricating grease.
Key lock door/engine cover

5 Lubricate the key locks on doors and hood with lock oil.
010243
Brake pedal
6 Lubricate the brake pedal’s hinge with grease.
7 Wipe off excess grease.
Lubrication points brake pedal

Chain wheel
8 Lubricate the chain wheels’ shafts with lubricating grease.
Lifting chains
9 Brush or spray the chains with chain oil. Ensure that the chains
are well lubricated.
Mast beam, outer, internal

10 Lubricate the inner mast’s slide surfaces with slide grease.
Start the engine and raise the mast to its highest position.
Lubricate the mast’s inner slide surfaces with slide grease.

11 Lubricate the mast’s outer slide surfaces with slide grease.

Support rollers, mast
12
The support rollers are lubricated with lubricating grease.
014016
Support rollers, trolley
13
The support rollers are lubricated with lubricating grease.
014015

Support rollers, forks

14 Lubricate the support rollers and fork wheels with lubricating
grease.
Side shift cylinder

15 Lubricate the side shift cylinder with lubricating grease.

Side shift frame

16 Lubricate the side shift frame with slide grease.
015730
Mast mount
17 Remove the load from the mast mountings in an appropriate
manner.
Lubricate the mast mounting with lubricating grease.
015731
Lubrication point for the mast mounting.

Link arms
1
18 Lubricate the link arms’ bearings with lubricating grease.
2
007924
4 3
1. Lubrication point, upper king pin bearing
2. Lubrication point, outer link bearing
3. Lubrication point, inner link bearing
4. Lubrication point, lower king pin bearing
Tilt cylinders
19 Lubricate the tilt cylinder using lubricating grease. There is a
grease point at each end of the tilt cylinder.
NOTE
Unload the mast when lubricating.

2 2
1
1
014772
Side lift attachment

20 Lubricate all slide surfaces with slide grease (pos. 1) with attach-
ment in max. extended position.
21 Lubricate the hydraulic cylinders’ shafts with lubricating grease
(pos. 2).
22 Lubricate the twistlock cylinder’s shaft with lubricating grease
(pos. 3).
23 Lubricate the twistlocks with lubricating grease (pos. 4).
24 Lubricate the contact pins with lubricating grease (pos. 5).

Lubricating 1000h
page
–
2 Clean the area around each grease cup before greasing.
3 Lubricate the machine’s grease points with lubricant as recom-
mended, see section F Technical data. Also perform a visual
check of all lubricated mounts.
2
3 3
4 4
007381
Lubrication points, lubricating grease
Pos. Lubrication points Reference

1 Lubricating 500h Lubricating 500h page 18
2 Hose wheels See Hose wheels page 29
3 King pin bearing See King pin bearing page 29
4 Wheel bearings, steering axle See Wheel bearings, steering axle page 30
5 Turnable operator’s station See Turnable operator’s station, gears and chain page 30
6 Electric connectors (not shown in diagram) See Electric connectors page 31
7 Side lift attachment See Side lift attachment page 31

Hose wheels
1 Remove the lock ring to release the hose wheel.
2 Remove the hose wheel.
3 Apply slide grease to the shaft.
4 Fit the hose wheel.
5 Fit the lock ring.
King pin bearing

1
6 Lubricate the wheel spindle’s bearings (upper and lower) with lu-
bricating grease on both sides.
If necessary, turn the wheels for better access.
2
007924
4 3
1. Lubrication point, upper king pin bearing
2. Lubrication point, outer link bearing
3. Lubrication point, inner link bearing
4. Lubrication point, lower king pin bearing

Wheel bearings, steering axle

7 Grease the wheel hub until grease comes out at the seal on the
hub’s inside.
Lift the seal ring’s lip with a small screwdriver to make it easier for
air to be pressed out. Lubricate until grease comes out at
the seal.
NOTE
Be careful so that the seal is not damaged.
007862
Turnable operator’s station, gears and chain
8
Remove the cover plate and clean and lubricate the gears with lu-
bricating grease.
9 Remove the cover plate and clean and lubricate the chain with lu-
bricating grease.

Electric connectors
10 Grease electric connectors with electric connector grease.
006645
Electric connector, example
014771
Side lift attachment
11 Machine in service position, see section B Safety.
12 Lubricate the rotary coupling (pos. 1) with lubricating grease.
13 Clean and lubricate the twistlocks with lubricating grease.

Checking for cracks

page
–
DANGER
All of the machine’s welds should be checked in ac-
cordance with the recommended intervals. Intervals
are calculated for machines used in normal operation
on level surfaces. For other uses or uneven surfaces,
for example, the interval should be shortened.
If the welds show signs of cracking, the machine

should be immediately taken out of operation and
Kalmar Service contacted.
2 Clean every weld carefully before inspection.
3 Check for damage and cracks in areas with high stress concen-
tration, see Checkpoints page 34. Check every weld along its en-
tire length.
When uncertain, welds can be tested with magnetic powder and
even penetrating fluid as follows:
a. The magnetic powder method is used to determine if there’s
a crack or not, and where it is. See Magnetic particle method
page 32.
b. Confirmed cracks are investigated further with penetrating
fluid. See Checking cracks with penetrating fluid page 33.
Magnetic particle method

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

Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
3 Wash off penetrating fluid with cleaning fluid part
no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
6 Visually inspect the area.
1 2
If the tested area does not show signs of linear or point-shaped
cracks, it is approved.
If the crack check indicates linear or point-shaped cracks, Kalmar
Service should be contacted.
001705
Example of cracks
1. Linear crack
2. Point-shaped crack

Checkpoints
Check the following welds extra carefully:
5
6
3
5
1 1
4
5
4
009124
7 2
Checking for cracks
Pos. Checkpoint Reference

1 Mast mount Mast mount page 35
2 Tilt mount Tilt mount page 36
3 Drive axle mounting Drive axle mount page 37
4 Lifting forks Lifting forks page 37
5 Trolley Trolley page 38
6 Counterweight box Counterweight box mounting against the frame page 40
7 Steering axle mounts Steering axle mounts page 40
8 Mounting of frame beam to back piece Mounting of frame beam to back piece page 40

Mast mount
1
a) Mast mount in frame
009131
b) Welds between mast beam and mount tab.

009146
c) Mast mount in frame, bottom view

009191
d) Weld between mast beam and mount tab, bottom view.

009193

Tilt mount
2
a) Tilt mount in mast.
009132
b) Tilt mount in frame.
009195
c) Tilt mount in frame.

009133
d) Tilt mount in the frame under the front mudguard.

009134

Drive axle mount

3
a) Drive axle mount in the frame
009137
b) Drive axle mount in the frame, bottom view
009136
Lifting forks
4
NOTE
There may be other variants of forks than those shown here.
a) The fork’s suspension bracket against the carriage beams.
Mounting of support rollers.
When checking fork material, see section 7 Load handling,
group 7.9.1 Lifting forks.
009139
b) Fork upper mounting bracket, bottom view.

009138

Trolley
5
NOTE
There may be other variants of trolleys than those shown
here.
a) Trolley side’s welds against the trolley beams.
009140
b) Outer struts’ welds against the trolley beams.

009145

c) Chain mounting in the trolley.

Also check the mounting pin to the chain and its split pin.
009196
d) Chain mounting in the mast.
Also check the chain tightener, mounting pin to the chain and
its split pin.
009396
e) The wheel pin welds in the trolley.

Check the inner mast wheel pins as well.
009198

Counterweight box mounting against the frame

6
a) Counterweight box mounting against the frame, under rear
mudguard.
Angle the steering wheels on the ground for easier access.
009143
Steering axle mounts

7
a) Steering axle mount in the frame, bottom view
b) Steering axle mount in steering axle cradle
009147
Mounting of frame beam to back piece

8
a) Mounting of frame beam to back piece.
009142

b) Mounting of frame beam to back piece, bottom view
009141


0 Complete machine 1
0 Complete machine
Table of Contents 0 Complete machine

mm mm mm mm mm mm
Complete machine ......................................................................................... 3

Complete machine, description ............................................................................. 3

2 0 Complete machine

0 Complete machine – Complete machine 3
Complete machine
mm mm mm mm mm mm
Complete machine, description

page
–
Kalmar DCF 90-180 is a fork-lift truck. The machine has a lifting capac-
ity of 9–18 tonnes depending on the version.
The engine is a six-cylinder, four-stroke diesel engine with direct
injection.
The transmission is hydromechanical with gears in constant mesh. It
has three forward gears and three reverse gears. Engine power is
transferred by means of a torque converter.
The power transmission consists of a propeller shaft and a rigid drive
axle with hub reduction. It is front wheel drive.
The service brakes are wet multiple disc brakes which are attached to
the drive wheel hub. The parking brakes are disc brakes and operate
on the drive axle input shaft.
Steering operates on the rear wheel with a double action hydraulic cyl-
inder. The steering axle is hung on the frame with pendulum
suspension.
The wheels are mounted on the hubs with nuts and washers. Twin
wheels are mounted on the drive axle, while the steering axle has sin-
gle wheels. The wheel rims are detachable.
Load handling consists of components and functions for handling the
load. The load is lifted with forks secured at a carriage on a mast. Load
handling is divided into the following functions: lifting/lowering, tilt, side
shift, spreading, levelling and load carrier.
• Lifting/lowering is the function that lifts and lowers the fork
carriage.
• Side shift is for repositioning the forks in parallel at the same dis-
tance from each other laterally along the carriage.
• Spreading is for adjusting the width between the forks on the
carriage.
• Tilt is for angling the load in the longitudinal direction of the ma-
chine by means of the mast.
• Levelling is for angling the load in the lateral direction of the
machine.
• The load carrier is for holding or gripping the load.
The control and monitoring system comprises functions for warning
the operator of dangerous situations and malfunctions. The control
and monitoring system has diagnostic capabilities that simplify
troubleshooting.
The frame supports the machine. Mounted in the frame are engine,
transmission, drive axle and steering axle etc. The sides of the frame
house tanks for fuel and hydraulic oil. The cab is centrally located and
can be tilted laterally.

4 0 Complete machine – Complete machine

1 Engine 1
1 Engine
Table of Contents 1 Engine

mm mm mm mm mm mm
1 Engine ............................................................................................................. 3
1.2 Fuel system .............................................................................................. 15
1.2.1 Fuel tank .............................................................................................. 18
1.2.2 Fuel filter .............................................................................................. 19
1.2.3 Fuel prefilter ......................................................................................... 21
1.3 Additional exhaust cleaning system ......................................................... 25
1.3.1 Particle filter ......................................................................................... 25
1.5 Engine’s mechanical parts ....................................................................... 26
1.5.4 Valve mechanism ................................................................................ 26
1.5.6 Crank mechanism ................................................................................ 30
1.6 Air intake and exhaust outlet .................................................................... 31
1.6.1 Air cleaning system .............................................................................. 31
1.6.2 Turbo ................................................................................................... 33
1.6.3 Exhaust system ................................................................................... 34
1.6.4 Intercooler ............................................................................................ 35
1.7 Cooling system ......................................................................................... 37
1.7.1 Coolant pump ...................................................................................... 37
1.7.4 Radiator and expansion tank ............................................................... 37
1.7.5 Cooling fan ........................................................................................... 38
1.7.7 Coolant ................................................................................................ 44
1.7.9 Sensor coolant temperature ................................................................ 54
1.8 Lubrication system ................................................................................... 55
1.8.3 Sensor oil pressure .............................................................................. 56
1.8.4 Oil filter ................................................................................................. 56
1.9 Control system engine .............................................................................. 59
1.10 Ignition/heating ......................................................................................... 60
1.11 Start/stop .................................................................................................. 61
1.11.1 Starter motor ........................................................................................ 61

2 1 Engine

1 Engine 3
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
The engine supplies power for propulsion and working hydraulics. The
following engine options are available:
• Volvo TAD650VE (147 kW).
• Caterpillar C6.6 (136 kW).
• Cummins QSB6.7 (129 kW).
• Cummins QSB6.7 (164 kW).
NOTE
Volvo engines are very similar, instructions that are common are
designated (engine alternative Volvo). Instructions that are
unique state the whole engine designation.
Emissions requirements
Low emission engines have newly designed combustion chambers,
injection systems and intercoolers that allow them to meet the emis-
sions requirements from the U.S. (California) and Europe. The new
engines provide a substantial improvement not only in exhaust emis-
sions but also in power and momentum curves.
Noise requirements
The engines meet all applicable requirements concerning noise and
vibration (EN13059).

4 1 Engine
Engine, description of functions

page
–
(engine option Volvo)
0
P I
II
III ˚C
. bar
7 <˚ 1
rpm
<˚
10 kph
ECU790
4
9 F
EDU795 R
R
1 2 3
4 5
ECU793
11
ECU794
2
007970
5 M 3 6 SENSORS 8 H2O
1. Ignition key lock 7. Accelerator pedal

2. Control unit engine (ECU794) 8. Make-contact (closing switch) coolant level
3. Preheating coil 9. Control unit terminal (EDU795)
4. Control unit general (ECU790) 10. Sensor fuel level (B757)
5. Starter motor 11. Control unit, transmission (ECU793)
6. Engine sensor

1 Engine 5
Engine, function description

page
–
(engine alternative Caterpillar and

Cummins)
0
P I
II
III ˚C
H2O
11 . bar
<˚ 1
8 rpm
<˚
10 kph
ECU790
5
9 F
EDU795 R
R
1 2 3
4 5
ECU793
4
ECU794
2
6 M SENSORS
008000
3 7
1. Ignition key lock 7. Engine sensor

2. Control unit engine (ECU794) 8. Accelerator pedal
3. Preheating coil 9. Control unit terminal (EDU795)
4. Control unit, transmission (ECU793) 10. Sensor fuel level (B757)
5. Control unit general (ECU790) 11. Make-contact (closing switch) coolant level
6. Starter motor

6 1 Engine
Electric components machine,

page
–
position
1 2 3 6
4
5
10c
0
P I
10b
II 7
III
9b 9a
10a
009412
Electric components machine
1. Control unit, steering (ECU792) 8. Accelerator pedal

2. Control unit, hydraulics (ECU796) 9a. Control unit, transmission Dana (ECU793)
3. Control unit general (ECU790) 9b. Control unit, transmission ZF (ECU793)
4. Fuel tank 10a. Control unit engine Volvo (ECU794)
5. Sensor fuel level (B757) 10b. Control unit engine Caterpillar (ECU794)
6. Control unit terminal (EDU795) 10c. Control unit engine Cummins (ECU794)
7. Ignition key lock

1 Engine 7
Component location
page
–
(Engine alternative Volvo

TAD650VE, TAD660VE)
The TAD650VE (147 kW) and TAD660VE (147 kW) engine’s are
straight, 6-cylinder, 4-stroke, turbocharged low-emission diesel en-
gines with a unit injectors, air to air intercooling and electronically con-
trolled fuel injection.
7
6 8
5
4
9
3
2
1
23
10
11
22 12
13
14
21 15
16
17
18
19
012610
20
Volvo TAD650VE and TAD660VE, left side (in machine’s direction of

travel)
1 High pressure pumps 13 Tensioning roller

2 Pressure reducing valve, fuel distribution pipe 14 Oil cooler
3 Injector 15 Oil filter
4 Preheating (glow plug) 16 Sensor oil pressure
5 Intake, intercooler 17 Sensor fuel pressure
6 Oil filling 18 Fuel filter
7 Sensor fuel pressure fuel distribution pipe 19 Drain plug oil sump
8 Lifting eye bolt 20 Dipstick
9 Alternator 21 RPM sensor, camshaft
10 Fuel pump 22 Terminal EMS 2 (engine electronics)

8 1 Engine
11 Drive belt 23 Solenoid valve for EGR (TAD660VE)

12 Coolant pump
4
3
2
1
5
6
7
8
16
10
15
14 11
13
12
007978
Volvo TAD650VE and TAD660VE, right side (in machine’s direction of
travel)
1 RPM sensor crankshaft 9 Intercooler pipe

2 Coolant input to thermostat housing 10 Coolant temperature
3 Fan hub 11 Flywheel housing
4 Coolant out from thermostat housing 12 Oil sump
5 Valve cover 13 Starter motor
6 Exhaust manifold 14 Oil pipe from turbo
7 Sensor boost pressure and temperature 15 Turbo
8 Crankcase ventilation 16 Charge air to radiator

1 Engine 9
Component location
page
–
(Engine alternative Volvo

TAD750VE, TAD760VE)
The TAD750VE (181 kW) and TAD760VE (181 kW) engines are
straight, 6-cylinder, 4-stroke, turbocharged low-emission diesel en-
gines with a unit injectors, air to air intercooling and electronically con-
trolled fuel injection.
14
13
12
11
10
6
5
4 15
16
17
3 18
19
20
21
2 22
23
24
25
012611
1 26
Volvo TAD750VE and TAD760VE, left side (in machine’s direction of

travel)
1 RPM sensor, camshaft 14 Sensor fuel pressure fuel distribution pipe

2 Flywheel housing 15 Alternator
3 Electric connection to EMS 2 (engine electronics) 16 Fuel pump
4 Coolant temperature 17 Coolant pump
5 Solenoid valve for EGR (TAD760VE) 18 Sensor oil pressure
6 High pressure pumps 19 Oil filter
7 Crankcase ventilation 20 Engine suspension
8 Pressure reducing valve, fuel distribution pipe 21 Sensor fuel pressure
9 Injector 22 Fuel filter
10 Preheating (glow plug) 23 Oil sump
11 Intake, intercooler 24 Dipstick

10 1 Engine
12 Oil filling 25 Oil drain plug

13 Bleeding 26 Return oil from separator
10
9
8
7
6
5
4
007976
Volvo TAD750VE and TAD760VE, right side (in machine’s direction of
travel)
1 Coolant from engine to radiator, after thermostat 6 Turbo

2 Sensor boost pressure and temperature 7 RPM sensor, crankshaft
3 Exhaust manifold 8 Drive belt
4 Starter motor 9 Coolant inlet
5 Lubricating oil pipe to turbo 10 Fan

1 Engine 11
Component location
page
–
(Engine alternative Caterpillar C6.6)

The Caterpillar C6.6 (136kW) is a straight, 6-cylinder, 4-stroke, turbo-
charged low-emission diesel engine with a unit injector, air to air inter-
cooling and electronically controlled fuel injection.
12
11
6 10
4 5 9
7 8
13
3
2 14
1 15
16
21
20
17
18
009540
19
Right side (in machine’s travel direction)
1 Pulley, fan 12 Sensor fuel pressure

2 Water pump 13 Connector J2
3 Sensor coolant temperature 14 Connector J1
4 Fuel pump 15 Engine control unit
5 Fuel filter 16 Sensor oil pressure
6 Sensor charge air temperature 17 RPM sensor crankshaft
7 Sensor boost pressure 18 Oil cooler
8 Fuel prefilter 19 RPM sensor camshaft
9 Hand pump 20 Vibration damper (rubber)
10 Air intake 21 Transmission housing cover
11 Fuel intake pipe

12 1 Engine
5
4
7
3
2
1 8
10
17
11
12
13
14
15
009539
16
Left side (in machine’s travel direction)
1 Front lifting ear 10 Drive belt tensioner

2 Exhaust manifold 11 Transmission housing
3 Turbo 12 Pulley, crankshaft
4 Valve cover 13 Oil sump
5 Exhaust pipe 14 Oil filter
6 Rear lifting ear 15 Starter motor
7 Dipstick 16 Flywheel
8 Pulley, alternator 17 Flywheel housing
9 Alternator

1 Engine 13
Component location (Engine

page
–
alternative Cummins QSB6.7)

The QSB6.7 (129 or 164 kW) is a straight, 6-cylinder, 4-stroke, turbo-
charged low-emission diesel engine with a unit injector, air to air inter-
cooling and electronically controlled fuel injection.
6 7
8
9
10
11
12
3 13
14
2
15
007397
1 16
Cummins QSB 6.7, left side (in the machine’s direction of travel)
1 Hole for flexplate 9 Intake coolant

2 Flywheel 10 Oil cooler
3 Crankcase ventilation 11 Oil filter
4 Draining injectors 12 Wastegate turbo
5 Lifting eye bolt 13 Intake turbo
6 Oil filling 14 Exhaust manifold
7 Outlet coolant 15 Starter motor
8 Alternator 16 Flywheel housing

14 1 Engine
7
6
8
10
5
11
4
12
13
14
15
007396
16
Cummins QSB 6.7, right side (in the machine’s direction of travel)
1 Drive belt tensioner 9 Sensor fuel pressure in fuel distribution pipe

2 Water pump 10 Fuel distribution pipe
3 Fan drive 11 Pressure reducing valve in fuel distribution pipe
4 Air intake 12 Fuel filter
5 Sensor coolant temperature 13 Dipstick
6 Air intake turbo 14 Electronic control unit
7 Air outlet turbo 15 RPM sensor, crankshaft
8 High pressure fuel lines 16 Vibration damper (rubber)

1 Engine – 1.2 Fuel system 15
1.2 Fuel system

Fuel system, description
page
–
For component locations, see Component location (Engine alternative

Volvo TAD650VE, TAD660VE) page 7, Component location
(Engine alternative Volvo TAD750VE, TAD760VE) page 9, Compo-
nent location (Engine alternative Caterpillar C6.6) page 11 or Compo-
nent location (Engine alternative Cummins QSB6.7) page 13.
NOTE
Read safety recommendations for handling fuel before starting
work, see section B Safety.
A
000873
A. Fuel filling
Sensors
A A. Sensor fuel level
The sensor is interchangeable and fitted in the manhole on the top of
the fuel tank. See also the figure in section Fuel tank, cleaning
page 18.
002315

16 1 Engine – 1.2 Fuel system
Fuel system, bleeding air (engine alternative

page
–
Volvo)
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
NOTE

2 Open the air bleeder screw (1).
1
3 Turn the hand pump anticlockwise to open the pump.
4 Pump until the fuel is completely free of air bubbles.
5 Tighten the air bleeder screw (1) and close the fuel hand pump.
2
6 Start the engine and check sealing.
008065
Volvo TAD750VE/TAD760VE

page
–
Caterpillar)
NOTE
NOTE
Do not activate the starter motor continuously for more than
30 seconds, then let the starter cool down for two minutes before
a new start attempt is made.
If air enters the fuel system the system must be vented before the en-
gine can be started. Air may enter the fuel system if any of the follow-
ing occurs:
• The fuel tank is empty or has been partially emptied.
• The low pressure fuel lines are disconnected.
• Leakage in low-pressure fuel lines.
• After replacing the fuel filter.

1 Engine – 1.2 Fuel system 17
Remove air from the fuel system as follows:

1 Make sure that the fuel system is not faulty and damaged, check
that the fuel cock is open.

2 Press in the hand fuel pump (position 1). Count the number of de-
pressions of the hand fuel pump, after 100 depressions the pro-
cedure should be stopped.
3 The engine’s fuel system must now be bled and the engine
1 should be ready to start.
4 Activate the starter motor and start the engine. When the engine
has started, allow it to run at idling speed for five minutes imme-
diately after the fuel system has been bled.
NOTE
Allowing the engine to run at idling speed for five minutes ensures
that the fuel system is free from air.
NOTE
007376
Do not loosen the fuel system’s high-pressure lines to bleed the

system.
After the engine has been switched off, wait 60 seconds before the
service or repair work is performed on the fuel system in order to allow
the fuel pressure to drop in the high-pressure lines. Minor adjustments
can be made if necessary.
Repair all leaks on the low pressure side of the fuel system, cooling
system, lubrication system or air system.
Replace leaking high-pressure lines in the fuel system, see Workshop
manual DCE 90-180, DCE 70-32E3–70-35E4 2006.

18 1 Engine – 1.2.1 Fuel tank

page
–
Cummings)
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
NOTE

2 Open the air bleeder screw.
3 Turn the hand pump anticlockwise to open the pump.
4 Pump until the fuel is completely free of air bubbles.
5 Tighten the air bleeder screw and close the fuel hand pump.
008002
Cummings QSB6.7
1.2.1 Fuel tank

Fuel tank, cleaning
page
–
NOTE
On the top of the fuel tank is a manhole to facilitate cleaning the
fuel tank.
1. Machine in service position, see Section B Safety.
2. Empty the fuel from the fuel tank. Use a pump.
3. Remove the drain plugs from the fuel tank.
4. Rinse the fuel tank clean through the fuel filler hole.
5. Reinstall the drain plugs.

1 Engine – 1.2.2 Fuel filter 19
1.2.2 Fuel filter

Fuel filter, changing (engine alternative Volvo)
page
–
NOTE

2 Remove the fuel filter.
3 Clean the filter’s contact face on the filter bracket.
4 Moisten the O-ring on the new filter with fuel.
NOTE
Do not fill the new fuel filter with fuel before installing. There
is a risk that impurities might get into the fuel system and
cause malfunctions or damage.
5 Install the new filter on the engine.
Tighten the fuel filter in accordance with the instructions on the
fuel filter.
6 When needed, bleed the fuel system, see Fuel system, bleeding
air (engine alternative Volvo) page 16.
006434
Fuel filter
Fuel filter, changing (engine alternative Caterpillar)

page
–
NOTE
manual DCE 90-180, DCE 70-32E3–70-35E4 2006.
2 Make sure that the fuel cock is closed.

20 1 Engine – 1.2.2 Fuel filter
3 Use suitable tools to remove the filter (position 1) from the

engine.
4 Lubricate the O-ring seal on the filter with clean diesel fuel and fit
the new filter to the engine.
Tighten the fuel filter in accordance with the instructions on the
filter.
NOTE
Do not use the tool to screw in the fuel filter, only use hand
force.
1 5 Open the fuel cock .

007521
air (engine alternative Caterpillar) page 16.

Fuel filter, changing (engine option Cummings)

page
–
NOTE

2 Remove the fuel filter.
3 Clean the filter’s contact face on the filter bracket.
4 Moisten the O-ring on the new filter with fuel.
NOTE
Do not fill the new fuel filter with fuel before installing. There
is a risk that impurities might get into the fuel system and
cause malfunctions or damage.
5 Install the new filter on the engine.
Screw on the fuel filter until it makes contact with the contact face,
008003
then tighten a further 3/4 turn.

Cummins QSB6.7 air (engine alternative Cummings) page 18.
Fuel filter 7 Start the engine and check sealing.

1 Engine – 1.2.3 Fuel prefilter 21
1.2.3 Fuel prefilter

Fuel pre-filter, changing (engine alternative Volvo)
page
–
NOTE
2 Remove the water reservoir, drain it of any water and clean the
reservoir.
3 Remove the filter cartridge.
4 Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush a little oil on the gasket.
5 Screw together the filter cartridge with the water reservoir and fit
them on filter bracket.
6 Bleed the fuel system, see Fuel system, bleeding air (engine al-
ternative Volvo) page 16.
1 7 Start the engine and check sealing.
008066
1. Fuel pre-filter
Water trap, draining (engine alternative Volvo)

page
–
NOTE
NOTE
The water trap should be drained of water daily.

2 Open the drain valve (1) and drain fuel/water.
3 Close the drain valve and bleed the system, see Fuel system,
bleeding air (engine alternative Volvo) page 16.
2
1
008067

22 1 Engine – 1.2.3 Fuel prefilter
Fuel pre-filter, changing (engine alternative

page
–
Caterpillar)
NOTE
manual DCE 90-180, DCE 70-32E3–70-35E4 2006.
2 Make sure that the fuel cock is closed.

3 Clean the fuel pre-filter externally.
4 Fit a suitable hose to the drain cock (position 1) and open the
drain cock. Empty the fuel pre-filter of fuel and remove the hose.
5 Tighten the drain cock (position 1) by hand.
6 Firmly hold the water reservoir (position 3) and loosen the screw
(position 2). Remove the water reservoir from the fuel pre-filter
(position 4).
7 Use a suitable tool to remove the filter (position 4). Treat the old
4
filter and gaskets as environmentally hazardous waste.
8 Clean the water reservoir (position 3).
007522
3 2 1
9 Lubricate the O-ring seal on the filter with clean diesel fuel and fit
the new filter to the engine.
Tighten the fuel pre-filter in accordance with the instructions on
the filter.
NOTE
Do not use the tool to screw in the fuel pre-filter, only use
hand force.
10 Fit a new O-ring seal (position 5) on the screw (position 2). Fit a
6 new O-ring seal (position 6) on the water reservoir.
4 11 Align the water reservoir on the fuel pre-filter, make sure that the
sensor is in the right position. Fit the screw (position 2) and tight-
2
en them to 5 Nm.
007523
5

1 Engine – 1.2.3 Fuel prefilter 23
NOTE
Fuel filters must be changed when fuel pre-filters are changed.
See Fuel filter, changing (engine alternative Caterpillar) page 19.
Water separator, draining

–
NOTE
NOTE
When the diesel engine is in operation there may be underpres-
sure in the water separator. Make sure that the drain screw is fully
tightened so that air is prevented from entering the fuel system.
2 Fit a suitable hose to the drain cock (position 1) and open the
drain cock. Empty the fuel pre-filter of fuel.
3 Tighten the drain cock (position 1) by hand and remove the hose.
1
007524

24 1 Engine – 1.2.3 Fuel prefilter
Fuel pre-filter, changing (engine alternative

page
–
Cummings)
NOTE

2 Open the drain cock and drain any water.
3 Remove the filter cartridge.
4 Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush a little oil on the gasket.
5 Screw the filter cartridge onto the filter bracket.
6 Bleed the fuel system, see Fuel system, bleeding air (engine al-
ternative Cummings) page 18.
1 7 Start the engine and check sealing.
008023
Cummins QSB6.7
1. Fuel pre-filter
Water trap, draining (engine alternative Cummings)

page
–
NOTE
NOTE
The water trap should be drained of water daily.

2 Open the drain valve (1) and drain fuel/water.
NOTE
Do not over-tighten the drain cock, as the threads may be
damaged.
008004
1
3 Close the drain valve by pushing the valve up and tightening it by
hand. Bleed the fuel system, see Fuel system, bleeding air (en-
Cummings QSB6.7 gine alternative Cummings) page 18.

1 Engine – 1.3 Additional exhaust cleaning system 25
1.3 Additional exhaust cleaning

system
1.3.1 Particle filter
Particle filter, cleaning
page
–
Once per year or every 1500 hours the particle filter should be cleaned
from fuel and lubricating oil residues in accordance with the following:
1 Clean-burn the filter as usual, see Operator’s manual

DCE 90-180.
2 Allow the filter to cool for 3–4 hours.
3 Undo the clamps and remove the filter section (centre section).
4 Set the filter section vertically and flush with water (not high pres-
sure) from the outlet side. Rinse thoroughly until the water is
clean.
5 Allow the water to drain thoroughly.
6 Refit the filter with new gaskets.

26 1 Engine – 1.5 Engine’s mechanical parts
1.5 Engine’s mechanical parts

1.5.4 Valve mechanism
Injectors, valves and double rocker arm (IEGR),
page
–
checking/adjusting (engine option Volvo)
NOTE
Must be carried out by personnel authorised by Volvo Penta.
Valves, checking/adjusting (engine option Cummins)

page
–

2 Preparation:
Disconnect battery
3 Before beginning work, carefully clean all attachments, mount-
ings and joints with compressed air to remove all loose particles.
4 Removing:
Unfasten the injectors’ drain hose from the back of the valve cov-
ers. Remove the screws that attach the drain hose to the valve
cover.
008025
NOTE
Do not remove the valve cover gaskets on engines where
the gaskets sit in a groove on the valve cover; these gaskets
can be re-used. If the gaskets are removed from the valve
cover, they must be replaced.
Remove mounting screws and insulators from the valve cover.
NOTE
008026
It might be necessary to bend the ventilation hose carefully

to prize it away from the valve cover.
Remove the valve cover

1 Engine – 1.5.4 Valve mechanism 27
NOTE
Check the valve cover gasket when it is still sitting in the
valve cover. When the gasket has been removed from the
valve cover, it must be replaced.
Check that the gasket does not show signs of damage at the
sealing area. Replace the gasket if it is removed from its groove
in the valve cover.
008027
7 If the valve cover gasket must be replaced, follow these instruc-
tions for installing a new gasket:
1. Begin by pushing down the corner of the gasket in the groove
on the valve cover.
2. Then push the rest of the gasket down into the valve cover.
008029
8 Check to see if the rubber insulators are cracked. Replace the in-
sulators if they are cracked or damaged.
008028
9 Adjusting
NOTE
Coolant temperature must be under 60 ºC.
Use special tool, part number 3824591 to rotate the crankshaft
until cylinder no. 1 is located in the top dead centre (T.D.C.).
The top dead centre (T.D.C.) can be determined by the following
method:
008030

28 1 Engine – 1.5.4 Valve mechanism
NOTE
The indicator for the top dead centre (T.D.C.) is on the vibra-
tion damper/crankshaft speed indicator.
Rotate the vibration damper/crankshaft speed indicator until the
indicator for the top dead centre (T.D.C.) is pointed straight up
(12 o’clock). If the valve lifters for cylinder 1 are loose, continue
to the next step. If the valve lifters for cylinder 1 are not loose, ro-
tate the crankshaft 360 degrees.
NOTE
008031
Cylinder number 1 is the cylinder nearest the cooling fan.
10 With the engine in this position, the valve clearance can be
checked for the following valves:
(E = exhaust valves, I = intake valves)
Cylinders 1I, 1E, 2I, 3E, 4I and 5E.
008032
11
Valve clearance tolerance

mm
Intake valves 0.152 MIN
0.381 MAX
Outlet valves 0.381 MIN
0.762 MAX
NOTE
008033
Valve clearance checks are usually performed as a part of

troubleshooting, and adjustments are normally not neces-
sary during inspection as long as the valve clearance lies
between the tolerance figures listed above.
NOTE
The valve clearance is correct when the thickness gauge
can be moved forward and backward between the top side
of the push rod and the valve lifter’s seat with only a slight
resistance.

1 Engine – 1.5.4 Valve mechanism 29
12 Measure the valve clearance by placing a thickness gauge, with

a thickness corresponding to the valve clearance to be adjusted,
between the top side of the push rod and the valve lifter’s seat. If
the valve clearance does not agree, loosen the lock nut and ad-
just the valve clearance to the correct value.
Valve clearance
mm
Intake valves 0.254
Outlet valves 0.508
008034
Tighten the lock nut and check the measurement of the valve
clearance again. Tighten with 24 Nm tightening torque.
13 Use special tool, part number 3824591, and rotate the crankshaft
360 degrees.
Follow the same steps and specifications as above and measure
the clearance for the following valves:
(E = exhaust valves, I = intake valves)
Cylinders 2E, 3I, 4E, 5I, 6I and 6E.
008030
14 Installing:
Reinstall the valve cover.
Reinstall the insulators and mounting screws.
Tighten the screws with 24 Nm tightening torque.
008026
15 Before the injector’s drain hose is installed on the valve cover, lu-
bricate the O-ring on the drain hose connection with clean
engine oil.
16 Install the injector drain hose on the valve cover. Tighten the
screws with 10 Nmtightening torque.
17 Completion:
Connect the batteries.
008035

30 1 Engine – 1.5.6 Crank mechanism
1.5.6 Crank mechanism

Vibration damper, rubber, checking
page
–
(engine alternative Cummins)

1 Check that the index lines (A) on the vibration damper hub (B)
and the outer part (C) are in line with each other. If the position
between the lines deviates more than 1.59 mm, replace the vibra-
tion damper.
008036
2 Check the rubber part for sign of wear. If any rubber pieces are
missing or if the surface of the rubber sits more than 3.18 mm be-
low the metal surface, replace the vibration damper.
Check that the damper ring cannot move lengthwise in relation to
the hub. Replace the vibration damper if it can move lengthwise.
For position of vibration damper, see Component location (En-
gine alternative Cummins QSB6.7) page 13.
008037

1 Engine – 1.6 Air intake and exhaust outlet 31
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air filter, changing
page
–

2 Fold up the hood.
B
000862
A. Positioning for air filter bracket

B. Replacement indicator
C. Dust reservoir

32 1 Engine – 1.6.1 Air cleaning system
3 Check that the dust ejector has emptied itself. Otherwise empty
the ejector.
4 Clean the outside of the air filter housing.
5 Remove the cap from the air filter housing.
6 Remove the primary filter.
7 If necessary replace the safety cartridge. The safety cartridge is

replaced every second time.
8 Fit the new primary filter.
NOTE
The filter insert should be changed, not cleaned.
9 Fit the cover to the air cleaner casing.
10 Check that the hoses from the filter housing (and other parts) are
intact and sealed.

1 Engine – 1.6.2 Turbo 33
11 Reset the indicator by pressing down the button on the top side.
1.6.2 Turbo
Checking the turbo, introduction (engine alternative
page
–
Caterpillar)
A regular visual inspection of the turbo is recommended.
If the turbo malfunctions when the engine is running it may cause dam-
age either to the turbo’s compressor wheel and/or engine. A damaged
turbo may cause further damage to the pistons, valves and cylinder
head.
NOTE
Failure of the turbo bearings may cause large amounts of engine
oil to enter the air cleaning and exhaust systems. Loss of engine
oil may cause serious engine damage.
Minor leakage of oil into the turbo if the engine runs for long peri-
ods at idling speed should not cause any problems, if it is not due
to a failure of the turbo’s bearings.
When a failure of the turbo’s bearings is accompanied by a no-
ticeable loss of power in the engine (increased emissions or the
engine speed is increased without load), switch off the engine
and do not start it again until the turbo has been replaced.
A visual inspection of the turbo can minimise unplanned downtime and
also reduce the risk of serious damage to other engine components.
NOTE
The turbo cannot be repaired but is replaced as a complete unit.

34 1 Engine – 1.6.3 Exhaust system
Turbo, checking (engine alternative Caterpillar)

–
NOTE
The turbo housing need not be removed before cleaning the
turbo.
The turbo’s control linkage is connected to the turbo housing. If
the control linkage is changed or moved from its location, it may
result in the engine failing to fulfil authority requirements for ex-
haust emissions.
1. Remove the hoses from the turbo housing’s air inlet and exhaust
outlet. Check if there is oil in the hoses. Clean during fitting.
2. Check for oil in the turbo. If oil is leaking from the rear of the com-
pressor wheel then this may be due to a damaged oil seal in the
turbo.
The presence of oil may be because the engine is running a lot at
idling speed, or may even be because the air line to the turbo is
blocked (or clogged air filter), meaning the turbo is contaminated
by oil.
3. Make sure that the turbo housing’s exhaust outlet is not attacked
by corrosion.
4. Fit the hoses on the turbo housing’s air inlet and exhaust outlet.
1.6.3 Exhaust system

Exhaust system, checking
page
–
WARNING
Hot exhaust system! During operation, the exhaust
system, especially the turbo and the muffler, become
scorching hot!
Risk of burn injuries.
Never touch the turbo or muffler when the machine is

in operation or has recently been shut off!
1. Machine in service position, see section B Safety.

2. Check the exhaust system’s sealing and other wear.
3. Check that the exhaust system suspension is intact.

1 Engine – 1.6.4 Intercooler 35
1.6.4 Intercooler
Intercooler, checking
page
–
CAUTION
Avoid the fuel cooler when cleaning with high-pres-
sure wash.

2 Remove the protective grille.
3 Clean the intercooler with compressed air.
NOTE
Do not use high pressure wash.
4 Check that the intercooler suspension is intact.
5 Check the sealing and check that the intercooler’s hoses and
clamps are in good condition.

36 1 Engine – 1.6.4 Intercooler
Charge air hoses, checking

–

2. Check the charge air hoses, the pipe connections and the condi-
tion of the clamps with regard to visible cracks and external dam-
age. If the hoses have damage or leaks in the connections, the
boost pressure will be too low and engine’s power output will be
impaired.
3. Check that there is no oil in the charge air hoses. If the hoses are
polluted by oil on the inside, this indicates leakage at the turbo’s
shaft seal. In that case, replace the whole turbo.
NOTE
If there is oil in the intercooler hoses, very carefully clean the
intercooler and all pipes and hoses in the intercooler system
on the inside before the engine is started.

1 Engine – 1.7 Cooling system 37
1.7 Cooling system

1.7.1 Coolant pump
Coolant pump, checking (engine alternative
page
–
Caterpillar)
A damaged coolant pump may result in the engine overheating, which
in turn could create the following problems:
• Cracks in the cylinder head
• Piston failure
• Other significant damage to the engine
NOTE
The coolant pump’s seal is lubricated by the coolant in the cooling
system. It is normal to have less leakage when the engine cools
down and the parts contract.
Check the coolant pump visually for leakage. The coolant pump can-
not be repaired but is replaced as a complete unit, Workshop manual
1 DCE 90-180, DCE 70-32E3–70-35E4 2006.
009031
1. Risk of leakage
1.7.4 Radiator and expansion tank

Radiator, cleaning
page
–

2 Remove the protective grille.

38 1 Engine – 1.7.5 Cooling fan
3 Clean the radiator with compressed air.
NOTE
Do not use high pressure wash.
NOTE
Mind the fuel cooler.
4 Check that the cooling flanges are whole.
1.7.5 Cooling fan

Drive belt/Alternator belt, checking
page
–
Check after operating when the belts are warm.

Check that the drive belt does not have any intersecting cracks.
Cracks across the belt are acceptable. Cracks along the length of the
belt that are crossed by cracks across the belt are not acceptable. Re-
place the drive belt if it is damaged or worn. See Drive belt, changing
(engine alternative Volvo) page 39 or Drive belt, changing (engine op-
tion Cummings) page 41 for drive belt replacements and adjustments.
Drive belt damage can be caused by:
• Incorrect drive belt tension
• Incorrect length or dimensions
008011
• Belt pulleys that are not in alignment

• Incorrect installation
• Stresses in operational environment
• Grease or oil on the sides of the drive belt
Alternator belts and drive belts should be able to be pushed down ap-
prox. 3-4 mm between the belt pulleys.
The alternator belt and the drive belt have an automatic belt tensioner
and do not need to be adjusted.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
008012

1 Engine – 1.7.5 Cooling fan 39
Drive belt, changing (engine alternative Volvo)

page
–

2. Loosen the belt tensioner and lock it with a drift (1).
008064
3. Remove the belt from the coolant pump first.
4. Install the new belt.
Loosen the belt tensioner and check that the belt is sitting correct-
ly in the grooves and is correctly tensioned.
1
007969
Drive belt, changing (engine alternative Caterpillar)

page
–
Removing
1
2 Insert a suitable square tool in the hole (position X) in drive belt
tensioner (position 3). Turn the tool clockwise (engine seen from
behind in machine’s direction of travel).
3 Position a locking pin (Ø 8 mm, L = 85 mm) in the hole (position
Y). Release the pressure on the square tool.
2
4 Remove drive belt (position 1).
3 NOTE
X Mark the rotation direction on the drive belt if it is to be re-used.
4
5 Turn the tool clockwise (engine seen from behind in machine’s di-
5 rection of travel). Release the pressure on the locking pin and re-
Y move it from the hole (position X).
009048
6 Release the pressure on the square tool and remove the tool
from the hole (position X).

7 If necessary, follow steps 7a and 7b to remove the belt tensioner

(position 3) from the bracket (position 2).
a) Remove the screw (position 4) that attaches the belt tension-
er (position 3) to the bracket (position 2).
b) Remove the belt tensioner (position 3) from the bracket
(item 2).
Installing
1 If the belt tensioner was removed earlier, follow steps 1a to 1c to
1
fit it.
a) Align the pin (not shown in figure) on the rear of the belt ten-
sioner (position 3) with the hole in the bracket (position 2).
b) Fit the belt tensioner (position 3) on the bracket (position 2).
2 c) Fit the screw (position 4). Tighten the screw to a tightening

torque of 45 ± 5 Nm.
2 Insert a suitable square tool in the hole (position X) in drive belt
3 tensioner (position 1). Turn the tool clockwise (engine seen from
X behind in machine’s direction of travel).
4 3 Position a locking pin (Ø 8 mm, L = 85 mm) in the hole
5 (position Y). Release the pressure on the square tool.
Y 4 Fit the drive belt (position 1). Make sure that the drive belt is cen-
009048
tred on the pulleys. If the drive belt is re-used then it must be re-
fitted with the same rotation direction as before.
NOTE
The ribs on the drive belt must be fitted into the grooves on all of
the pulleys.
5 Turn the tool clockwise (engine seen from behind in machine’s di-
rection of travel). Release the pressure on the locking pin and re-
move it from the hole (position X).
6 Release the pressure on the square tool until the drive belt is ten-
sions. Remove the tool from the hole (position X).
NOTE
Check that the belt tensioner is now in the correct working posi-
tion, and not close to any outer stop position.

Drive belt, changing (engine option Cummings)

page
–

2. Lift up the belt tensioner to remove the drive belt.
NOTE
The belt tensioner is tensioned in the direction that the
springs are bent over the tensioner arm. To reduce the ten-
sion on the belt, rotate the tensioner in order to tighten the
springs more firmly.
CAUTION
008013
do not use excessive force in either the winding direc-
tion or in the opposite direction. After the tensioner
has been wound to its positive stop, continued wind-
ing can cause the belt tensioner to break.
3. Lift up the belt tensioner and install the drive belt. If it is difficult to
install the drive belt (the belt seems too short), first place the belt
in the grooved belt pulley. Then continue to hold up the belt ten-
sioner and pry the belt over the coolant pump’s belt pulley.
Loosen the belt tensioner and check that the belt is sitting correct-
ly in the grooves and is correctly tensioned.
Drive belt tensioner, checking (engine option

page
–
Cummins)
With the engine turned off, check that neither the lower nor the upper
tension lever stop is touching the cast stop lugs on the belt tensioner’s
housing. If any tension lever stop is touching a stop lug, the drive belt
must be replaced. Check to ensure that the correct drive belt is used.
008014

Check that there are no cracks on the drive belt tensioner’s wheels or
levers. If there are cracks, the belt tensioner must be replaced. See
supplier’s documentation, engine.
Check that dirty deposits have not built up on the drive belt tensioner.
If they have, the drive belt tensioner must be removed and steam
cleaned.
008015 With the drive belt removed, check that the lower tension lever stop is
lying against the lower stop lugs of the tension levers on the belt ten-
sioner housing. If these two are not in contact with each other, the
drive belt tensioner must be replaced.
008016
Check the drive belt tensioner for signs of wear and damage between
the tension wheel and the radius of the tension lever. If there are indi-
cations that these two surfaces are rubbing against each other, then
the centre bearing is worn out and the drive belt tensioner must be
replaced.
008017
A worn drive belt tensioner that is slack or a drive belt that "wanders"
off the pulleys indicates that the pulleys are not in alignment.
NOTE
The pulleys may not be more than 3 degrees out of alignment.
This can be measured with a straight edge and a clinometer.
Install the drive belt.
008018

Fan hub, checking (engine option Cummins)

page
–

2. Remove drive belt, see Drive belt, changing (engine option Cum-
mings) page 41.
NOTE
The fan hub must rotate without wobbling or excessive
length clearance.
Fan hub length clearance

mm
0.15 MAX
008019

44 1 Engine – 1.7.7 Coolant
1.7.7 Coolant
Coolant level, check
page
–
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap (position B) very slowly when the

engine is warm. Wait until the coolant has cooled
down before topping up.
Coolant is filled in the system’s expansion tank (position A). The cool-
ant level should be between the MIN and MAX markings (position C)
on the expansion tank.
NOTE
Open very carefully as hot coolant may jet up.
If the coolant level should become too low an error code is shown in
the control system’s display.
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.

2 When needed, top up with ready-mixed recommended coolant.
For volume and quality, see section F Technical data.
C A B
CAUTION
MAX
Different types of coolant must not be mixed.

MIN Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use

coolant of the same type that was used before.
000863
A. Position for expansion tank

B. Pressure cap for filling point
C. Level marking, MIN and MAX

1 Engine – 1.7.7 Coolant 45
IMPORTANT
On machines with ECC or AC, it is of the utmost im-
portance that the engine’s cooling system be refilled
with coolant that contains the correct mixture of anti-
freeze glycol; otherwise there is a risk that the air con-
ditioning will freeze and break during use.
Cooling system, changing the coolant and cleaning

page
–
(engine alternative Volvo)

Cooling performance is reduced due to deposits in radiator and cool-
ing channels. In connection with changing coolant, clean the system.
WARNING
may jet out.
Open the filler cap very slowly when the engine is

warm. Wait until the coolant has cooled down before
topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact. Wear protective

glasses and protective gloves. In case of skin contact,
wash the skin.

IMPORTANT
Machines with ECC or AC are equipped with a com-
bined heating and cooling package which may lead to
a risk of freezing if the machine is operated without
coolant.
Risk of freezing and damage to heating and cooling

package!
When cleaning the radiator with water or cleaning

agent without anti-freeze properties, the electrical
connection to the AC compressor must be
disconnected.
NOTE
Read safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block with a drain hose. The drain nipples are located under
the radiator and on the engine block’s right side.
007394
3 Check that all coolant drains.
NOTE
There may be deposits inside the cock or the plug that must
be cleaned; otherwise there is a risk that coolant may re-
main and cause freezing damage.
Allow the drain cocks/plugs to remain open and ensure that the
heating knob is set to full heat during cleaning.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
008039
5 If there still are contaminants after flushing for some time, clean-
ing with coolant can be performed. Otherwise continue in accord-
ance with step 10.

6 cleaning with coolant:

Fill the cooling system with 15-20% concentration coolant mix.
Only use recommended concentrated coolant mixed with clean
water.
7 Drain the coolant after 1-2 days operation.
NOTE
To avoid that dissolved loose material jams in the system again,
drain the system quickly, within 10 minutes, without the engine
being switched off for a long time. Remove the filler cap from the
expansion tank and the lower coolant hose if necessary to in-
crease drain speed.
8 Flush the system immediately and very thoroughly with clean
warm water to avoid dirt from being deposited on the inside sur-
faces once again. Flush until the draining water is completely
clean. Make sure that the heat control is set to full heat during
cleaning.
9 If there still are contaminants after flushing for some time, clean-
ing with coolant can be performed, contact Cargotec Service.
NOTE
Only use cleaning agents approved by the engine manufac-
turer. Make sure that you follow the instructions on the
packaging.
NOTE
Only use recommended coolant.
IMPORTANT
It is of utmost importance that the right concentration
and volume of the coolant is filled in the system. Mix
in a separate, clean container before filling the cool-
ing system. Make sure the fluids mix well.

Filling point
page
–
1. When the cooling system is completely free from impurities, close

the drain cocks and plugs.
NOTE
Only use recommended coolant.
CAUTION
Risk of engine damage and damage to the cooling


2. Fill the coolant to a level between the MIN and MAX markings.
The engine may not be started before the system has been
bled and completely filled.
3. Start the engine when the cooling system is bled and completely
filled. Open any bleeder valves some time after start, so that the
trapped air can escape.
Check that the water valve is fully open so that the heater unit
is bled.
4. Stop the engine after about one hour and check the coolant level,
top up if needed.


page
–
(engine alternative Caterpillar)
WARNING
may jet out.

topping up.
WARNING
health.
Health hazard!

wash the skin.
IMPORTANT
coolant.

package!

disconnected.
NOTE
section B Safety.

Clean and flush out the cooling system before the recommended
maintenance interval, if any of the following occurs:
• The engine often overheats.
• Foam is observed in the coolant
• Oil has seeped into and contaminated the cooling system.
• Fuel has seeped into and contaminated the cooling system.
NOTE
Only clean water is required for cleaning the cooling system.
NOTE
section B Safety.
2. Stop the engine and let it cool down. Open the filler cap on the
cooling system’s expansion tank slowly and remove it.
3. Open all drain points. Drain the coolant from the radiator and en-
gine block with a drain hose. The drain nipples are located under
the radiator and on the engine block’s right side.
1 4. Check that all coolant drains.
NOTE
be cleaned; otherwise there is a risk that coolant may remain
and cause freezing damage.
Allow the drain cocks/plugs to remain open and ensure that the
heating knob is set to full heat during cleaning.
009034
5. Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
7. Fill with clean water so that the level is between the MIN and MAX
marks. Fit the filler cap on the cooling system’s expansion tank.
The engine must not be started until the system has been bled
and filled fully.
8. Start the engine when the cooling system is fully bled and filled.
Allow the engine to run at idling speed until the temperature is be-
tween 49 and 66 °C.
Open all heat controls on the heater unit so that it is ventilated.
9. Stop the engine and let it cool down. Open the filler cap on the
cooling system’s expansion tank slowly and remove it. Open all
drain points. Drain the coolant from the radiator and engine block
with a drain hose. Insert a hose in the filler hole in the expansion
tank and flush with clean water, until the draining water is clear.

11. Fill the coolant to a level between the MIN and MAX markings.
The engine must not be started before the system has been
bled and completely filled. Do not fit the filler cap on the cooling
system’s expansion tank.
NOTE
Air pockets in the cooling system can damage the engine.
CAUTION


12. Start the engine and let the engine run at idling speed until the
cooling system is fully bled and filled. Increase the engine speed
to raised idling speed and open all the heat controls on heater unit
so that it is ventilated.
Allow the engine to run at raised idling speed for a minute to expel
air that may be present in the cavities in the engine block. Stop the
engine.
13. Check coolant level and top up if required.
14. Clean the pressure cap on the radiator and check the gasket, re-
place the pressure cap with a new one if the gasket is damaged.
If the gasket is intact, pressurise the pressure cap with a suitable
pressurising pump. The pressure that the pressure cap should
withstand is stamped on the top of the cap. If the pressure cap
does not withstand the intended pressure, replace the
pressure cap.
15. Start the engine. Check the cooling system’s sealing integrity and
the engine will reach the correct operating temperature.


page
–
(engine alternative Cummins)

Cooling performance is reduced due to deposits in radiator and cool-
ing channels. In connection with changing coolant, clean the system.
WARNING
may jet out.

topping up.
WARNING
health.
Health hazard!

wash the skin.
IMPORTANT
coolant.

package!

disconnected.
NOTE
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.

1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block. A drain nipple is located under the radiator and a drain
plug under the coolant intake on the engine block.
3 Check that all coolant drains.
NOTE
be cleaned; otherwise there is a risk that coolant may re-
main and cause freezing damage.
Check if the installation has additional taps or plugs on the cool-
008020
ant line’s lowest points. Leave drain valves or plugs open and
make sure that the heat control is at full heat while cleaning.
4 Check the condition of the hoses, clamps and radiator sealing.
Replace and clean if needed.
CAUTION
The system must be filled well to prevent air pockets.
During filling, the air must be ventilated out from the
cooling channels. Wait 2-3 minutes to allow the sys-
tem to bleed; then fill the system.
5 Cleaning:
NOTE
Do not put on the pressure cap. The engine must run without
pressure cap during this process.
Fill the system with a mixture of sodium carbonate and water (or
equivalent).
NOTE
008021
Use 0.5 kg of sodium carbonate per 23 litres of water.
6 Start and run the engine for 5 minutes with a coolant temperature
over 80 ºC.
Turn off the engine and empty the cooling system.
7 Fill the cooling system with clean water.
NOTE
Ensure that the cooling system is properly bled when filling.
NOTE
Do not put on the pressure cap.
008022

54 1 Engine – 1.7.9 Sensor coolant temperature
8 Start and run the engine for 5 minutes with a coolant temperature
over 80 ºC.
Turn off the engine and empty the cooling system.
NOTE
If the emptied water is still dirty, the system must be flushed
until the water is clean.
9 When the cooling system is completely free from impurities, close
CAUTION


10 Filling:
Fill the coolant to a level between the MIN and MAX markings.
The engine may not be started before the system has been
bled and completely filled.
11 Put on the pressure cap and start the engine when the cooling
system is completely bled and filled.
Open all heat controls on the heater unit so that it is ventilated.
12 Stop the engine after about one hour and check the coolant level,
top up if needed.
1.7.9 Sensor coolant temperature

Coolant temperature sensor, component location
page
–
For overview figure with positioning of the engines’ sensors, see Com-
ponent location (Engine alternative Volvo TAD650VE, TAD660VE)
page 7, Component location (Engine alternative Volvo TAD750VE,
TAD760VE) page 9, Component location (Engine alternative Caterpil-
lar C6.6) page 11 or Component location (Engine alternative Cum-
mins QSB6.7) page 13.

1 Engine – 1.8 Lubrication system 55
1.8 Lubrication system

Lubrication system, description
page
–
The engine’s lubrication system is completely closed and has no con-

nections to the machine.
Engine oil, changing

page
–
NOTE
Read safety instructions for oil before starting work, see
section B Safety.
Always follow recommended oil change intervals and always
change oil filter in connection with oil change.
Do not change the engine oil when the engine is cold. When the en-
gine oil cools down undissolved contaminating particles sink and col-
lect in the bottom of the oil sump. These particles do not follow out of
the engine if you change the oil with a cold engine.
Change the engine oil with the engine switched off after it has been
warmed up. This ensures that the contaminating particles that are dis-
solved in the oil follow out of the engine during the oil change.
Not following the above recommendations will result in the contami-
nating particles being dissolved again, contaminating the new oil and
continuing to circulate in the lubrication system which increases stress
on the engine.
1 Run the engine until warm.
3 Remove the drain plug from the engine and drain the engine of
oil.
4 When the oil has drained out fit the oil plug with a new gasket.
Torque tighten to max. 79 Nm for Volvo TAD650VE/TAD660VE
and Volvo TAD750VE/TAD760VE, 34 Nm for Caterpillar C6.6
and to 80 Nm for engine alternative Cummins QSB6.7.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
5 Replace the oil filter, see Oil filter, changing page 56.
6 Fill engine oil to the right level. For volume and grade, see
007317
NOTE
Do not fill over MAX-level.

56 1 Engine – 1.8.3 Sensor oil pressure
7 Start engine and let it idle. Check that the oil pressure is normal.
8 Stop the engine, check the oil level, see Engine oil level, checking
page 58, as well as the sealing around the filters. Top up oil, if
needed.
1.8.3 Sensor oil pressure

Sensor, oil pressure, component location
page
–
For overview figure with positioning of the engines’ sensors, see Com-
ponent location (Engine alternative Volvo TAD650VE, TAD660VE)
page 7, Component location (Engine alternative Volvo TAD750VE,
TAD760VE) page 9, Component location (Engine alternative Caterpil-
lar C6.6) page 11 or Component location (Engine alternative Cum-
mins QSB6.7) page 13.
1.8.4 Oil filter

Oil filter, changing
page
–
NOTE
section B Safety.
NOTE
Change oil filter with every oil change.
1. Drain the oil, see Engine oil, changing page 55.
007360
Engine option Volvo

1 Engine – 1.8.4 Oil filter 57
2. Remove the oil filter.
2 3. Check that the contact face on the filter bracket is clean and that
no gasket remains from the old filter.
Apply a little oil onto the new filter’s rubber gasket and the contact
3 surface of the filter bracket. Fill the filter with clean oil. For oil
grade, see section F Technical data.
4. Screw on the filter by hand until the rubber gasket just touches the
contact face on the filter bracket.
Engine alternative Volvo: Then turn another full turn, not more.
Engine alternative Caterpillar: Tighten the filter to 12 Nm.
Engine alternative Cummins: Then turn another 3/4 turn,
not more.
007530 5. Fill with oil, see Engine oil, changing page 55.
Engine alternative Caterpillar

6. Start the engine and check sealing.
008006
Engine option Cummins

Oil filter, checking (engine alternative Caterpillar)
–
NOTE
The following action can be performed as a preventative mainte-
nance measure.
Cut up the old oil filter with a suitable tool. Separate the folded filter
material and check for any metal debris. A large amount of metal de-
bris in the oil filter indicates wear or impending failure.
Use a magnet to distinguish whether it is ferrous or non-ferrous metal
debris in the oil filter. Ferrous contaminants may indicate wear of steel
or cast material in the engine.
Non-ferrous contaminants may indicate wear of aluminium, brass, or
bronze parts in the engine. Parts which may be affected include: frame
bearings, connecting rod bearings and turbo bearings.
It is not unusual to discover a small amount of contaminants in the oil
007529
filter due to normal wear and tear.

58 1 Engine – 1.8.4 Oil filter
Engine oil level, checking

page
–
NOTE
section B Safety.
The engine’s oil filling (position B) and dipstick (position A) are located
under the hood on the left side for engine alternative Volvo and on the
right side for engine alternatives Caterpillar and Cummins.
A B 2 Check the oil level when the engine is warm. The dipstick has two
markings, MAX. and MIN.; the oil level should be between these
markings.
Wipe off the dipstick before checking.
3 Fill engine oil (position B) if needed (for volume and grade, see
section F Technical data).
4 It is recommended that the engine oil be filled when the engine
and the oil are at operating temperature. Fill – wait a while –
check the dipstick.
NOTE
A B Work carefully when filling to prevent other fluids or particles
from contaminating the engine oil, which means risk of en-
gine damage.
000864
A. Dipstick
B. Filling point

1 Engine – 1.9 Control system engine 59
1.9 Control system engine

Control system engine, description
page
–
The engine is controlled by a control system, for which the central unit
is a control unit.
The system consists of, among other things, sensors, control unit and
electric injectors. The sensors give input signals to the control unit,
which in turn controls the injectors.
The control unit receives input signals on the engine’s operating con-
dition from the following components:
• speed sensor, camshaft
• speed sensor, crankshaft
• coolant temperature sensor
• boost pressure and temperature sensor
• oil pressure sensor
• sensor water-in-fuel
• fuel pressure sensor
• sensor low fuel pressure (only engine alternative Volvo)
• coolant level sensor (only engine alternative Volvo)
• sensor ambient temperature (only engine alternative Volvo)
• sensor ambient air pressure (only engine alternative Cummins)
Based on the input signals the control unit controls:
• injection times
• electric preheating (glow plug)
If serious malfunctions are detected by the control and monitoring sys-
tem on the engine, then engine power is limited to protect the engine
from further damage.
The information from the sensors accurately advises the current oper-
ating conditions and allows the processor in the control unit to calcu-
late the correct fuel quantity and check the engine condition, among
other things.
For more information about control unit engine, see section 11 Com-
mon electrics, group 11.5.3 Control units and supplier documentation
engine.

60 1 Engine – 1.10 Ignition/heating
1.10 Ignition/heating
Ignition/heating, description
page
–
The engine is equipped with preheating of the induction air, for faster
start at low temperatures. Preheating is activated when the start key is
in position I. When preheating is activated the preheating symbol illu-
minates in the display. The ignition switch sends signals to Control unit
General (ECU790) which sends messages via CAN-bus drivetrain to
Control unit engine (ECU794).

1 Engine – 1.11 Start/stop 61
1.11 Start/stop
Start/stop, general
page
–
The electrical system operates at 24 volts.

The positive terminal is connected to a battery disconnector (A).
1. When starting the gear selector must be in neutral position.
2. Turn the ignition switch to position 1, preheating is activated if the
engine senses the requirement. The display shows the preheating
symbol down on the left edge.
3. Turn the ignition switch to position 3, the ECU790 sends a signal
to the engine via the CAN bus for engine alternative Volvo, or ac-
tivates the starter motor directly via digital output for engine alter-
native Caterpillar and Cummins until the engine starts.
A-D
4. The engine is stopped by the ignition key lock being turned to
position 0.
NOTE
The battery disconnector must not be used as an emergency
switch!
A. Battery disconnector
B. Knob for opening the battery cover
C. Position for main current on
D. Position for main current off
000870
A B C D
1.11.1 Starter motor

Starter motor, checking (engine alternative
page
–
Caterpillar)
Check that the starter motor is operating without any faults, and to
check and clean the electrical connections to the starter motor.

62 1 Engine – 1.11.1 Starter motor

2 Transmission 1
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2 Transmission.................................................................................................. 3
2.3 Mechanical transmission .......................................................................... 10
2.6 Lubrication system ................................................................................... 11
2.6.4 Oil filter ................................................................................................. 13
2.7 Cooling system ......................................................................................... 14
2.8 Control system transmission .................................................................... 15

2 2 Transmission

2 Transmission 3
2 Transmission
mm mm mm mm mm mm
Transmission, function description

page
–
The transmission transfers the engine power to the drive wheels (drive
axle) via the drive shaft and also power to drive the hydraulic oil pumps
for the hydraulic system. The following transmission alternatives are
available:
• Dana TE13FF.
• Dana TE17FF.
• ZF 3WG161.
The transmission is manual with torque converter. The transmission
has three gears in each direction.
The torque converter and transmission work together via a common
hydraulic system. The torque converter is a hydraulic clutch located
between the engine’s output shaft and the transmission’s input shaft.
The hydraulic oil pumps and the oil pump for control and lubrication of
the transmission are mounted on the torque converter but directly con-
nected to the torque converter’s input shaft, i.e. they are directly driven
by the engine and not affected by the torque converter.
Gear positions are selected by pressure modulation with electrical
valves that are controlled by Control unit, transmission (ECU793). The
control unit uses sensors for pressure, temperature and speed to de-
cide which gear position should be activated as well as solenoid valves
to activate the gear.

4 2 Transmission

–
(Transmission TE17FF)
F
1 3 R
F
6 1 2
R
3
5
4 5
2
4
8
10 Pa 7
9 ECU790
11
EDU795
ECU793 ECU794
12 30
19 20 21 22 23 24
Pa Pa
25
28
18 26
17
27 16
15 29
14
015550
13

2 Transmission 5
1. Switch parking brake (S107) 16. Servo valve gear 1/3 (Y6067)
2. Accelerator pedal 17. Solenoid valve gear selection 1/3 (Y6075)
3. Gear selector (S160) 18. Servo valve gear 2 (Y6069)
4. Relay inching (K334) 19. Pressure sensor gear 1/3 (B6067)
5. Declutch pedal (S220) 20. Pressure sensor gear 2 (B6069)
6. 21. Sensor engine speed (B7530)

Potentiometer inching (R690-2)
7. 22. Sensor turbine speed (B7510)

Break contact declutch (S220-1)
8. 23. Sensor, drum rpm (B7520)

Switch inching (1039)
9. Sensor operator in seat (S230) 24. Sensor rpm output shaft (B7580)
10. Control unit general (ECU790) 25. Sensor oil temperature (B7660)
11. Control unit terminal (ECU795 26. Temperature monitor torque converter (S2210)
12. Control unit, transmission (D793) 27. Oil pump transmission
13. Solenoid valve drive forward (Y6300) 28. Oil filter transmission
14. Solenoid valve drive reverse (Y6310) 29. Oil cooler
15. Servo valve gear forward/reverse (Y6096) 30. Control unit engine (ECU794)

6 2 Transmission

–
(Transmission ZF)
3 F
1
R F
°<
N
20 R
<° 6 1 2
R
3
4 5
19
2
ECU790
18 Pa
EDU795
16
17
UDS ECU794 ECU793
7
9, 10, 11, 12, 13
8 SENSORS
14
5
15
013958
1. Gear selector (S160) 11. Sensor output shaft speed (B758)
2. Control unit general (ECU790)) 12. Sensor temperature converter (B766)
3. Switch parking brake (S107) 13. Sensor engine speed (B753)
4. Oil pump transmission 14. Filter monitor
5. Oil filter transmission 15. Transmission oil cooler
6. Accelerator pedal (R690-1) 16. Control unit terminal (EDU795)
7. Control unit, transmission (D793) 17. Control unit engine (ECU794)
8. Solenoid valves for travel direction and gear position

18. Break contact (opening switch) declutch (S1039)
in valve block transmission control (KV, KR, K1-K3)
9. Sensor turbine speed (B751) 19. Switch for inching (S220-1)
10. Sensor inner transfer shaft speed (B752) 20. Brake pedal potentiometer (R690-2)

2 Transmission 7
Transmission, component location

–
1 2 3
4
5 6
7
8
10
11
12
16
015547
20 19 18 17 15 14 13
1. Connection transmission oil cooler 11. Pressure sensor gear 2 (B7652)

2. Sensor turbine speed (B7510) 12. Output shaft
3. Breather filter torque converter 13. Servo valve gear 2 (Y6069)
4. Sensor engine speed (B7530) 14. Sensor oil temperature (B7660)
5 Solenoid valve drive forward (Y6300) 15. Sensor, drum rpm (B7520)
6. Solenoid valve drive reverse (Y6310) 16. Oil filter transmission
7. Solenoid valve gear selection 1/3 (Y6075) 17. Connection transmission oil cooler
8. Servo valve gear 1/3 (Y6067) 18. Temperature monitor torque converter (S2210)
9. Pressure sensor gear 1/3 (B7651) 19. Connection oil filling and oil dipstick
10. Servo valve forward/reverse (Y6096)) 20. Sensor rpm output shaft (B7580)

8 2 Transmission

–
1 2 3 4
5
6
7
8
10
11
12
13
16 15 14
015546
20 19 18 17
1. Connection transmission oil cooler 11. Servo valve forward/reverse (Y6096)

2. Sensor turbine speed (B7510) 12. Pressure sensor gear 2 (B7652)
3. Breather filter torque converter 13. Output shaft.
4. Sensor engine speed (B7530) 14. Servo valve gear 2 (Y6069)
5. Sensor, drum rpm (B7520) 15. Sensor oil temperature (B7660)
6. Solenoid valve drive forward (Y6300) 16. Oil filter transmission
7. Solenoid valve drive reverse (Y6310) 17. Connection transmission oil cooler
8. Solenoid valve gear selection 1/3 (Y6075) 18. Temperature monitor torque converter (S2210)
9. Servo valve gear 1/3 (Y6067) 19. Connection oil filling and oil dipstick
10. Pressure sensor gear 1/3 (B7651) 20. Sensor rpm output shaft (B7580)

2 Transmission 9

–
(Transmission ZF)
1
2
3
55
4
5
12
6
7 11
10
012612
8 9
1. Filter monitor 7. Sensor inner transfer shaft speed (B752)

2. Sensor engine speed (B753) 8. Oil drain plug
3. Output to oil cooler 9. Sensor output shaft speed (B758)
4. Sensor temperature converter (B766) 10. Oil filter transmission
5. Input from oil cooler 11. Oil filling
6. Sensor turbine speed (B751) 12. Transmission oil cooler

10 2 Transmission – 2.3 Mechanical transmission
2.3 Mechanical transmission

Mechanical transmission, description
page
–
The transmission is built with all gears in constant mesh. It is shifted

through hydraulic pressurising of clutch discs for each one of the
gears. The clutch discs connect the input shaft with the main shaft or
tubular shaft, depending on which gear has been selected. Shifting
takes place without disengaging the transmission from the engine.
The FORWARD and REVERSE clutches are electro-hydraulically
modulated, which means that clutch pressure is built up gradually.
This allows gearshifting between FORWARD and REVERSE during
operation at a speed that is lower than the set limit value. The modu-
lation also provides soft shifting between FORWARD and REVERSE.
High modulation (that is, soft operation/intensive slipping between
gear positions) results in high transmission wear and high oil temper-
ature. The sensor for oil temperature generates a warning when the oil
is hotter than 100 C for transmission Dana and when the oil is hotter
than 120 C for transmission ZF. If the oil temperature sensor indicates
125 C, the transmission ceases to function.
There are three gears in each direction for the transmission. Disen-
gaging the drive normally takes place at a certain brake pressure.
The electronic gearshifting system is either manual or automatic. Us-
ing inching avoids the transmission being fully disengaged.

See Transmission, component location (Transmission TE13FF)
page 7, Transmission, component location (Transmission TE17FF)
page 8, or Transmission, component location (Transmission ZF)
page 9 for component positions.

2 Transmission – 2.6 Lubrication system 11
2.6 Lubrication system

Lubrication system, description
page
–
The transmission has its own lubrication system which is used for lu-
brication, controlling and cooling of the transmission. The transmission
oil cooler is at the bottom of the cooling unit behind the engine, a ther-
mostat in an aluminium block on the side of the transmission enables
the oil to reach operating temperature faster.
See Transmission, component location (Transmission TE13FF)
page 7, Transmission, component location (Transmission TE17FF)
page 8, or Transmission, component location (Transmission ZF)
page 9 for component positions.
Transmission oil, changing

page
–
NOTE
section B Safety.
NOTE
Do not over-fill the transmission!
Equipment: receptacle for gearbox oil (40 l)
NOTE
Oil filters should be changed in connection with oil change.
1 Operate and warm up the transmission oil.
4 Place a container under the transmission.
5 Remove the drain plug from the transmission oil and let the oil
drain into the receptacle.
NOTE
Make sure that the drain plug’s washer seal is also removed.
Drain plug transmission Dana

12 2 Transmission – 2.6 Lubrication system
6 Clean the drain plug and sealing surface on the transmission.

7 Fit the drain plug with a new seal when the oil has drained out.
009415
Drain plug transmission ZF

8 Remove the transmission dipstick and fill new transmission oil
through the dipstick’s hole to the marking for low level on the
dipstick.
For volume and grade, see section F Technical data.
9 Start the engine and allow it to run at idling speed for at least two
minutes.
10 Check that the drain plug for transmission oil seals tightly.
11 Check the transmission oil level with the engine running at idling
speed (600 rpm) and transmission in neutral. Top up to the mark-
ing for low level.
Oil dipstick and filling point transmission oil

12 Warm up the transmission so that the oil temperature is 60-70 °C
for transmission Dana and 80-90 °C for transmission ZF on the
60 ˚C a
display. Use the operating menu oil temperature to check the
transmission oil temperature.
- +
28.7 V b 13 Check the oil level and top up to the MAX marking for oil level.
006995
14 Replace the dipstick and affix it by turning it clockwise.

Operating menu oil temperature
a. Transmission oil temperature NOTE
b. Battery voltage
After the oil change it is recommended that the transmission is
calibrated, see Transmission, calibration (Transmission Dana)
page 17 or Transmission, calibration (Transmission ZF) page 19.

2 Transmission – 2.6.4 Oil filter 13
2.6.4 Oil filter

Transmission oil filter, changing
page
–
NOTE
section B Safety.
NOTE
Do not over-fill the transmission!
Special tools: filter tool
Equipment: receptacle (5 L)
2 Place a container under the transmission oil filter.
3 Remove the transmission oil filter, pour the oil into the receptacle.
Oil filter transmission Dana

4 Moisten the O-ring on the new filter with clean transmission oil.
5 Fit the new transmission oil filter.
Tighten to contact and then another two-thirds of a turn for trans-
mission Dana, or tighten to contact and then another one-third to
one half of a turn for transmission ZF
6 Switch on the main electric power and start the engine.
7 Check that there is no leakage.
8 Check the oil level, see Transmission oil, changing page 11.
009416
Oil filter transmission ZF

14 2 Transmission – 2.7 Cooling system
2.7 Cooling system

Cooling system, description
page
–
The transmission is cooled by the lubrication system see Lubrication

system, description page 11.
For position of components see Transmission, component location
(Transmission TE13FF) page 7 or Transmission, component location
(Transmission ZF) page 9.

2 Transmission – 2.8 Control system transmission 15
2.8 Control system transmission

Control system transmission, description
page
–
(Transmission Dana)
The transmission control unit controls gearshifting based on signals
from pressure, temperature and rpm sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure
in the transmission, so that the selected gear gives the right speed.
For component locations see section 11 Common electrics,
group 11.5.3 Control units.
In case of serious transmission malfunctions the control unit uses two
modes with reduced functionality to protect the transmission, Limp-
home and Shut-down.
Mode Limp-Home
The display on transmission control unit shows LH.
In case of:
• a malfunction of a control output from the transmission is
detected.
• a malfunction connected to a sensor for "engine speed" is
detected.
• two of three "vehicle speed" sensors are defective.
In case that any of the above events take place, the transmission will
be placed in neutral. To be able to continue operation, a gear must be
selected with the gear selector.
In this mode, the operator can use the transmission’s two first gears in
both directions. In case the error occurs while operating in a higher
gear, the operator must downshift manually to first or second gear to
continue.
The control unit uses standard values for modulation.
Mode Shut-Down
The display on transmission control unit shows "Sd".
The transmission has an integrated secondary solenoid and pressure
sensor that monitor the transmission’s internal oil pressure. This sec-
ondary solenoid is handled by the control unit.
When the control unit gives the "Shut Down" control signal, the oil
pressure drops at all pressure modulators. This happens in the event
of a serious malfunction.
In this mode the transmission is in permanent neutral position as there
is no oil pressure to enable selection of a gear.

16 2 Transmission – 2.8 Control system transmission
Control system transmission, description

–
(Transmission ZF)
The transmission control unit controls gearshifting based on signals
from pressure, temperature and rpm sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure
in the transmission, so that the selected gear gives the right speed.
For component locations see section 11 Common electrics,
group 11.5.3 Control units.
For serious transmission malfunctions the control unit uses four differ-
ent modes with reduced functionality to protect the transmission: Sub-
stitute clutch control, Limp-home and Transmission-shutdown and
ECU793-shutdown.
SUBSTITUTE CLUTCH CONTROL mode

Shown as an alarm in the KCS display if a fault arises.
In this mode, the operator can use the machine as usual. On the other
hand shifting and changing direction does not occur under the control
of normal modulation. The control unit uses standard values for mod-
ulation of the clutches.
LIMP-HOME mode
In this mode, the operator can use one of the transmission gears in
each direction, and in some cases only in one direction. In order to
continue to drive in the event of an error in "Limp home" mode, the ma-
chine must be stopped to a standstill, the gear selector moved to neu-
tral before the gear can again be selected.
TRANSMISSION-SHUTDOWN mode
In this mode, the transmission is permanently in neutral position when
the solenoid valves for the clutches and elements of power to the
transmission are switched off. Park the machine and switch off the
engine.
ECU793-SHUTDOWN mode
In this mode, the transmission is permanently in neutral position when
all solenoid valves and elements of power to the transmission are
switched off. Park the machine and switch off the engine.

Transmission, calibration (Transmission Dana)

page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idle speed.
2 To select the function to calibrate, first navigate to the service
menu. Then press Enter.
000056
3 Enter the code for calibration.

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

(Diagnostics, Initiation or Calibration).
4 Select AUTOMATIC GEAR SHIFT ECU 793 by scrolling with the
arrow keys (1 and 2) and confirm with Enter.
AUTOMATIC GEAR SHIFT
ECU793
007741
5 Select CALIBRATION by scrolling with the arrow keys (1 and 2)

AUTOMATIC 2(2) and confirm with Enter.
GEAR SHIFT ECU793
CALIBRATION
007742
6 Select "hEAt" by scrolling with the arrow key (1) and then confirm
ECU793 D M with the arrow key (2).
E
007745
F S
7 Increase the oil temperature in the transmission as follows:

ECU793 D M A. Apply the parking brake so that the machine is stationary.
E
B. Select direction of travel forward or backward and apply half
007744
F S
to full throttle for 30 seconds.
C. Engage neutral position and apply half throttle for
10 seconds, run the engine at idle.
D. Repeat steps B and C until the oil is above 60 °C or maxi-
mum 90 °C. The temperature display starts to flash when cal-
ibration of the clutches can be started.
8 Check that the gear lever is in neutral position.

9 Select "trAn" by scrolling with the arrow key (1) and then confirm
ECU793 D M with the arrow key (2).
E 10 Start the calibration by selecting direction of travel forward.
007745
F S
11 Current temperature is shown if it is lower than 60 °C. Otherwise

ECU793 D M "Go F" is shown. When all conditions for calibration are fulfilled,
E start calibration.
007743
F S The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.
IMPORTANT
Calibration can be aborted at any time by selecting
travel direction reverse.
12 The calibration starts (takes approx. 15 minutes).

ECU793 D M The following is shown during the calibration: "c1.n1", "c1.n2",
E "c2.n1", "c2.n2" etc. This means clutch 1 and mode 1-2, clutch 2
007747
F S and mode 1-2, etc.

13 Depending on current calibration mode, a different engine speed
may be required.
– When engine speed is too low, the display shows the
ECU793 D M following:
E
007748
F S
– When engine speed is too high, the display shows the

ECU793 D M following:
E
007749
F S
14 Change accelerator pedal position until the display appears as to

ECU793 D M the left.
E The calibration continues when the engine has been within the
007750
F S limit values for three seconds.

After successful calibration the calibration results are saved in
the flash memory.

15 The display shows donE after calibration.

ECU793 D M If one or more errors have occurred during calibration, vertical
E lines are shown to indicate the calibration results for each clutch
007751
F S (the first line represents clutch 1, the second line represents
clutch 2, …). A flashing line indicates that the calibration of the
current clutch has not been successful.
16 Turn off the ignition to store the values.
Transmission, calibration (Transmission ZF)

–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed and
check the oil level and that the transmission oil temperature is be-
tween 70 - 90 ºC.
000056

1 23
4 5 NOTE
000060

4 Select AUTOMATIC GEAR SHIFT ECU 793 by scrolling with the
arrow keys (1 and 2) and confirm with Enter.
AUTOMATIC GEAR SHIFT
ECU793
007741
5 Select CALIBRATION by scrolling with the arrow keys (1 and 2)

AUTOMATIC 2(2) and confirm with Enter.
GEAR SHIFT ECU793
CALIBRATION
007742
6 Only shown when the engine is running.

CALIBRATION 1(2)
The signals for parking and declutch have been temporarily dis-
GEARBOX HEAT MODE connected to make it possible to run "Heat mode", the highest
009098
ACTIVATE P-BRAKE! gear possible is always selected.

7 "Heat Mode" is a function for heating the transmission when the

CALIBRATION
machine is stationary by using the parking brake to slow the ma-
chine and allowing the converter to heat the gearbox oil.
FWD<->NTRL 15S CYCLE!
SELECTED GEAR F3 Increase the oil temperature in the transmission as follows:
009541
TEMPERATURE 70”C A. Apply the parking brake so that the machine is stationary.
B. Select direction of travel forward or backward and apply half
to full throttle for 30 seconds.
C. Engage neutral position and apply half throttle for
10 seconds, run the engine at idle.
D. Repeat steps B and C until the oil is above 70 °C or maxi-
mum 90 °C. The temperature display starts to flash when cal-
ibration of the clutches can be started
8 Only shown when the engine is running. Press "Enter" to access
CALIBRATION 2(2)
the next menu.
AUTOMATIC CLUTCH
FILLING PARAMETER
009100
ADJUSTMENTS (AEB)
9 The following requirements must be fulfilled in order to start cali-

CALIBRATION
bration: Transmission in neutral position and parking brake acti-
>SELECT NEUTRAL
vated. Check that all requirements are fulfilled and that the oil
>P-BRAKE ACTIVE
009101
>TEMP >70grC temperature is 70 °C before proceeding to the next menu by

pressing Enter.
10 When the TCU has started the calibration the display shows in-
CALIBRATION
formation about the calibration process in clear text. Any error
STATUS
messages are also shown here.
009103
K1 ADJUST! 11 During the calibration process engine speed is governed auto-

matically to a preset value that is adapted to each respective
transmission.
After completion of calibration the following text is shown in the
display: "ADJUSTMENT FINISHED SWITCH OFF IGNITION
FOR 5 SECONDS!"
12 Only shown when the engine is switched off and inching is in-
CALIBRATION 2(2)
stalled, this is an option.
009104
INCH PEDAL To able to see "CALIBRATION INCH PEDAL" requires that the
engine is already switched off, otherwise this is not shown at all.
--> Engine switched off = INCH PEDAL CALIBRATION
Engine running = AEB CLUTCH CALIBRATION
13 When the TCU has started the calibration the display shows in-
CALIBRATION
formation about the calibration process in clear text. Any error
STATUS
messages are also shown here.
009105
PRESS PEDAL SLOW! 14 Depress the pedal slowly and hold until the information in the dis-
play changes to "Release pedal slow!". Release the pedal slowly.
If everything has worked the following is shown: ADJUSTMENT
FINISHED SWITCH OFF IGNITION FOR 5 SECONDS!"

3 Driveline/axle 1
3 Driveline/axle
Table of Contents 3 Driveline/Axle

mm mm mm mm mm mm
3 Driveline/Axle ................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 4
3.3 Drive axle ................................................................................................... 5

2 3 Driveline/axle

3 Driveline/Axle 3
3 Driveline/Axle
mm mm mm mm mm mm
Driveline/Axle, description
page
–
The machine’s power transmission consists of propeller shaft and

drive axle with differential and hub reduction.

4 3 Driveline/axle – 3.2 Propeller shaft
3.2 Propeller shaft

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

page
–
• Clean.
• Check-tighten the retaining bolts at the mountings for the drive
axle and transmission to 98 Nm (oil).
• Check clearance in universal joints.
1
007797
1. Propeller shaft

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

Drive axle, description
page
–
The drive axle transmits the engine power to the wheels. After the
drive axle’s input shaft is a differential which changes the reduction ra-
tio, distributes the power between right and left drive wheels and also
makes it possible for the drive wheels to rotate at different speed when
cornering. The insert shaft transmits the power from the differential to
the wheel hubs. There are hub reductions at the wheel hubs that
change the reduction ratio between wheel and engine to reduce the
stress on the insert shaft.
1 2 3 4 1
000585
1. Hub reduction
2. Insert shaft
3. Differential
4. Drive axle housing

6 3 Driveline/axle – 3.3 Drive axle
Drive axle, checking

page
–

2 Check the drive axle’s attachment to the frame so that there is no
corrosion on structural elements (e.g., attaching bolts).
3 Check-tighten the drive axle’s attaching bolts to 650 Nm (oil).
15368
4 Visually inspect the drive axle’s welding seams at the mountings.

5 Check that the drive shaft and hub reductions are sealed. Listen
for noise.
6 Check the bolted joint to the parking brake caliper’s attaching
plate and brake disc.
7 Check whether the drive axle’s wheel bearings have play by

means of the following:
– Lift the machine under the mast beam. Support securely un-
der the drive axle.
– Check whether the drive axles’ wheel bearings have play. If
the bearings have play then they must be adjusted, see
Workshop manual DCE 90-180.

Drive axle oil, level check

page
–
NOTE
section B Safety.
Equipment: receptacle (30 l).

1 Position the machine so that the drain plug on one of the hub re-
ductions is in the lowest position.
2 Turn off the engine and apply the parking brake.
3 Place a drainage receptacle at the hub. Place a piece of sheet
metal or similar in the wheel rim to lead any oil to the receptacle.
4 Remove the level plug.
5 Check that the oil level is at the lower edge of the filler hole. Top
up if necessary.
6 Fit the hub reduction’s filler plug.
NOTE
Make sure that the sealing washer is fitted in place.
7 Repeat steps 1 and 6 on the other hub.
Drive axle oil, changing

page
–
NOTE
section B Safety.
Equipment: receptacle (30 l).

1 Position the machine so that the hub reductions’ drain plugs at
the wheels are in the lowest position.
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (lift the machine under the
drive axle) and turn the wheel in the correct position. Lower the
wheel.
2 Turn off the engine and apply the parking brake.
3 Place a receptacle under the differential carrier’s drain plug.
NOTE
The drive axle has a capacity of approx. 23 l oil.

4 Remove the differential carrier’s drain plug.

5 Place a drainage receptacle at every hub. Place a piece of sheet
metal or similar in the wheel to lead the oil to the receptacle.
6 Remove the drain plug and the level plug.

8 When the oil has drained, fit the drain plugs.
NOTE
Make sure that the sealing washers are fitted in place.
9 Fill one hub with oil until the oil level is at the lower edge of the
filler hole.
NOTE
The oil is very viscous and filling should be slow. A level
check should be made in stages so that the oil has time to
distribute itself.
10 Fit the hub reduction’s filler plug.
NOTE

12 Remove the filler plug for the differential carrier.

13 Fill the differential with new oil until the oil is level with the
filler hole.
14 Fit the differential carrier’s filler plug.
NOTE
15 Remove and clean the drive axle’s ventilation.
16 Clean the axle from oil spillage.
17 Remove the receptacles and pieces of sheet metal. Handle the
oil as environmentally hazardous waste.
18 Test drive the machine for a short distance without load.
19 Check the oil level in hubs and differential carrier assembly.


4 Brakes 1
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 4
4.1.1 Brake pedal ............................................................................................ 4
4.3 Power-assisted brake system .................................................................... 5
4.3.6 Distribution block ................................................................................... 8
4.5 Parking brake system ................................................................................. 9
4.5.4 Parking brake unit ................................................................................ 11
4.8 Temperature control, cleaning and hydraulic oil ....................................... 13

2 4 Brakes

4 Brakes 3
4 Brakes
mm mm mm mm mm mm
Brakes, general
page
–
Brakes are installed to enable stopping of the machine. The brakes act
on the drive axle, (the steering axle has no brakes).
The brake system is divided into three functions:
• Power-assisted brake system, function description page 5
• Parking brake system, function description page 9
• Temperature control, cleaning and hydraulic oil, function descrip-
tion page 13

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

4.1.1 Brake pedal
Brake pedal, checking and adjustment
page
–
1 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal’s travel is smooth.
4 Check that the rubber on the pedal is intact and that the tread pat-
tern isn’t worn out. Change if needed.
Stop bolt screw for adjusting clearance between brake

pedal and brake valve. (Illustration shows loose brake
pedal.)

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

Power-assisted brake system, function
page
–
description
The power assisted brake system consists of a hydraulic oil tank, hy-
draulic oil pump, hydraulic oil filter, accumulator charging valve, accu-
mulator, brake valve, pressure sensors, brake cylinder and wheel
brake units.
The hydraulic oil pump pumps oil (from tank) which is cleaned in the
oil filter. The accumulator charging valve directs pressure to the accu-
mulator that stores pressure or directs the oil through the wheel brake
for cooling of the brake discs. The brake valve directs pressure from
the accumulator to the brake cylinder. The brake cylinder compresses
the discs in the brake units that brake the machine. Make-contact
brake pressure gives a signal so that the brake lights are activated
when the brake cylinder is pressurised.
When the accumulator is charged the accumulator charging valve
routes oil through the drive axle’s brake units and cools the brakes,
and back to the tank. Pressure from the accumulator is also used for
the load handling servo circuit.
On machines with turnable operator’s stations there is an extra brake

pedal for driving backwards. The brake pedal is connected in parallel
with the brake pedal for driving forwards. A shuttle valve selects the
strongest pressure signal and forwards it to the wheel brakes.

6 4 Brakes – 4.3 Power-assisted brake system
ECU790
12,14
D1
<˚ 13b D3
Pa
P
11 A
10
T 5
16 D2
Pa Pa
13a 9
T
7 8
A
P 6
15
X
C
4
C
2
3
ACK1
PA
ACK2
TA
008624
B
1. Hydraulic oil pump 10. Relay, brake light (K308-1)
2. Hydraulic oil filter 11. Break contact (opening switch), low accumulator
pressure
3. Valve block, accumulator charging valve 12. Control unit general (ECU 790)
4. Brake valve 13a. Break contact (opening switch), declutch (S220)
5. Accumulator 13b. Inching potentiometer

6. Distribution block 14. Control unit general (ECU 790)
7. Brake cylinder 15. Brake valve
8. Wheel brake 16. Shuttle valve

9. Make-contact brake lights (S216)

4 Brakes – 4.3 Power-assisted brake system 7
Power-assisted brake system, component

page
–
location
1 2 3 6 8
4
5
7
13 12 11 10
007564
1. Hydraulic oil pump 8. Shuttle valve
2. Brake valve 9. Distribution block
3. Break contact (opening switch), low accumulator 10. Wheel brake
pressure
4. Make-contact brake lights (S216) 11. Hydraulic oil filter
5. Break contact (opening switch), declutch (S220) 12. Hydraulic oil tank
6. Valve block 13. Accumulator
7. Accumulator charging valve

8 4 Brakes – 4.3.6 Distribution block
4.3.6 Distribution block

Brake pressure, checking
page
–
1 Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 C.
3 Connect the pressure gauge to the measuring outlet on the dis-
tribution block, see also Power-assisted brake system, compo-
nent location page 7.
4 Start the engine and let it idle.
Measuring nipple, brake pressure on the distribution

block
5 Depress the brake pedal and read the pressure. Compare with
the permissible pressure on the pressure plate (located next to
the cab tilting device for the machine).
6 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
Sign with pressure data

4 Brakes – 4.5 Parking brake system 9
4.5 Parking brake system

Parking brake system, function description
page
–
The parking brake consists of a hydraulic oil tank, hydraulic oil pump,
hydraulic oil filter, accumulator charging valve, accumulator, pressure
sensors, parking brake valve and parking brake unit.
The hydraulic oil pump pumps oil (from the tank) which is cleaned in
the oil filter. The accumulator charging valve controls pressure to the
accumulator which stores the pressure. The parking brake unit is re-
leased with pressure from the accumulator by means of the parking
brake valve pressurising the parking brake caliper. Make-contact
(closing switch) for the parking brake produces a signal so that the
symbol for activated parking brake is shown when the parking brake is
applied.
800 rpm N
0 km/h
10
13
F
N
EDU795
R
1 2
R
3
4
4 5
ECU790
C D1
10,12 D2 5,11
7
9
C
2
Pa 8
3,6
PB
PA
ACK2
PBM
TA
P
007402
1. Hydraulic oil pump 8. Break-contact parking brake (S200)

2. Hydraulic oil filter 9. Relay, parking brake (K314)
3. Valve block, accumulator charging valve 10. Control unit general (ECU 790)
4. Accumulator 11. Indicator light in switch, parking brake (S107)
5. Switch parking brake (S107) 12. Control unit general (ECU 790)
6. Control valve, solenoid valve, parking brake (Y642) 13. Control unit terminal (EDU 795)
7. Parking brake unit

10 4 Brakes – 4.5 Parking brake system
Parking brake system, component location

–
1 2
9 8 7 5
007565
1. Hydraulic oil pump 6. Make-contact (closing switch) parking brake (S200)
2. Valve block 7. Hydraulic oil filter
3. Solenoid valve, parking brake (Y642) 8. Hydraulic oil tank
4. Accumulator charging valve 9. Accumulator
5. Parking brake unit

4 Brakes – 4.5.4 Parking brake unit 11
4.5.4 Parking brake unit

Brake shoe lining, changing
page
–
1 Machine in service position and blocked wheels.

2 Remove the cover from the brake caliper. Check that there is no
oil inside the cover.
3 Loosen the lock nut.

4 Loosen the adjusting screw so that the brake pads become loose.
5 Remove the split pin and loosen the nut on the attaching bolt
holding the parking brake caliper.
6 Pull out the attaching bolt so that the brake pads can be twisted
out and removed.
NOTE
The bolt does not have to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Fit the new parking brake pads.
10 Press back the attaching bolt.

12 4 Brakes – 4.5.4 Parking brake unit
11 Fit the nut and fit a new split pin.

13 Release the parking brake.
14 Adjust the adjustment screw so that the brakes are applied.
15 Turn back the adjusting screw so that the clearance between pad
and disc becomes 0.5 ± 0.1 mm.
16 Tighten the lock nut.
NOTE
To avoid turning the adjustment screw as well, it must be
held still when tightening the lock nut.
17 Refit the cover on the caliper.
18 Check the function of the parking brake.

4 Brakes – 4.8 Temperature control, cleaning and hydraulic oil 13
4.8 Temperature control,

cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page
–
function description
The wheel brakes are cooled when the hydraulic oil is pumped through
the brake unit.
The temperature control system consists of hydraulic oil tank, hydrau-
lic oil pump, hydraulic oil filter, accumulator charging valve and wheel
brake units.
The hydraulic oil pump pumps oil (from the tank) which is cleaned in
the oil filter. When the accumulator is charged the accumulator charg-
ing valve directs oil through the drive axle’s brake units and cools the
brakes, and back to the tank.
C
4
C 5
2 3
COOL
PA
TA
007461
1. Hydraulic oil pump 4. Wheel brake
2. Hydraulic oil filter 5. Bypass valve in distribution block
3. Control valve, accumulator charging valve

14 4 Brakes – 4.8 Temperature control, cleaning and hydraulic oil

page
–
component location
1 2
7 6 5
007566
1. Hydraulic oil pump 5. Wheel brake
2. Valve block 6. Hydraulic oil filter
3. Accumulator charging valve 7. Hydraulic oil tank
4. Bypass valve in distribution block

5 Steering 1
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5 Steering........................................................................................................... 3
5.2 Power assisted system ............................................................................... 4
5.2.6 Link arm ................................................................................................. 9
5.2.9 Sensor, wheel angle .............................................................................. 9
5.2.11 Sensor steering wheel actuation .......................................................... 10

2 5 Steering

5 Steering 3
5 Steering
mm mm mm mm mm mm
Steering, general
page
–
The steering function involves steering the machine during operation.

The machine is steered by the rear wheels. The function includes con-
trols and instruments for steering and the power-assisted system’s
functions.
On machines with turnable operator’s stations, the steering reading is

alternated with the directional control valve for the turnable operator’s
station when driving with the operator’s station turned backward so
that the steering wheel actuation and steering deflection are in
agreement.

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

Power-assisted system, description
page
–
The power-assisted system refers to steering the machine. The ma-

chine’s steering is servo-assisted with pressure from one of the hy-
draulic oil pumps.
Steering consists of steering wheel, steering wheel shaft, steering
valve, hydraulic oil pump, valve block, steering cylinder, link arms and
wheel spindles.
The steering wheel acts on the steering valve (via the steering wheel
shaft), which in turn controls the oil pressure from the hydraulic oil
pump to the steering cylinder. Between the hydraulic oil pumps and
the steering valve is the valve block with built-in priority valve, which
prioritises oil supply to the steering valve before load handling. The
steering cylinder acts on the wheel spindles. The link arms are located
between the steering cylinder and the wheel spindles.
Power assisted system, function description

–
3
5
LSO
O
P T LS
4 C
2
L R
6
007567
1. Hydraulic oil pump 4. Steering valve

2. Hydraulic oil filter 5. Valve block
3. Steering wheel 6. Steering cylinder

5 Steering – 5.2 Power assisted system 5
Power-assisted system, turnable operator’s

–
station, function description
Applies to the Spirit Delta cab.

On machines with turnable operator’s stations, the steering reading is
alternated with the directional control valve for the turnable operator’s
station when driving with the operator’s station turned backward so
that the steering wheel actuation and steering deflection are in
agreement.
3
5
LSO
O
P
6 6
D6 P T LS
7 4
ECU790 C1
L R
2
9
D7 8 8
1
10
009369
1. Hydraulic oil pump 6. End position switch, seat forward (S720-1) and seat
backward (S720-2)
2. Hydraulic oil filter 7. Control unit (ECU 790)
3. Steering wheel 8. Solenoid valve steering forward (Y636-1) and steering
backward (Y636-2)
4. Steering valve 9. Directional control valve
5. Valve block 10. Steering cylinder

Power-assisted system, mini-wheel/joystick

–
control, function description
Joystick control or mini-wheel means that the machine is steered with

an electric control in the operator seat’s left armrest. The electric con-
trol sends signals to the control system. The steering cylinder is pres-
surised by a control valve which also is controlled by the control
system.
Joystick control and mini-wheel function in the same way, the differ-
ence is in the design of the control.
NOTE
Standard steering wheels are always prioritised over joystick
control or mini steering wheels. As soon as the steering wheel is
moved, the joystick control or mini-wheel is disconnected.

5 Steering – 5.2 Power assisted system 7
Condition Reference value

Joystick control activated Voltage signal from switch mini-wheel/joystick steering.
Steering wheel stationary No signal from sensor steering wheel actuation.
Speed Under 2 km/h (when activated)
Control breaker Not activated
8 D3 9
D1 D4
ECU792 11
4, 12
D2 5 D2
6
10
P1 P2 P
LSP LS
TP
2 T
T1
A B L R
007516
7
1. Hydraulic oil pump 7. Steering cylinder

2. High-pressure filter 8. Feedback joystick control: wheel angle sensor (R807)
3. Potentiometer, joystick control (R825) mini-wheel 9. Steering wheel
(R825)
4. Control unit, steering (ECU 792) 10. Steering valve
5. Solenoid valve, steering right (Y615-1) steering left 11. Sensor steering wheel actuation (B770)
(Y615-2)
6. Control valve

Power assisted system, component location

–
2 4 7 8
3 6
5
16
15
14 12 11 10
13
007592
13
1. Steering cylinder 9. Steering valve
2. Hydraulic oil pump 10. Sensor steering wheel reading (B770)

3. Hydraulic oil pump for mini-wheel/joystick control 11. Hydraulic oil filter
4. Control valve for mini-wheel/joystick control 12. Directional control valve
5. Solenoid valve, steering right (Y-615-1) 13. Solenoid valve (Y636-1 and Y636-2)
6. Solenoid valve, steering left (Y615-2) 14. Hydraulic oil tank
7. Valve block 15. Sensor (S720-1 and S720-2)

8. Potentiometer, joystick control (R825) mini-wheel 16. Feedback joystick control: wheel angle sensor (R807)
(B825)

5 Steering – 5.2.6 Link arm 9
5.2.6 Link arm

Bearing in link arm, checking
page
–
1 Machine in service position, see section B Safety, with transverse

wheels.
2 Check the play in the wheel hub, see section 6 Suspension sec-
tion 6.2.3 Wheel hub.
3 Lift the machine under the rear counterweight.
4 Press inward on the wheel’s front section.
009395
5 Press inwards at the rear of the wheel. If play can be felt then the
link arm’s bearing must be replaced, see Workshop manual
DCE 90-180.
009409
5.2.9 Sensor, wheel angle

Sensor, wheel angle, check
page
–
A
Only for feedback joystick control.
This sensor measures the angle of the steering wheels to enable joy-
stick control and, for example, to enable the wheels to return to the
centre position (straight ahead) when the lever is in neutral position.
The sensor is located under a cover by the left king pin on the
001142
steering axle.
A Sensor, wheel angle Check the sensor with regard to play. Check the wiring.

10 5 Steering – 5.2.11 Sensor steering wheel actuation
5.2.11 Sensor steering wheel actuation

Sensor steering wheel actuation, checking
page
–
1
Check that the joystick control and mini-wheel disengage when the
steering wheel is turned. Also check that the sensor for steering wheel
deflection is secure in its bracket and that the multi-function levers are
secure by unfastening the bottom of the steering wheel panel.
012609
1. Metal plate (with four gears)

2. Sensor steering wheel reading

6 Suspension 1
6 Suspension
Table of Contents 6 Wheel suspension

mm mm mm mm mm mm
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 4
6.2.1 Steering axle cradle ............................................................................... 5
6.2.2 Steering spindle ..................................................................................... 5
6.2.3 Wheel hub .............................................................................................. 6
6.3 Tyres and rims ............................................................................................ 7
6.3.1 Tyres .................................................................................................... 17
6.3.2 Rim ...................................................................................................... 18

2 6 Suspension

6 Suspension 3
6 Suspension
mm mm mm mm mm mm
Suspension, description
page
–
The machine’s wheel suspension is made up if its tyres (with accom-

panying bolts and rims), steering axle with hub, wheel spindles and the
steering axle’s suspension in the frame. The drive axle is part of the
power transmission, see section 3 Driveline/axle, group 3.3 Drive axle.

4 6 Suspension – 6.2 Suspension
6.2 Suspension
Suspension, description
page
–
The steering axle cradle is secured to the frame with two bushings,
one in the front edge and one in the rear edge of the steering axle cra-
dle. Two steering spindles are located in the steering axle cradle on
bearing-mounted axles. The steering spindles are jointed to allow
steering. There are bearing-mounted wheel hubs fitted on the steering
spindles where the wheels are mounted.
Suspension, component location

–
Suspension refers to:

4
• Steering axle cradle
5 • Steering spindle
1
2 • Wheel hub
3
007811
11 10 9 8 7 6
1. Steering axle cradle
2. Attaching lug
3. Rubber damper
4. Tyres
5. Rim
6. Steering cylinder
7. Piston rod
8. Link arm
9. Steering spindle
10. Hub
11. Bolts and nuts

6 Suspension – 6.2.1 Steering axle cradle 5
6.2.1 Steering axle cradle

Steering axle cradle, checking
page
–

wheels.
2 Check that the bushings in the suspension are intact.
3 Measure the distance between the frame and the steering cradle.
Note down the measurement.
NOTE
Do not lift under the steering axle.
5 Re-measure the distance between the frame and the steering
cradle. Note down the measurement.
6 Calculate the difference between the two measurements. The dif-
ference may not be more than 3 mm.
6.2.2 Steering spindle

Steering spindle bearing, check
page
–

wheels.
2 Measure measurement A with thickness gauge. Note down the
measurement.
4 Re-measure measurement A.
5 Calculate the difference between the two measurements. The dif-
ference may not be more than 0.25 mm.
If the difference is greater, shimming must be done again, see
Workshop manual DCE 90-180.
A
007812

6 6 Suspension – 6.2.3 Wheel hub
6.2.3 Wheel hub

Wheel hub, checking
page
–

3 Wedge between the frame and the steering axle cradle.
4 Check the play by lifting with an iron-bar lever under the wheel. If
play is detected then the wheel bearings should be replaced, see
the Workshop manual DCE 90-180.
009394

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

Tyres and rims, safety
page
–
DANGER
Always block the wheels on the side of the axle where
no work is to be done before positioning the jack. Al-
ways secure the jack to prevent it from sliding out of
position.
Fully deflate the tyre before removal. Otherwise parts

from the wheel rim can loosen and shoot out when the
pressure is changed. With double wheel fitting both
tyres must be fully deflated!
The air should always be released through the valve.

If this is not possible - drill holes in the tread to re-
lease the air. Damaged tyres may explode.
Never stand directly opposite the tyre when deflating

or inflating. Parts from the wheel rim may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It’s prohibited to repair rims with welding.
It’s prohibited to operate the machine if one of the

tyres is flat.
Wheels, tyres, and rims are dimensioned and select-

ed for each machine type so that maximum wheel
loads and speeds are not exceeded. For this reason,
it is not permitted to change tyre dimension, tyre
make, tyre type, rim type, or rim brand without ap-
proval from Cargotec.

8 6 Suspension – 6.3 Tyres and rims
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the

wheels are fixed when the spacer rings are removed.
If the wheels move, they may move the spacer rings
and crushing damage may result.
When installing drive wheels, ensure that the clamps

clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4–5 oper-

ating hours.
Always follow the tyre manufacturer’s or other ap-

proved instructions when changing tyres.
Never use a steel hammer to install or remove rim

components. Instead, use a lead, brass or plastic
mallet.
Keep the tyre pressure at the prescribed level. Insuf-

ficient tyre pressure impairs stability and reduces the
machine’s capacity.
Remove penetrating objects such as crushed glass,

pieces of wood, metal filings, etc.
Check if tyre wear is abnormal, this could indicate a

mechanical fault. Rectify faults immediately and
change damaged tyres.
Tyre and rim system, description

–
The tyres are the points of contact between the machine and the
ground, and the tyres absorb unevennesses and provide suspension.
The drive axle is subjected to great stress during operation, if the drive
wheels’ rolling circumferences are different then the stresses increase
on the drive axle. It is important that the tyres on the drive axle are the
same model, type and brand, and that they have similar wear and cor-
rect air pressure.

Tyres and rims, check

page
–
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety page 7.
DANGER
or inflating. Parts from the wheel rim may release and
shoot off when the pressure changes.
The air should always be released through the valve.

If this is not possible - drill holes in the tread to re-
lease the air. Damaged tyres may explode.
Do not exceed the prescribed air pressure. When

changing tyre or rim version, another air pressure
may apply, contact Cargotec.
1 Check the rims.

• Check that the lock ring and side ring are in the correct
position.
• Check that there are no cracks in the rims’ parts.
In case of damage, the tyre and rim must be removed and
checked.
3 2
1
007777
1. Lock ring
2. Side ring
3. Lock ring

2 Check the air pressure in the tyres, see Tyres, inflating page 17.
The pressure must be 1.0 MPa, inflate if necessary.
3 Check the tyres.
• Check for uneven and fast wear, this is caused by mechani-
cal problems such as, e.g., uneven brake action. Make sure
that such malfunctions are taken care of immediately.
• Remove penetrating objects such as crushed glass, pieces
of wood, metal filings, etc.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change page 18.
4 If the tyres and rims have no defects, check-tighten the
wheel nuts.
Tighten crosswise to a torque of 650 Nm.
007778
Example: The figure shows inflation of drive wheel.

Tyre and rim system, removing and fitting

page
–
(drive axle)
Removing
2 Raise the machine under the mast beam. Support securely under
the drive axle.
DANGER
With double wheel fitting both tyres must be deflated
otherwise the inner may explode when the outer is
removed.
Risk of tyre explosion! Fatal danger!
Empty both tyres of air.
3 Release the air from the tyres by:

A. Unscrewing the valve and releasing the air.
014571
The figure shows tubeless installation

B. If this does not work, undo the valve in the rim and release
the air.
NOTE
Only applies to tubeless tyres.
014573
C. If this does not work, break off, cut or saw off the valve pipe.
014572

D. If it is not possible to release the air via the valve connection,

the tyre must be emptied by drilling a hole in the tyre’s tread.
Use a drill bit of max. Ø 5 mm.
005123
4 Loosen the wheel nuts.
5 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
6 Remove the wheel nuts.
7 Remove the outer wheel and store it somewhere safe.
005124

8 Move the lifting equipment to the inner wheel.

9 Remove the spacer ring between the outer and inner wheels.
10 Remove the inner wheel and store it somewhere safe.
Installing
11 Make sure the mounting surfaces (location A) on the hub and
wheel are clean and free from paint and grease.
12 Fit the inner drive wheel.
A 13 Fit the spacer ring between the outer and inner wheels.
14 Fit the outer drive wheel. Fit the outer wheel so that inner wheel’s
valve is routed through one of the two valve holes on the outer
wheel.
15 Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
NOTE
Don’t forget any holder for the inner tyre’s valve extender.
007740
16 Inflate the tyres, see Tyres, inflating page 17.

17 Test-drive the machine and check that the wheels are secure.
18 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.

Tyre and rim system, removing and fitting

page
–
(steering axle)
Removing
2 Lift the machine under the steering axle at the wheel in question.
Support under the steering axle in a safe way.
3 Release the air from the tyres by:

A. Unscrewing the valve and releasing air.
014571
The figure shows tubeless installation

B. If this does not work, undo the valve in the rim and release
the air.
NOTE
Only applies to tubeless tyres.
014573

C. If this does not work, break off, cut or saw off the valve pipe.
014572
D. If it is not possible to release the air via the valve connection,
the tyre must be emptied by drilling a hole in the tyre’s tread.
Use a drill bit of max. Ø 5 mm.
005123
4
Remove the wheel nuts holding the nut caps and remove the
nut caps.

5 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
6 Remove the remaining wheel nuts.
7 Remove the wheel and position it safely so that it does not fall
or move.
Installing
8 Make sure the mounting surfaces on the hub and wheel are clean
and free from paint and grease.
9 Fit the wheel.
10 Fit the wheel nuts and nut caps. Tighten the wheel nuts crosswise
in turn with increasing torque to 650 Nm.
11 Inflate the tyre, see Tyres, inflating page 17.
005124
12 Test-drive the machine and check that the wheels are secure.
13 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.

6 Suspension – 6.3.1 Tyres 17
6.3.1 Tyres
Tyres, inflating
page
–
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must

be dismantled and the rim checked for damage.
Never install rim components by striking with a ham-

mer during inflation. Never strike fully or partly inflat-
ed tyres or rim assemblies.
Never inflate tyres before all parts are in place.
Wheels shall be inflated on the machine or in a protec-

tive device, designed and dimensioned so that it can
handle or dissipate a shock wave from a tyre explo-
sion as well as catch the ejected parts.
Do not exceed the prescribed tyre pressure. When

007778
changing tyre or rim version, another air pressure

may apply, contact Cargotec.

or inflating. The lock ring and lock lugs may release
and shoot off when the pressure changes.
Check that all parts are in place when the tyre pres-
sure is 30 kPa.
NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1 Make sure that the lock ring and side ring are in the correct posi-
tion before inflating.
2 Connect the compressor with a locking air-chuck to the nipple on
the tyre.
3 Stand at an angle behind the tyre and remain there until inflating
has been completed in order to prevent being hit by rim parts in
the event of an explosion.
4 Inflate the tyre to the prescribed level, see specifications.
When changing tyre or rim version, another air pressure may ap-
ply, contact Cargotec.

18 6 Suspension – 6.3.2 Rim
Tyre, change
page
–
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre

company.
Check the rim in connection with tyre change, see Rim, check
page 18.
6.3.2 Rim
Rim, check
page
–
DANGER
Perform the following checks to minimise risks of ac-
cidents for all split rims.
Always use the correct tyre dimension and design

corresponding to the manufacturer’s rim type and di-
mension. Oversize tyres may not be used.
Replace all damaged, worn or corroded rims or

mounting parts.
1 Dismantle the rim, see Tyre, change page 18.

2 Carefully clean the outside of the rim edge with a steel brush.
003773

6 Suspension – 6.3.2 Rim 19
3 Measure wear after the lock ring.

The lock ring’s wear on the tyre bead often results in a mark. The
mark shows up between the lock ring’s ends.
Measure L1 and L2 as illustrated.
Calculate the depth of the wear as follows:
L2 - L1 = max. 0.5 mm.
If wear exceeds 0.5 mm then the wheel rim, lock ring and the ta-
pered rim must be discarded and replaced with new parts.
003774

4 Check that the lock ring (position 1) and rim flange (position 2)
3 are intact and in the correct position. Replace damaged parts.
2
003770
1. Lock ring
2. Rim flange
3. Conical ring
5 Check for damage in the areas with high stress concentration.
Checking is done in two steps:
1. The magnetic particle method is used to determine if there’s
a crack or not, and where it is.
2. Confirmed cracks are investigated further with penetrating
fluid.
Typical rim damages are circumference cracks, corrosive dam-
age, rust, warping and wear.
Magnetic particle method

003772
1 Blast clean the marked area around the entire rim so that it is
completely clean from all paint.
003773
2 Test using magnetic particle inspection and the following

equipment:
• Equipment: Yoke Tiede
• Method:
a. Alternating current AC
b. Contrast colour

6 Suspension – 6.3.2 Rim 21
• Checking medium:
a. Wet
b. Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,
checking is finished and the rim is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.
Checking cracks with penetrating fluid

1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
003773
and let dry 10 min.
3 Wash off penetrating fluid with cleaning fluid part
no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
6 Visually inspect the lock ring groove.
1 2
If the tested area does not indicate linear or point-shaped cracks
in the lock ring groove the rim is approved.
If the crack check indicates linear or point-shaped cracks the rim
should be discarded.
001705
Example of cracks
1. Linear crack
2. Point-shaped crack


7 Load handling 1
7 Load handling
Table of Contents 7 Load handling

mm mm mm mm mm mm
7 Load handling................................................................................................. 3
7.2 Lifting/lowering ........................................................................................... 5
7.2.6 Mast ....................................................................................................... 9
7.2.8 Chains .................................................................................................. 14
7.4 Side shift ................................................................................................... 16
7.4.4 Side shift cylinder ................................................................................. 20
7.5 Spreading ................................................................................................. 21
7.7 Tilt ............................................................................................................. 25
7.7.5 Tilt cylinder ........................................................................................... 29
7.8 Levelling ................................................................................................... 30
7.9 Load carrier .............................................................................................. 34
7.9.1 Lifting forks .......................................................................................... 34
7.10 Other functions ......................................................................................... 35
7.10.1 Electric scales ...................................................................................... 35
7.10.3 Tilt control ............................................................................................ 36
7.10.4 Optimum lift ......................................................................................... 37
7.10.5 Side lift attachment .............................................................................. 38
7.10.12 Optimum drive ..................................................................................... 42

2 7 Load handling

7 Load handling 3
7 Load handling
mm mm mm mm mm mm
Load handling, general

page
–
The load handling function refers to lifting, lowering, side-shifting and

tilting the load for example.
Load handling has been divided into the following subfunctions:
• Lifting/lowering
006939
• Tilt
006938
• Side shift
007012
• Spreading
007013

4 7 Load handling
• Levelling
007014

7 Load handling – 7.2 Lifting/lowering 5
7.2 Lifting/lowering
Lifting/lowering, description
page
–
Lifting/lowering means that the mast parts are extended up and down
so that the fork carriage is raised and lowered. For lifting, the inner
mast is raised by means of the lifting cylinders. The chain, which is at-
tached to the carriage (and in the outer mast), runs over the chain
wheel in the top of the mast. This way the carriage is lifted at the same
time as the inner mast.
The machine can be equipped with a special free-lift mast . The

fork carriage is raised in two stages, first the free-lift stage and then the
lifting stage. In the free-lift stage the fork carriage is raised to the top
of the inner mast (machine transport height is not affected). In the lift-
ing stage the inner mast is lifted to its max. position (machine transport
height is affected).
The free-lift cylinders and the lift cylinders are pressurised by the con-
trol valve for load handling.
There are two versions of the lifting/lowering function, depending on
how the function is controlled:
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the lifting/lowering function.
•
Electric servo means that the control levers are electrical and
send voltage signals to the control system to control the lifting/low-
ering function.
In order to absorb and dampen the pressure surges that arise when
running on an uneven surface a piston accumulator is connected via
a male stud branch tee between the control valve and the lift cylinders.
The accumulator absorbs the pressure surges that arise when running
on an uneven surface and in the event of a sudden stop of the lowering
movement. This way the harmful impact on the hydraulic system and
mechanical parts is reduced, while operator comfort is improved.

6 7 Load handling – 7.2 Lifting/lowering
Lifting/lowering, function description

–
(hydraulic servo)

11
6 10
9
8
C
4
3, 5, 7
PP
PA
B
ACK2
TA
b 11
10
P2
T1
C
P
A
T
9
8
2 2 2 C
1 1 1
014757
1. Hydraulic oil pump 7. Control valve lifting/lowering and tilt
2. High-pressure filter 8. Load control valve

3. Valve block, accumulator charging valve 9. Lift cylinder
4. Accumulator 10. Load control valve
5. Valve block, reducing valve 11. Free-lift cylinder

6. Control lever, lifting/lowering

7 Load handling – 7.2 Lifting/lowering 7
Lifting/lowering, function description

–
(electric servo)

Sensor, operator-in-seat Activated
7 ECU796 13
D 12
6 11
D
10
4
8
3, 5, 9 PA
B
ACK2
TA
13
12
P2
T1
C
P
A
T
11
8 10
2 2 2 C
1 1 1
014758
1. Hydraulic oil pump 8. Solenoid valve, lift mast (Y6005) lower mast (Y6004)
2. High-pressure filter 9. Solenoid valve load handling
3. Valve block, accumulator charging valve 10. Load control valve
4. Accumulator 11. Lift cylinder

5. Valve block, reducing valve 12. Load control valve
6. Control lever lifting/lowering (R8071) 13. Free-lift cylinder

7. Control unit, hydraulics (ECU 796)

8 7 Load handling – 7.2 Lifting/lowering
Lifting/lowering, component location

–
6
2 7
3 5 5
8
9
11
4 10
12
13
18 17 16
14
15
007662
1. Hydraulic oil pump 10. Solenoid valve side shift, spreading and levelling
(electric servo)
2. Main valve 11. Lifting mast
3. Control valve lifting/lowering and tilt 12. Free-lift cylinder

4. Solenoid valve side shift, spreading and levelling 13. Lift cylinder
5. Valve block 14. Load control valve
6. Main valve (electric servo) 15. Load control valve
7. Solenoid valve, lift mast (Y6005) (electric servo) 16. High-pressure filter
8. Solenoid valve, lower mast (Y6004) (electric servo) 17. Hydraulic oil tank
9. Control valve lifting/lowering and tilt (electric servo) 18. Accumulator

7 Load handling – 7.2.6 Mast 9
7.2.6 Mast
Mast suspension, checking
page
–
Visually check that the mounting points and welding seams are intact.
See also section 9 Frame, body, cab and accessories,
group 9.12 Frame.
Mast suspension, checking bearings

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

10 7 Load handling – 7.2.6 Mast
3 Make a marking on the mast.

4 Remove the load from the mast mountings in an appropriate
manner.
5 Make a new marking on the mast. Measure the distance between
the markings. The measurement should not be more than 2 mm.
6 If the difference is greater, the bearings in the mast mountings
must be replaced, see Workshop manual DCE 90-180.
009391
Side support, checking
page
–
Top support
1 Lift the inner mast to its top position.
2 Check that the slide surface on the outside of the inner mast has
a normal appearance and does not show signs of damage or
unevenness.
3 Fully lower the inner mast.
4 Lift the inner mast approx. 150 mm from the bottom position.
5 Check the clearance between the top support’s slide plate and
the body of the inner mast’s beam. If the clearance exceeds
014011
1 mm then additional shims need to be fitted.

6 Check how the inner mast is centred in the outer mast and wheth-
er the clearance is the same at the front and rear.
7 Loosen the screws a few turns and press in the required number
of shims.
Do not over-shim; this will increase the wear on the slide plates.
8 Tighten the screws and check the clearance again.
014012

Carriage
1 Check that the chains are correctly tensioned and that the car-
riage is not pulled diagonally in the mast, see Chains, checking
and adjusting page 14
2 Lift the carriage to its top position.
3 Check that the slide surface on the inside of the inner mast has a
normal appearance and does not show signs of damage or
unevenness.
4 Lower the carriage to its bottom position.
5 Check the top section that has been "obscured" by the carriage.
6 Lift the carriage about 0.5 m from its bottom position.
7 Check the clearance between the side of the carriage and the in-
ner mast’s flange by pushing the carriage sideways with a pry
bar.
8 If the carriage moves more than 1 mm compared to the inner
mast’s flange then additional shims need to be fitted.
9 Check how the carriage is centred in the inner mast.
10 Loosen the screws a few turns and press in the required number
of shims.
Five shims can be fitted for each slide plate. Full shimming is an
indication that the slide plate is worn and must soon be replaced,
to replace the slide plate, see Workshop manual DCE 90-180.
11 If the holder for the slide plate rotates then a pin can be inserted
through the hole in the side of the carriage and into the corre-
sponding hole in the holder.
Do not over-shim; this will increase the wear on the slide plates.
014009
Carriage/Mast with slide plates

12 7 Load handling – 7.2.6 Mast
12 Tighten the screws and check the clearance again
014013
Carriage/Mast with support rollers Inner mast

1 Lift the inner mast to its top position.
2 Check that the slide surface on the inside of the outer mast has a
normal appearance and does not show signs of damage or
unevenness.
3 Fully lower the inner mast.
4 Lift the inner mast approx. 1.5 metres.
5 Check the clearance between the outside of the inner mast and
the outer mast’s flange by pushing the inner mast sideways with
a pry bar.
6 If the inner mast moves more than 1 mm compared to the outer
mast’s flange then additional shims need to be fitted.
7 Check how the inner mast is centred in the outer mast.

8 For shimming of the inner mast, see Workshop Manual

DCE 90-180.
014010
Mast with slide plates

014014
Mast with support rollers

14 7 Load handling – 7.2.8 Chains
7.2.8 Chains
Chains, checking and adjusting
page
–
With the aim of increasing safety, the lifting chains should be checked
regularly according to the following:
The chains must be properly cleaned along their entire length. Check-
ing is performed without load on the forks.
1 The chain may not have lengthened more than 3%. Measure the
length of the 25 links that during lifting first (and most often) break
over the chain wheel. This is where lengthening is greatest. Com-
pare with the values in the table. If the 3% limit is exceeded, the
chains must be replaced.
2 P-measurement = the distance between 2 pins
P-measurement P-measurement Measurement over

005670
[in] [mm] 25 links [mm]

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

measuring tape intended to measure the wear.
The measuring tape is marked with:
• Zulässige Verlängerung = permitted lengthening.
• Kette austauschen = chain must be replaced.
The measuring tape can be ordered from Cargotec.

7 Load handling – 7.2.8 Chains 15
Adjusting
1 Check that the pins for the outer washers are securely fastened.
2 Check that the washers are free of visible cracks.
3 Check that the chain is free from mechanical damage.
4 Check that the chain is free of rust.
5 Check that the chain bends easily over the pulley (does not jam
when bending).
6 Place the machine on level surface with the mast vertical (0 tilt).
7 Lower the forks to the bottom position.
8 Check that there is 10–20 mm of clearance between the under-
side of the forks and the ground. Adjust the position by tensioning
or loosening the chains equally on the adjustment nuts in the top
edge of the mast.
NOTE
If the chain is slack when the carriage is in its lowest posi-
tion, the chain must be tightened.
9 Adjust the chains so that the load carrier is lifted evenly in
the mast.
• Adjust the nuts on each side to balance the load carrier.
• Test lift and check that the lifting chain is lengthened equally
on each side so that the load carrier is balanced.
Repeat adjustments as needed.
10 Lubricate the chains after completed inspection.

16 7 Load handling – 7.4 Side shift
7.4 Side shift

Side shift, description
page
–
Side shift means moving the lifting forks laterally. Control valve, load
handling, pressurises the side shift and spreading cylinders which ex-
tend the fork attachments on the fork carriage in relation to the mast.
During side shift the rod side of one of the side shift and spreading cyl-
inders is pressurised. The pressure from the piston side on the first cyl-
inder is directed to the piston side of the second cylinder and
compresses the second cylinder.
With the spreading and side shift carriage the same hydraulic cylin-
ders are used for side shift as for fork spreading. (If there is no spread-
ing function then the cylinders are just for side shift, on the side shift
carriage.)
There are two versions of side shift, depending on how the function is
controlled.
hydraulic pressure, which controls the side shift.
•
send a voltage signal to the control system to control the side shift.

7 Load handling – 7.4 Side shift 17
Side shift, function description (hydraulic servo)

–

6
8
C 4
3,5,7
PP
b
P2
B
PA
ACK2
TA
T1
C
P
9
T
A
a
2 2 2 C
1 1 1
007474
1. Hydraulic oil pump 6. Control lever, side shift
2. High-pressure filter 7. Solenoid valve side shift, spreading and levelling
3. Valve block, accumulator charging valve 8. Side shift cylinder
4. Accumulator 9. Side shift cylinder
5. Valve block, reducing valve

18 7 Load handling – 7.4 Side shift
Side shift, function description (electric servo)

–

7 ECU796
6 D1
D2 10
8 3,5,9
b
P2
B
PA
ACK2
TA
T1
P
T
A
a
11
8
C
2 2 2 C
1 1 1
007475
1. Hydraulic oil pump 7. Control unit, hydraulics (ECU 796)

2. High-pressure filter 8. Solenoid valve, side shift left (Y6020) and side shift
right (Y6021)
3. Valve block, accumulator charging valve 9. Solenoid valve side shift, spreading and levelling
4. Accumulator 10. Side shift cylinder
5. Valve block, reducing valve 11. Side shift cylinder
6. Control lever, side shift

7 Load handling – 7.4 Side shift 19
Side shift, component location

–
6
8
C 4
3,5,7
PP
b
P2
B
PA
ACK2
TA
T1
C
P
9
T
A
a
2 2 2 C
1 1 1
007474
1. Hydraulic oil pump
8. Solenoid valve, side shift left (Y6020) (electric servo)
2. Main valve 9. Solenoid valve side shift, spreading and levelling
(electric servo)
3. Control valve lifting/lowering and tilt 10. Solenoid valve, side shift right (Y6021) (electric servo)
4. Solenoid valve side shift, spreading and levelling 11. Side shift cylinder
5. Valve block 12. High-pressure filter
6. Main valve (electric servo) 13. Hydraulic oil tank

7. Control valve lifting/lowering and tilt 14. Accumulator
(electric servo)

20 7 Load handling – 7.4.4 Side shift cylinder
7.4.4 Side shift cylinder

Side shift cylinder, checking
page
–
Visually check that the cylinders are straight and that the mounting
points and welding seams are intact.

7 Load handling – 7.5 Spreading 21
7.5 Spreading
Spreading, description
page
–
Spreading involves changing the relative distance of the lifting forks.

Control valve side shift, spreading and levelling pressurises the
spreading cylinders which in turn move the forks.
There is a flow distributor between the valve and the cylinders that en-
sures that the forks move uniformly even if the resistance on the forks
should be different.
With the spreading and side shift carriage the same hydraulic cylin-
ders are used for side shift as for fork spreading.
There are two versions of spreading, depending on how the function
is controlled.
hydraulic pressure, which controls the spreading.
•
send a voltage signal to the control system to control the
spreading.

22 7 Load handling – 7.5 Spreading
Spreading, function description

–
(hydraulic servo)

6
9
8
C 4
3,5,7 9
PP
b
P2
B
PA
ACK2
TA
T1
C
P
T
A
a
2 2 2 C
1 1 1
007476
1. Hydraulic oil pump 6. Control lever, spreading

2. High-pressure filter 7. Solenoid valve side shift, spreading and levelling
3. Valve block, accumulator charging valve 8. Flow distributor
4. Accumulator 9. Spreading cylinder

7 Load handling – 7.5 Spreading 23
Spreading, function description (electric servo)

–

ECU796
7
6 D1 11
D2 10
8 3,5,9 11
PP
b
P2
B
PA
ACK2
TA
T1
P
T
A
a
8
C
2 2 2 C
1 1 1
007477
2. High-pressure filter 8. Solenoid valve, spreading inwards (Y6019) outwards
(Y6018)
4. Accumulator 10. Flow distributor
5. Valve block, reducing valve 11. Spreading cylinder
6. Control lever, spreading

24 7 Load handling – 7.5 Spreading
Spreading, component location

–
6
2
3 5 5
10
7
9
8
4
11
15 14 13
12
014752
1. Hydraulic oil pump 9. Solenoid valve side shift, spreading and levelling
(electric servo)
2. Main valve 10. Solenoid valve, spreading outwards (Y6018)
(electric servo)
3. Control valve lifting/lowering and tilt 11. Spreading cylinder
4. Solenoid valve side shift, spreading and levelling 12. Flow distributor

(electric servo)
8. Solenoid valve, spreading inwards (Y6019)
(electric servo)

7 Load handling – 7.7 Tilt 25
7.7 Tilt
Tilt, description
page
–
Tilt means the angling of the mast in relation to the machine. The con-
trol valve lifting/lowering and tilt pressurises the tilt cylinders, which an-
gle the mast in relation to the machine. Tilt is controlled by control
lever tilt.
There are two versions of tilt, depending on how the function is
controlled.
hydraulic pressure, which controls the tilting.
•
send a voltage signal to the control system to control the tilting.

26 7 Load handling – 7.7 Tilt
Tilt, function description (hydraulic servo)

–

9
C 4
3, 5, 7
PP
b
P2
PA
B
ACK2
TA
8 9
VB C1
T1
VA C2
C
P
T
A
a
2 2 2 C
1 1 1
007472
1. Hydraulic oil pump 6. Control lever, tilt

2. High-pressure filter 7. Control valve lifting/lowering and tilt
3. Valve block, accumulator charging valve 8. Load holding valve
4. Accumulator 9. Tilt cylinder

7 Load handling – 7.7 Tilt 27
Tilt, function description (electric servo)

–

7 ECU796
6 D2
D1
11
4 8
3, 5, 9
P2
PA
B
ACK2
TA
10 11
VB C1
T1
VA C2
C
P
A
T
2 2 2
1 1 1
007473

2. High-pressure filter 8. Solenoid valve, tilt in (Y6011), tilt out (Y6010)
3. Valve block, accumulator charging valve 9. Control valve lifting/lowering and tilt
4. Accumulator 10. Load holding valve
5. Valve block, reducing valve 11. Tilt cylinder
6. Control lever tilt (R8072)

28 7 Load handling – 7.7 Tilt
Tilt, component location

–
6
2 7
3 5 5
8
9
4 10
11
15 14 13 12
007677
1. Hydraulic oil pump 9. Control valve lifting/lowering and tilt (electric servo)
10. Solenoid valve side shift, spreading and levelling

2. Main valve (electric servo)
3. Control valve lifting/lowering and tilt 11. Tilt cylinder
4. Solenoid valve side shift, spreading and levelling 12. Load holding valve
7. Solenoid valve, tilt out (Y6010) (electric servo) 15. Accumulator
8. Solenoid valve, tilt in (Y6011) (electric servo)

7 Load handling – 7.7.5 Tilt cylinder 29
7.7.5 Tilt cylinder

Tilt cylinder, checking
page
–
Visually check that the mounting points and welding seams are intact.
Tilt mount, checking bearings

page
–

2 Make marks on the mast and frame when the mast is vertical.
3 Add blocks under the outer mast in order to unload the tilt mounts
and tilt out to the maximum. Measure the distance to the mark.
The measurement should be max. 2 mm.
4 If the difference is greater, the bearings in the tilt mounting must
be replaced, see Workshop manual DCE 90-180.
009392
009393

30 7 Load handling – 7.8 Levelling
7.8 Levelling
Levelling, description
page
–
Levelling means that the load is angled horizontally. This enables the
machine to handle loads on uneven surfaces.
There are two different types of levelling, fork levelling and central lev-
elling (with the central levelling carriage specified).
For machines with fork levelling, one of the forks (right or left) is sus-
pended via a hydraulic cylinder that moves the fork vertically through
a sleeve secured to the carriage.
With central levelling the front section of the fork carriage is levelled
(turned) around the centre line of the carriage, four degrees up
or down.
There are two versions of levelling, depending on how the function is
controlled.
hydraulic pressure, which controls the levelling.
•
send a voltage signal to the control system to control the levelling.

7 Load handling – 7.8 Levelling 31
Levelling, function description (hydraulic servo)

–

6
C
3,5,7
PP
b
P2
B
PA
ACK2
TA
T1
8
C
A
P
T
a
2 2 2 C
1 1 1
007478
1. Hydraulic oil pump 5. Valve block, reducing valve
2. High-pressure filter 6. Control lever, levelling
4. Accumulator 8. Levelling cylinder

32 7 Load handling – 7.8 Levelling
Levelling, function description (electric servo)

–

7 ECU796
D1
6 D2
8 3,5,9
P2
B
PA
ACK2
TA
T1
10
A
P
T
C 8
2 2 2 C
1 1 1
007479
1. Hydraulic oil pump 6. Control lever, levelling

2. High-pressure filter 7. Control unit, hydraulics (ECU 796)
3. Valve block, accumulator charging valve 8. Solenoid valve, levelling down (Y6022) up (Y6023)
4. Accumulator 9. Solenoid valve side shift, spreading and levelling
5. Valve block, reducing valve 10. Levelling cylinder

7 Load handling – 7.8 Levelling 33
Levelling, component location

–
6
2
3 5 5
7 10
4 9
8
11
14 13 12
007678
1. Hydraulic oil pump 8. Solenoid valve, levelling down (Y6022) (electric servo)
2. Main valve 9. Solenoid valve side shift, spreading and levelling

(electric servo)
3. Control valve lifting/lowering and tilt 10. Solenoid valve, levelling up (Y6023) (electric servo)
4. Solenoid valve side shift, spreading and levelling 11. Levelling cylinder

(electric servo)

34 7 Load handling – 7.9 Load carrier
7.9 Load carrier

7.9.1 Lifting forks
Lifting forks, checking
page
–

2 Check the fork arms with regard to blade thickness, cracks and
deformation.
• Blade wear (at position a) must not exceed 10% (calculated
from initial dimensions and measured 150 mm from the heel
of the fork).
• Visible cracks may not be present.
Pay special attention to the fork heel. Surface cracks are
generally not longer than 5 mm.
If surface cracks are discovered, grind down approx. 0.5 mm
and test with magnetic powder to see if the crack is still visi-
ble. Testing must be performed by an approved company.
3 Check the forks’ suspension mountings, e.g. clearance.
4 If the forks need repair - contact Cargotec or one of Cargotec’s
a
approved service personnel, who will determine whether the
150 mm
forks can be repaired.
007781
NOTE
Surface cracks and wear must not be dealt with using
welding.
5 Forks which have been hot-straightened must be heat treated
again (carried out by an approved firm).

7 Load handling – 7.10 Other functions 35
7.10 Other functions

7.10.1 Electric scales
Electric scales, description
page
–
The scales function is available in two versions.

1. Electric-hydraulic scales that do not display anything to the driver,
but can be used by other functions in the machine. A pressure
sensor in the lift cylinder measures the pressure and so estimates
the weight of the load.
2. Electric scales which have a more direct interface with the driver.
With the electric scales there are two load cells in the chain tightener
with built-in amplifier that gives the weight of the load. The accuracy
depends on mast movement before measuring. The scales and load
sensors are very sensitive and are affected by several factors such as
friction in the mast and fork carriage, oil temperature and bearings.
The mast should be in a vertical position and the fork carriage centred.
Under these conditions the load sensors in the chain tightener function
optimally. The fork carriage should be raised and then lowered to
about 1 metre above the ground before calibration and weighing. If the
system is calibrated after gentle lowering, and weighing is performed
in the same way, then an accuracy of about 1% of the maximum load
capacity is achieved. The weight is presented continuously on the dis-
play, in tonnes to one decimal place (e.g. 5.2 tonnes).
Electric scales, calibration

page
–
The scales on a machine equipped with complete scales are always

adjusted and calibrated from the factory. For correct use of the scales
they must be calibrated regularly against a known test weight.
NOTE
The mast should be in a vertical position and the fork carriage
should be centred for weighing, calibration and taring.
1 Operate the trolley up and down a few times to remove any me-
chanical tension.
2 Operate the machine for a few minutes before zero adjustment
and weight calibration take place.
000056

36 7 Load handling – 7.10.3 Tilt control

The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
5 Select SCALE by scrolling with the arrow keys (1 and 2) and con-
firm with Enter.
SCALE
000803
6 Unload, operate the trolley up and lower it slowly to about 1 metre

CALIBR 1(2) above the ground. Reset to zero by pressing in the
600 menu 1 (2).
SCALE 600
WITHOUT LOAD (mV)
000804
7 Load with a known weight (preferably a frequently used loading

CALIBR 2(2) weight or close to the machine’s maximum load), adjust with 4
4000 8000 KG
4000 8000 KG and 5 to the correct weight and lower the trolley slightly. Con-
SCALE WITH LOAD firm the weight by pressing in the menu 2 (2). For the weight
000805
to be adjustable there must be a value in setup for maximum lift

capacity.
7.10.3 Tilt control

Tilt control, description
page
–
The vertical alignment function constantly works towards holding the

load vertical. The system is load compensating and also takes into
consideration the downward pitch of the machine when a load is
picked up or deposited. Load compensation takes place after lift and
lower is concluded. Instead of the operator needing to seek vertical ori-
entation manually, it takes place automatically via pressing the switch
by the tilt lever.
There is an indicator light on the mast to display the status of tilt
control.

7 Load handling – 7.10.4 Optimum lift 37
7.10.4 Optimum lift

Optimum lift, description
page
–
Optimum lift optimises lift speed in relation to engine speed, load and
lifting lever deflection when the machine is operated under a fixed set
speed limit. This results in a higher lift speed, lower sound level, lower
fuel consumption and reduced exhaust emissions during load
handling.
The function intelligently controls a variable pump in relation to engine
speed, current load and the lifting lever’s position when lifting. The
pump is load sensing, which only allows the oil quantity (flow) and the
pressure required in each step to be added to the flow and pressure
that the fixed pump supplies. The variable pump operates in parallel
with the fixed pump. This means that the lift speed can be increased
significantly (up to 60%).
Optimum lift is activated when engine speed exceeds a lower adjust-
able limit (e.g. 1000 rpm), the machine’s speed is below 8 km/h and
the position of the lifting lever fulfils set limit values.
Depending on the value from the load sensor, control unit (ECU 790)
reduces the pump’s displacement linearly in order to prevent the en-
gine being overloaded. The engine speed is limited to an upper adjust-
able limit in order to use the engine’s torque more efficiently.

38 7 Load handling – 7.10.5 Side lift attachment
7.10.5 Side lift attachment

Side lift attachment, description
page
–
Side lift attachments are designed on the basis of simple, safe and fast
handling, low weight and easy maintenance.
Both corner boxes of the side lift attachment are telescopic and spring-
mounted to the main beam, which enables levelling of 195 mm on
each side for coupling tilting containers. A hydraulic cylinder between
the attachment and carriage allows ±600 mm side shift.
A hydraulic system ensures that the container is locked via twistlocks
to the attachment before lifting.
An electric safety system blocks locking and release of twistlocks un-
less the attachment is aligned properly in contact with the container.
The system also prevents lifting unless twistlocks are either fully
locked or released.
A lamp panel shows contact, locked container or released container.

7 Load handling – 7.10.5 Side lift attachment 39
Twistlocks, checking
page
–
WARNING
Dropped load.
Fatal danger!
Twistlocks can be locked automatically if all sensors

for contact are activated manually.
DANGER
Make sure that the engine is off when working on the
twistlocks.
Twistlock holds the load during load handling and

therefore it is crucial that twistlocks are checked ac-
cording to instructions and replaced at the slightest
sign of damage or wear.
1 Check that the twistlocks function correctly.

1 2 3
Lock and open the twistlocks, check that the indicator lights work,
both in cab and on attachment.
2 Clean the twistlocks from any dirt.
3 Under the rubber cover for twistlocks: check pin, link arm and
lock nut.
4 Clean the area around sensor contact.
5 Push in the contact pin so that the head is level with the under-
side of the spreading beam. Check the distance to sensor con-
tact; the distance must be 51 mm. Adjust if needed
4 NOTE
The contact pin should move easily and spring back
completely.
007922
6 5 6 Check that the lock guide and lift pin can move freely.
1. Sensor unlocked twistlock 7 Fit a pry bar between the lift pin (position 5) and the lock guide
2. Sensor contact (position 4) and check the clearance max clearance: 1–1.5 mm.
3. Sensor locked twistlock
4. Lock guide
5. Lift pin
6. Contact pin

40 7 Load handling – 7.10.5 Side lift attachment
8 Turn the twistlocks to locked position and check lift pin wear. Re-
place the lift pin if necessary.
9 Repeat steps 1–8 on the other side.
m
Max. 4 mm
m
70
.
in
M
002311
Wear limits lift pin.
Twistlock, checking for cracks

page
–
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or oth-

er external damage, or twistlocks with more than
1 Remove the lift pins from the attachment.
NOTE
Twistlocks are heavy, be careful when removing.
2 Check for cracks within the marked area on the pins without
causing damage.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
002313
4 Install approved twistlocks.

Area for checking for cracks on lift shoe.
NOTE
Use new attaching nut and washers.

7 Load handling – 7.10.5 Side lift attachment 41
Sensor contact, checking and adjusting

page
–
1 Check that the alignment pins in the corner boxes can move eas-
ily up and down. The alignment pins should spring down when
they are not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the light indicators
on the sensor are turned off.
4 Lower the attachment onto a container and check that Indicator
light contact is lit.
5 Lift the container a little bit so that the Indicator light contact is
switched off.
6 With the container raised, check how much movement on the
007782
1 2 contact pins is needed to detect contact (light indicator on the
sensor is lit). The movement should be 3–4 mm.
Right side
1. Sensor contact 7 If necessary, loosen the lock nut and screw in/out the sensor until
2. Contact pin the distance between the sensor and the contact pin is 5 1 mm.
1 2
007919
Left side
1. Sensor contact
2. Contact pin

42 7 Load handling – 7.10.12 Optimum drive
Sensor twistlocks, checking and adjusting

page
–
1 Check that the sensors are free of damage and dirt.

2 Turn the start key to position I and check that the light indicator
on the sensor for unlocked twistlock is lit.
If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is
5  1 mm.
3 Check that indicator light twistlocks open is lit.
4 Lower the attachment over a container and lock twistlocks.
5 Check that the light indicator on the sensor for locked twistlock is
lit.
007783
If necessary, loosen the lock nut and screw in/out the sensor until
1 2 the distance between the sensor and the indicator plate is
Right side 5  1 mm.
1. Sensor unlocked twistlock 6 Check that indicator light twistlocks locked is lit.
1 2
007920
Left side
1. Sensor unlocked twistlock
7.10.12 Optimum drive

page
–
This function facilitates increased productivity and safety. Optimum

drive provides the conditions for inching and maximum hoisting at the
same time. Unlike electronic inching (inching) the operator does not
need to use the brake pedal to control the speed of the machine which
makes the function both safer and faster. The accelerator pedal’s po-
sition controls the speed and the lifting lever the engine’s power
(speed) - completely independently of each other. The accelerator
pedal also works as a brake during normal driving. The service brake’s
effect on the accelerator pedal’s position is set from 1 to 9 with the op-
erating menu for Optimum drive.

8 Control system 1
8 Control system
Table of Contents 8 Control and monitoring system

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.2 Monitoring functions ................................................................................... 6
8.2.3 Speed limitation ..................................................................................... 6
8.2.4 Service indicator .................................................................................... 7
8.3 Error codes ................................................................................................. 8
8.4 Diagnostics ................................................................................................. 9
8.4.1 ECU 790 .............................................................................................. 10
8.4.2 ECU 792 .............................................................................................. 11
8.4.3 ECU 793 .............................................................................................. 11
8.4.4 ECU 796 .............................................................................................. 11
8.4.5 Load alarms (latest alarm) ................................................................... 12

2 8 Control system

8 Control system 3
8 Control system
mm mm mm mm mm mm
Control system, general

page
–
In many cases, the machine’s functions are controlled electrically. The

signals that control the machine are monitored to warn the operator or
limit the machine’s functions in case of certain dangerous situations or
if there are malfunctions in the machine.
The function control system is divided into the following functions:
• Monitoring functions
• Error codes
• Diagnostics
• Settings
• Software
Monitoring functions describe the machine’s monitoring functions that
warn the operator or limit the machine’s functions in the event of a dan-
gerous situation.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control and monitoring
system.
Control system, description

page
–
The machine is equipped with an electronic system used for control-

B C ling and monitoring certain of the machine’s different functions.
The system gives the operator information in the form of alarm infor-
mation and operating information. The information is presented on the
steering wheel panel’s display (position B).
The function keys are used to navigate in the display menus for serv-
ice and troubleshooting, for example.
F
R
1 2 3
4 5
007801
A
A. Function keys
B. Display
C. Alarm indicator

4 8 Control system
Function keys
R The function keys (position A) are used to navigate in the menu sys-
1 2 3 tem for information, setting and diagnostic menus.
They are also used to enter values into the system and to confirm error
codes.
000693
4 5
• Function key 1 1 : Scroll counter-clockwise in menu system as
well as enter value 1.
• Function key 2 2 : Scroll clockwise in menu system as well as

enter value 2.
• Function key 3 R : interrupt selection of menu or procedure in

3
progress and confirm error codes displayed. Also works as a

shortcut to the operational menus if held down for a short time.
• Function key 4 4 : enter value 4, gradual settings adjustment

and gradual decrease of values in menus (counts down when the
function key is held down, counts faster if held down longer).
• Function key 5 5 :menter value 5, for gradual settings adjust-

ment and gradual increase of values in menus (counts up when
the function key is held depressed, counts faster if held down
longer).
• Function key 6 : confirms selection of menu and confirms val-

ue entered (stored in memory).
Operating menus
50
When the machine is started the operating menu is shown with engine
speed, speed, clock, current gear (gear positions 1-3 are not shown
with inching or declutch), as well as fuel level. This menu is shown until
another menu is selected or an event-controlled menu is shown (e.g.
82 °C in case of error code of the type "WARNING" and "STOP"). Menus are
selected with the function keys for right arrow and left arrow. With each
2.4 bar press of the key, the display changes to the next menu. To quickly re-
turn to the original display, press and hold in the function key for
60 °C Reset (R).
- +
This section describes the information that can be obtained from the
28.7 V different operating menus. The figures show example data.
(+/-) 1.2
1430 km
75 t
158 t 300 h
1240 rpm 50 bar

90 bar
016656
120 bar
160 bar
Example of operating menus

8 Control system 5
NOTE
The availability of the menus is dependent on the machine’s
equipment.
The following operating menus are available to aid the operator:
• Operating menu
• Operating menu engine
• Operating menu transmission and electrical system
• Operating menu service interval
• Operating menu paper handling
• Operating menu scale
• Operating menu Optimum drive
• Operating menu joystick control/mini-wheel
• Operating menu trip computer
• Operating menu statistics

• Operating menu service
Service menu
The service menu is the gateway to the machine’s diagnostic system.
By pressing "Enter" and entering different codes, different parts of the
Service menus are accessible. The code to access the diagnosis men-
us is 11111, while the code to access the settings menus requires spe-
cial authority (contact Kalmar Industries with any questions).
000056
The different service menus are:

• Error codes, description page 8.
• Diagnostics, general page 9.

6 8 Control system – 8.2 Monitoring functions
8.2 Monitoring functions

Monitoring functions, general
page
–
The machine is equipped with a number of control functions to in-

crease safety during load handling:
• Speed limitation
• Service indicator
8.2.3 Speed limitation

Speed limitation, description
page
–
Speed limitation prevents the machine’s speed from exceeding a pre-

set value by controlling the engine speed.

8 Control system – 8.2.4 Service indicator 7
8.2.4 Service indicator

Service indicator, resetting
page
–

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

(Service, Diagnostics, Initiation or Calibration).
4 Reset the service indication by pressing Enter.
500h TO NEXT SERVICE

PRESS ENTER TO
CONFIRM!
000808

8 8 Control system – 8.3 Error codes
8.3 Error codes

Error codes, description
page
–
When a malfunction occurs in the machine error messages (error

codes) are generated by the control unit in question that is sending the
error code via the CAN-bus to control unit EDU 795 that shows the er-
ror codes on the display and stores the error codes.
Explanation of error codes is found in Operator’s manual and Work-
shop manual.
Error code indication

An error code is indicated with an illuminated indicator for active error
41 42 codes (position 42). The error codes are divided into three error code
levels depending on their severity.
The error code levels are indicated as follows:
• STOP is indicated with a STOP sign in the display together with a
fixed red light from the indicator for the control system
B (position 42).
Error code with level STOP is shown automatically in the display.
• WARNING is indicated with a warning triangle in the display, to-
gether with a fixed red light from the indicator for the control sys-
tem(position 42).
Error code with level WARNING is shown automatically in the
display.
• INFORMATION is indicated with an adjustable wrench in the dis-
play together with fixed red light from the indicator for the control
system (position 42).
Error code with level INFORMATION is shown automatically on
007192
display.
B. Symbol error code level
41. Display for control system (KCS)
42. Indicator for control system (KCS)
Error code display

Error code information is displayed with display images and symbols
307 that give an indication about the nature of the error arising.
The error code and the image can be removed temporarily with the
Reset (R) function key and then they disappear from the display. If the
error code is active then they will return in the display in 1-3 minutes.
004257
If the error code is the information type and is removed with Reset (R)
Example of automatic display figure then it is not displayed again until the system is restarted.

8 Control system – 8.4 Diagnostics 9
8.4 Diagnostics
Diagnostics, general
page
–
The machine has built-in functions for troubleshooting called diagnos-

tic test. The diagnostic test consists of several menus that are shown
DIAGNOSTICS in the display. The menus are grouped according to control unit for
faster access.
On the following pages, there are compilations of the diagnostic men-
000916
us. The Workshop manual has a more detailed description of each di-
agnostic menu.
The diagnostic test is divided into the following groups:
• Control unit ECU 790, ECU 790, menu overview page 10.
• Control unit ECU 793, ECU 793, menu overview page 11. Only
applies to Dana TE13FF/17FF.
• Error code history, Load alarms, description page 12.
The diagnostic test varies between the different control units as to
what type of diagnostics can be carried out, but the following alterna-
tives are possible:
• View inputs – means that the inputs can be checked (digital and
analogue).
• View outputs – means that the outputs can be checked (digital and
analogue).
• Control outputs – means that the outputs can be checked and
controlled (digital and analogue).
Diagnostics, operating instructions

page
–
To choose diagnostics, do the following:

1 Navigate to the service menu.
2 Press .
000056
3 Enter the code for diagnostics (11111).
1 23
4 5
000060
4 Select Diagnostics by pressing .
DIAGNOSTICS
000916

10 8 Control system – 8.4.1 ECU 790
5 Main option for diagnostic test is now shown on the display.

Choose which control unit shall be investigated using the function
DIAGNOSTICS ECU790 keys 1 and 2 and confirm with .
Only accessible control units on the machine are displayed.
Each diagnostic function comprises a sequence of a number of
diagnosis menus. The first diagnosis menu for selected diagnos-
DIAGNOSTICS ECU792 tic group appears in the display. Choose the next diagnosis menu
using 1 and 2 .
DIAGNOSTICS ECU793
DIAGNOSTICS ECU796
LAST ALARMS
007891
8.4.1 ECU 790

ECU 790, menu overview
page
–
DIAGNOSTICS ECU 790
DIAG ECU 790 1(3) DIAG ECU 790 2(3) DIAG ECU 790 3(3)
VIEW INPUTS VIEW OUTPUTS CONTROL OUTPUTS

007886

8 Control system – 8.4.2 ECU 792 11
8.4.2 ECU 792

page
–
DIAGNOSTICS ECU 792
007887
8.4.3 ECU 793
page
–
Applies to Dana TE13FF/17FF.
DIAGNOSTICS ECU 793
ECU793 D M
E
F S
007888
8.4.4 ECU 796
page
–
DIAGNOSTICS ECU 796

007890

12 8 Control system – 8.4.5 Load alarms (latest alarm)
8.4.5 Load alarms (latest alarm)

Load alarms, description
page
–
A history of the latest error codes generated can be seen under this
menu. If the same error code is generated several times this is count-
ed and the number of faults is shown on the display. The date and time
for when the error code was last generated is also displayed.
Select diagnostics and Load alarms as per Diagnostics, operating in-
structions page 9. This display indicates if Load alarms is selected.
LAST ALARMS Press function key to proceed.
000995 The 10 latest error codes are displayed in chronological order (with er-
ror code number, number of error codes and the date and time for the
last error code of this type received).
If only one error code is saved there is only the menu for that fault and
the last menu "Clear all alarms". So the number of menus under Load
alarms is dynamic. Max. number of error codes saved is 10.
1 Latest active error codes (1, latest) in chronological order.
LAST ALARMS 1(13)
ALARM NUMBER 354
COUNTER 11
16.01.2007 10:58
009350
2 Latest active error codes (2) in chronological order.

LAST ALARMS 2(13)
ALARM NUMBER 358
COUNTER 8
16.01.2007 10:58
009351

LAST ALARMS 3(13)
ALARM NUMBER 361
COUNTER 3
16.01.2007 10:58
009352

LAST ALARMS 4(13)
ALARM NUMBER 364
COUNTER 2
16.01.2007 10:58
009353

LAST ALARMS 5(13)
ALARM NUMBER 380
COUNTER 6
16.01.2007 10:58
009354

8 Control system – 8.4.5 Load alarms (latest alarm) 13

LAST ALARMS 6(13)
ALARM NUMBER 384
COUNTER 1
16.01.2007 10:58
009355
LAST ALARMS 7(13)
ALARM NUMBER 601
COUNTER 3
16.01.2007 10:58
009356
LAST ALARMS 8(13)
ALARM NUMBER 610
COUNTER 1
16.01.2007 10:58
009357

LAST ALARMS 9(13)
ALARM NUMBER 900
COUNTER 1
16.01.2007 10:58
009358

LAST ALARMS 10(13)
ALARM NUMBER 1200
COUNTER 2
16.01.2007 10:58
009359
11 Latest active error codes (11) for the engine. In the event of more
LAST ALARMS 11(13) than one error code, scroll through the codes by pressing
ENGINE ALARM 1(X) function key 5 .
SPN: 110
FMI: 10
009360
PRESS (+) FOR NEXT

12 Latest active error codes (12) for the transmission. In the event of
LAST ALARMS 12(13) more than one error code, scroll through the codes by pressing
GEARBOX ALARM 1(X) function key 5 .
SPN: 5490
FMI: 11 This menu does not work for Dana TE13000/17000.
009361
PRESS (+) FOR NEXT

13 Clear all error codes (only possible with service code). This menu
13(13) is shown if there is one or more error codes. To clear all error
CLEAR ALL ALARMS? codes, press the function key (Yes = ).
YES = ENTER
This menu does not clear error codes for Dana TE13000/17000
009362
or Volvo TAD650VE/TAD750VE.

14 8 Control system – 8.4.5 Load alarms (latest alarm)
Shown if no saved error codes exist and after reset. If there are no er-
13(13) ror codes from the KCS system then the display only shows
menu 11-13.
NO ALARMS
009364

9 Frame, body, cab and accessories 1
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9 Frame, body, cab and accessories............................................................... 3

9.1 Controls and instruments ........................................................................... 5
9.2 Safety and emergency equipment ............................................................ 16
9.3 Seats ........................................................................................................ 17
9.4 Heating, ventilation and air conditioning ................................................... 23
9.4.4 Fresh air filter ....................................................................................... 35
9.4.9 Condenser unit .................................................................................... 36
9.5 Wiping and cleaning of windows .............................................................. 39
9.6 Lighting system ........................................................................................ 40
9.7 Signalling system ..................................................................................... 41
9.8 Entertainment and communication ........................................................... 42
9.9 Glass/windows/mirrors ............................................................................. 43
9.10 Construction and suspension of cab ........................................................ 45
9.10.1 Cab frame ............................................................................................ 45
9.10.2 Doors ................................................................................................... 46
9.10.3 Cab undercarriage ............................................................................... 47
9.10.4 Cab tilting ............................................................................................. 48
9.10.5 Door stop ............................................................................................. 49
9.11 Cab interior ............................................................................................... 50
9.12 Frame ....................................................................................................... 51
9.13 Body structure .......................................................................................... 53
9.13.4 Counterweights .................................................................................... 54
9.14 Central lubrication .................................................................................... 55
9.15 Paint/coatings ........................................................................................... 57

2 9 Frame, body, cab and accessories

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

mm mm mm mm mm mm
accessories
Frame, body, cab and accessories,
page
–
description
The machine consists of frame, body and cab.
The frame (chassis) is the machine’s structural part and is made of
high-strength steel.
The body consists of fenders, hood and other parts mounted on
the frame.
The cab is built separately and is insulated from the frame using
heavy-duty rubber dampers. The driver’s seat, steering wheel and
controls for hydraulics can be adjusted for optimal individual operating
position. Effective insulation results in minimal vibration and a low
sound level. The machine is equipped with a heating and ventilation
system, and can be equipped with an optional air conditioning system
(not for FlexGuard cab).
WARNING
Each case of mechanical damage to the cab can in-
volve risks as the strength is changed. Consequently,
making holes in load bearing parts is forbidden.
Contact Cargotec for recommendations.
WARNING
Never work underneath a cab that is not tilted over its
balance point or secured in another way.
Risk of crushing danger.
Always tilt the cap as far as possible. At maximum tilt-

ing angle (on horizontal surface) arrange the cab’s
centre of gravity so that it does not risk tilting back.

4 9 Frame, body, cab and accessories
WARNING
The hood may be slippery.
Danger of slipping.
It is forbidden to walk on the hood when it has no anti-

slip protection or is not flat.
WARNING
Applies to the Spirit Delta cab alternative.
The strength of the roof window can be substantially

reduced by exposure to substances that contain aro-
matic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at reg-

ular intervals. Clean only with windscreen washer flu-
id or a mild cleaning agent. Rinse thoroughly with
plenty of lukewarm water. Replace a damaged roof
window immediately if it is cracked or significantly
scratched!
CAUTION
All reworking of the roof window is forbidden (e.g.
making holes, cutting or widening existing holes).
Risk of material damage.
Small cracks in the material around screw holes for

example indicate that the strength of the roof window
is affected and it must be replaced immediately.

9 Frame, body, cab and accessories – 9.1 Controls and instruments 5
9.1 Controls and instruments

Overview Spirit Delta
page
–
1 2 3 4A 5
R
1 4 5
14 2 3
7A
4B 7B
014486
13 12 11 10 9 8
1 Left-hand dashboard panel
2 Gear and travel direction selector
3 Steering wheel panel
4A Steering wheel
4B Joystick or mini-wheel
5 Multi-function lever
6 Parking brake
7A Control for load handling
7B Alternative control for load handling
8 Arm rest
9 Driver’s seat
10 Accelerator pedal
Accelerator pedal with function for selecting travel direction (forward/reverse)
11 Brake pedal
12 Brake pedal
13 Electronic box with fuses and relays
14 Hour meter

6 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Left-hand dashboard panel
30 31 32 33 15 Control for heating
16 Control for fan
17 Control for defroster/cabin
18 Control for cooling AC

27 28 29
19 .. 26
19 Switch for recirculation/fresh air
(Only for heater unit with cooling AC)
18
17 20 Switch for cooling AC
16
15 Switch for extra work lights
21 Switch for work lights on mast
30 31 32 33
24 Switch for revolving beacon
27 28 29 25 Switch for warning beacon

19 .. 26
26 Switch for headlights
006908
TO DE
AU MO
34 27 Switch for seat heating

(The switch may be in the driver’s seat)
Left- hand dashboard panel, upper with heater unit
and lower with air conditioning
28 Switch for central lubrication
29 Switch for short-stop heater
30 Spare
31 Spare
32 Spare
33 Socket for 12/24 V
34 Air conditioning ECC

Steering wheel panel

A buzzer is built in under the steering wheel panel (not visible). It is ac-
tivated if:
• starting attempts are made with a gear engaged and parking
brake not activated
• the parking brake is not activated when the operator leaves the
driver’s seat
• the machine has low coolant level, low brake pressure or a park-
ing brake fault
• an error code is generated, at which point a short sound signal is
emitted
35 36 37 38 39 40 41 42 43
35 Warning lamp for exhaust cleaning (particle filter)
36 Warning lamp, replace air filter
37 Indicator light for tilt control
38 Warning lamp for low battery charge
F 39 Indicator light for high beam

N
R
40 Indicator light for direction indicators
1 2
R
3
41 Display for control system, KCS
4
42 Alarm indicator for control system, KCS
5
43 Ignition key lock

006903
44 45 46 47 48 49 44 Switch for turnable driver’s seat

45 Switch for engagement and disengagement of alternative di-
rection of travel selector
Switch for engagement and disengagement of alternative

gear selector
46 Switch for inching
47 Function keys for control system, KCS
48 Switch for windscreen wiper, rear
49 Switch for windscreen wiper, roof

Right-hand dashboard panel
51 52 53 54 55 56 57 58 59
51 Switch for disengaging reverse alarm
52 Switch for raising/lowering the driver’s seat
54 Switch for electrically heated rear view mirrors
007728
55 Spare
Right-hand dashboard panel 56 Spare
57 Spare
58 Spare
59 Spare

Overview Spirit Delta

–
(applies to cab with relocated KCS display).
1 2 4A 5
14 7A
6
4B
7B
014488
13 12 11 10 9 8
1 Left-hand dashboard panel
3 Not used
4A Steering wheel
4B Joystick or mini-wheel
6 Parking brake
8 Arm rest
9 Driver’s seat
11 Brake pedal
12 Brake pedal
14 Hour meter


A buzzer is built in under the left-hand dashboard panel (not visible).
47 41 42 33 It is activated if:
brake not activated
R
3
1 2
4 5 driver’s seat
27 28 29 ing brake fault
20 .. 26
46
AU
TO
MO
DE
emitted
34
009060
43
25 Switch for warning beacon
26 Switch for headlights
27 Switch for seat heating

(Can be in driver’s seat)
29 Switch for short-stop heater
33 Socket for 12/24V
34 Air conditioning ECC

Arm rest
44 Switch for turnable driver’s seat

006997
44, 45 48 49 gear selector
Arm rest 48 Switch for windscreen wiper, rear

A buzzer is built in under the left-hand dashboard panel (not visible).
It is activated if:
brake not activated
driver’s seat
ing brake fault
emitted
51 52 53 54 36 38 40 58 59
35 Warning lamp for exhaust cleaning (particle filter)
36 Warning lamp, replace air filter

35 37 39
007018
39 Indicator light for high beam
40 Indicator light for direction indicators

51 Switch for disengaging reverse alarm
52 Switch for raising/lowering the driver’s seat
54 Switch for electrically heated rear view mirrors
58 Spare
59 Spare

Overview FlexGuard and FlexCab

–
2 3 4 5
R
1 4 5
2 3
7A 7B
014485
13 12 11 10 9 1
1 Dashboard panel
3 Steering wheel panel
4 Steering wheel
6 Parking brake
9 Driver’s seat
11 Brake pedal
12 Brake pedal


A buzzer is built in under the steering wheel panel (not visible). It is
activated if:
brake not activated
driver’s seat
ing brake fault
emitted
35 36 37 38 39 40 41 42 43 35 Spare
36 Spare
39 Indicator light for high beam

F
N 40 Indicator light for direction indicators

R

R
1 2 3
4 5

006903
44 Spare
44 45 46 47 48 49

gear selector
48 Switch for windscreen wiper, rear

Dashboard panel
30 31 14 61 62 15 63 14 Hour meter
15 Control for heating
006919 25 Switch for warning beacon

21 22 23 24
26 25 26 27 28 29 26 Switch for headlights
Dashboard panel
27 Switch for seat heating
(Can be in driver’s seat)
29 Spare
30 Spare
31 Spare
61 Spare
62 Spare
63 Switch for fan
Control for air conditioning

A 64 65 A
AIR 64 Control for fan

TEMP
65 Control for cooling output

006930
Cooling unit in cab

Operating menus, overview

–
1. Operating menu
50
2. Operating menu engine
3. Operating menu transmission and electrical system
4. Operating menu service interval
82 °C 5. Operating menu paper handling
2.4 bar 6. Operating menu scale
7. Operating menu Optimum drive

60 °C
- + 8. Operating menu joystick control/mini-wheel
28.7 V
9. Operating menu trip computer
(+/-) 1.2
1430 km 10. Operating menu statistics
75 t
158 t 300 h 11. Operating menu service
1240 rpm 50 bar

90 bar
016656
120 bar
160 bar
Example of operating menus

16 9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment
9.2 Safety and emergency

equipment
General
page
–
A good working environment has safety and emergency equipment to

make the operator’s work safe.
The machine may be equipped with the following:
2 11 9 8 7 1. Back-up alarm
2. Revolving beacon/flashing beacon

The revolving beacon is also vertically adjustable.
3. Horn
4. Electrically powered loud horn
5. Fire extinguisher
A fire extinguisher is normally located on the left front fender, but
may also be located on the right front fender or inside the cab.
If the machine is supplied with a fire extinguisher, it should be of
the type ABE according to EN 3 pt. 1, 2, 4 and 5. With such a fire
extinguisher, it is possible to extinguish fires in both solid organic
009379
materials and fluids. Adapted fire extinguishing equipment can be

1, 8 6 10 3 5 4 8
ordered from Cargotec.
6. Seat belt
7. Buzzer in the cab to indicate an alarm or forgotten action, e.g. if
the operator leaves the driver’s seat without applying the parking
brake.
8. TV camera with monitor

Used to provide improved rearward visibility while manoeuvring
and/or load handling with the machine. The monitor is normally lo-
cated inside the cab by the front right-hand door pillar.
9. External rear view mirrors :

Used to provide increased visibility for operating and load
9a
handling.
9a shows a glimpse of the area in front of the machine
9b shows blocked area at the side/behind the machine
10. Control breaker for load handling

(servo circuits, only at electric servo controls for load handling)
11. Grating for roof window .

009464
9b

9 Frame, body, cab and accessories – 9.3 Seats 17
9.3 Seats
Seats, general
page
–
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
Machines with the Spirit Delta cab alternative can be equipped with the
turnable driver’s seat .
NOTE
Other alternative driver’s seats may be installed.
Seats, description (product alternative Bege)

page
–
The seat has the following equipment:

• mechanical adjustment
1 2 • armrest right
• seat belt, 2-point
3 • seat belt, 3-point
• armrest left
4
• seat heating
• head restraint
• air suspension
5
• integrated horizontal suspension (disengageable)
• ventilated seat and backrest cushion (air-vent). The seat requires
8 6
006825
7 compressed air. The option includes an externally mounted com-

Controls Bege pressor on the underside of the cab .
1. Adjustable lower back (lumbar) support
2. Adjustable arm rest, right
3. Adjustable arm rest, left
4. Adjustable tilt, backrest
5. Adjustable suspension position
6. Adjustable seat angle
7. Adjustable seat height
8. Longitudinal adjustment

18 9 Frame, body, cab and accessories – 9.3 Seats
Seats, description (product alternative

page
–
Isringhausen 6500)
• air suspension
• armrest right
• air-adjusted lower back (lumbar) support
• mechanically adjustable seat tilt
• mechanically adjustable damping
• horizontal suspension (disengageable)
• seat heating
• integrated compressor
8
• head restraint
• armrest left
003712
2 3 6 1 5 7 4 9
Controls Isringhausen 6500
5. Adjustment of damping
6. Seat heating

Seats, description (product alternative Grammar

page
–
Actimo XXL)
• air suspension
• armrest right
8
• mechanically adjustable seat length
9 • integrated horizontal suspension

• seat heating
10 • integrated compressor
2
5 • head restraint
4
6 • armrest left
003710
3 1 7
Control, Grammer Actimo XXL
2. Adjustable seat
7. Level damping

Seats, description (product alternative Grammer

page
–
MSG 20)
• mechanical adjustment of height
• adjustable tilt
• seat belt
The suspension adjusts automatically to the operator’s body weight.
000540
1 2 3
Control, Grammer MSG 20


Seats, description (product alternative

page
–
Isringhausen 6000)
• mechanical adjustment of height
• integrated horizontal suspension
• armrest right
• armrest left
6
003713
2 3 1 5 4 7
Controls Isringhausen 6000
5. Adjustment of damping/weight setting

Seats, description (product alternative Grammar

page
–
Maximo XXL)
11 • air suspension (height)
• armrest right
8
• mechanically adjustable seat length
• integrated horizontal suspension
9 10
• seat heating
• integrated compressor
5
• armrest left
1
2
4
003711
7 3 6
Control, Grammer Maximo XXL
2. Adjustable seat
7. Level damping
11. Adjustable backrest plate

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 23
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
page
–
A standard equipped machine with FlexGuard has no system for heat-
er/defroster. A standard equipped machine with Spirit Delta cab and
FlexCab has a heater unit (cabin/defroster) that is connected to the en-
gine’s cooling system and which provides heat when the engine is
warm. The heater unit consists of a fan and heater elements for heat-
ing the air. In the Spirit Delta cab the air is distributed through integrat-
ed ducts in the cab’s interior equipment and can be directed towards
e.g. defroster or floor. In the FlexCab cab the air is distributed through
three air nozzles that can be directed towards e.g. defroster or floor.
The air conditioning unit is available in different types:
• Air conditioning, AC (manual control of cooling and heating)

• Air conditioning, ECC (Electronic Climate Control, electronic con-
trol of cooling, dehumidifying and heating)

24 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning
Air conditioning includes the parts presented in the illustration and en-
sures the operator’s cab climate is as comfortable as possible. Air con-
F
ditioning function is to:
• warm the air when it is cold
2 • dehumidify the air when it is humid
4 • clean the air from impurities
D
C • cool the air when it is warm
• defrost (defroster function)
E E
The unit is controlled with switches and controls on the dashboard
3 panel.
The unit’s fan is controlled in steps 0-I-II-III (with the fan control). For
air conditioning ECC the fan is steplessly variable 0–100%.
6 A B
5 1
G
000762
1. Fluid reservoir/receiver dryer

2. Evaporator
3. Fan
4. Expansion valve
5. Condenser
6. Compressor
A. High pressure gas
B. High pressure fluid
C. Low pressure fluid
D. Low pressure gas
E. Hot cab air
F. Cooled air to cab
G. Outdoor air for removal of heat

Heating, ventilation and air conditioning

–
(Spirit Delta), component location

1 2 3 4 5 6
O E
7 8
AUT MOD
10
9
11
12
13
21
20 19
18 17 16 15 14
009495
1. Sensor, outside temperature ECC 12. Heat exchanger, heating
2. Condenser 13. Engine, recirculation
3. Pressure switch 14. Expansion valve
4. Particle and moisture filter 15. Sensor, deicing ECC
5. Sight glass 16. Heat exchanger, cooling
6. Sensor, temperature air conditioning ECC 17. Fresh air filter

7. Control for cooling AC with thermostat 18. Fan
8. Air conditioning ECC 19. Water valve, standard heating and AC
9. Fine filter 20. Water valve ECC
10. Engine, air distribution 21. Compressor
11. Sensor, after heat exchanger ECC

Heating, ventilation and air conditioning

–
(FlexCab), component location

2
AIR
TEMP
4
3
1
5
11
007469
10 9
1. Compressor 7. Cooling fan
2. Air conditioning 8. Expansion valve
3. Particle and moisture filter 9. Evaporator
4. Control for fan and cooling 10. Thermostat
5. Condenser 11. Water valve

6. Cab fan, heater/defroster

Air conditioning unit

page
–
General recommendations for work on the air

conditioning unit
CAUTION
Authorisation is required to perform repairs on the cli-
mate control unit.
Check/performance test of air conditioning unit
NOTE
The air conditioning unit does not function at temperatures below
approx. 0 C because the pressure in the refrigerant circuit be-
comes too low. If the pressure in the refrigerant circuit becomes
too low, the low-pressure monitor power supply to the compres-
sor’s magnetic clutch is broken, which causes the air conditioning
unit to stop functioning.
Should be performed during continuous operation every week from
early spring to late autumn as well as in winter during long periods of
high humidity.
In winter, during cold and dry periods of low operation, the compressor
should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are lubricated.
1. Check that the condenser is not clogged – clean condenser flang-
es with compressed air as necessary.
2. Check that the compressor turns on and off without error.
3. Check that the drain for the cooling element’s condensation water
is not clogged.
4. Check that there is no leakage of refrigerant. Leaking often caus-
es oil and gas to form a dusty and dirty stain.
5. Start the engine and turn on the cooling function set to maximum
cooling. With EEC: Choose Cool mode with temperature on
minimum.
Let the engine run at at least 1500 r/min. (At temperatures below
approx. 0 C, the cooling function will not start due to low pressure
in the system.)

6. With AC: Set fan control to position I or II.

With ECC: Set fan to medium speed.
7. After running for 10 minutes, check that there are no bubbles vis-
ible in the receiver dryer’s sight glass. (Bubbles should occur only
when the compressor starts and stops).
8. Place a thermometer at the exhaust nozzle nearest the evapora-
tor. After 5-10 minutes, the temperature should be under 10 C.
(Deviations in the measurement result can occur if the perform-
ance test is conducted when the ambient temperature is under ap-
prox. 18 C). If bubbles occur, subsequent filling should be done
by an expert.
Check the temperatures on the hoses and similar items as

follows:
1. Check that the hoses and components on the pressure side keep
a roughly even temperature by feeling them with your hand.
NOTE
In the event of a stop in one of cooling circuit’s components,
and during long-term operation, certain parts (possibly hoses
before the condenser) can be very hot. Risk of burns!
2. All hoses and components on the pressure side (from the com-
pressor to the expansion valve) should be warm.
3. All hoses and components on the suction side (from the evapora-
tor to the compressor) should be cold.
4. Check the expansion valve. Frost or cold temperatures on the in-
take side indicate that it is defective or clogged and that circulation
is limited or stopped on the pressure side.
5. Check that the compressor engages and disengages normally.
Operate the cab fan at low speed and allow the compressor to op-
erate at high speed. When the temperature in the air vents ap-
proaches 0 °C the compressor is disengaged via the thermostat
or ECC and is re-engaged when the temperature has increased
approx. 3-7 °C. (If the compressor is not disengaged then the
evaporator risks icing up and the cooling output subsides.)

WARNING
If there is a rupture in the cooling coils or a leakage on
the attachment – immediately switch off the unit.
It is dangerous to allow refrigerants to come in con-

tact with skin or eyes.
Never release refrigerant in a closed rum; the gas can

cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air

conditioning.
Work may only be performed on the refrigerant circuit

by an accredited company.
Checking refrigerant quantity
WARNING
Electric fans can injure hands.
Avoid placing hands near the cooling fans when the

engine is running.
Using the sight glass it is possible to check estimates of the correct

quantity of refrigerant. Visible bubbles should not normally be notice-
able when the air conditioning system is in operation. Bubbles can oc-
cur if the system contains the incorrect quantity of refrigerant, in
connection with the compressor stopping and starting, and if the con-
denser is defective or at very high ambient temperatures.
It is easiest to detect bubbles if you examine the sight glass while the
compressor is being started. In which case bubbles are normally visi-
ble from a few seconds after the compressor has started, until the sys-
tem has started to work normally.
NOTE
Reliable checking of refrigerant quantity through the sight glass
can only be made when the ambient temperature is above ap-
prox. 15 C.

Only applies to the Spirit Delta cab: on the left-hand side of the con-
denser is a sight glass on the line to the evaporator. In the centre of
sight glass is a coloured point for moisture indication. Normally the in-
dication is GREEN. If the indication shows YELLOW then there may
be moisture in the system (can occur if the system is not properly
evacuated before filling refrigerant or if refrigerant has leaked).
Inspection of sight glass on the rear-mounted condenser

and condenser mounted behind the roof, or in rearwardly
adjusted position
2 Check that refrigerant quantity is correct via the sight glass.
3 The sight glass can be inspected from below.
Inspection of sight glass on roof-mounted condenser

NOTE
Reliable inspection of the sight glass is difficult without an in-
spection mirror.
Inspection can also be performed by loosening the condenser’s
outer protective cover, see steps 3-5.
Inspection with inspection mirror.

3 Remove the attaching bolts on the left-hand side of the condens-

er’s outer protective cover.
4 Carefully lift the left-hand side of the condenser’s outer

protective cover.

Inspection of sight glass on the FlexCab cab with AC

3 Switch on the air conditioning with max. cooling and fan.
4 Check that no bubbles are visible in the sight glass on the particle
and moisture filter.
Bubbles in the glass means that the quantity of refrigerant is in-
correct or that the condenser is defective, clogged by e.g. dust,
or that the ambient temperature is very high.
005384

Action in the event of leakage in the system

1. Turn off the air conditioning.
2. Examine the system and locate any leaks. Use special leak test
equipment for this purpose. If there is still refrigerant remaining
then the remaining quantity of refrigerant must be evacuated and
then measured.
3. Rectify faults, seal leaks by replacing gaskets, hoses, etc.
4. Fill with the correct quantity of R-134a refrigerant in accordance
with the following points when all faults have been rectified.
5. The following work requires special filling equipment.
6. Connect the suction pressure gauge’s blue hose to the service
valve on the compressor’s suction side marked with S, SUC or
SUCTION.
7. Connect the pressure gauge’s red hose to the service valve on the
compressor’s pressure side marked with D, DIS or DISCHARGE.
8. Connect the hoses to the fluid reservoir.
9. Connect the yellow filling and vacuum hose to the nitrogen tube.
Open the cock on the tube and then the cock on the pressure side.
Now the gas flows forward through the system and back to the
suction side of the compressor, which can be seen on the blue
pressure gauge which slowly indicates a pressure equivalent to
the pressure in the tube (see red pressure gauge). (If the blue
pressure gauge does not move then there is a stop in the system.)
Turn off the cock on the pressure side and then the cock on
the tube.
10. The system now contains a mixture of nitrogen and air. This quan-
tity of gas is sufficient to indicate a leak.
11. Conduct leakage detection of all hose nipples and other connec-
tions by applying leakage indicator around all sealing surfaces
and check whether gas bubbles arise.
12. Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.
13. Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then, open the cock on the pressure side, use vacuum suction for
at least 30 minutes. Preferably longer.
14. First close both cocks on the manometer set. Then switch off the
vacuum pump. Work in this sequence, otherwise the air will rush
back. Wait for about 15 minutes and check on the pressure gaug-
es that the vacuum is not changed.
15. Move the yellow hose to the refrigerant tube and open the cock on
the tube.
16. Bleed the yellow hose by unloading the service connection at the
manometer set until pure gas flows out.
17. Open the cock on the suction side and allow the gas to flow
around until the pressure gauges indicate the same pressure as
in the tube.

18. Start the compressor and set the cooling thermostat and fan
to max.
19. Open the cock on the pressure side and allow the compressor to
suction from the tube. Observe the sight glass. The fluid is heavily
mixed with bubbles to start with. The longer the compressor can
suction, the fewer the bubbles and the clearer the liquid becomes.
If the bubbles suddenly disappear, then the cooling thermostat
has probably disengaged. Connect over the thermostat by using
a cable directly from the 24 V connection, or wait until the thermo-
stat re-engages. Continue filling until the correct quantity of refrig-
erant is reached.
NOTE
Directly bypassing the compressor’s coupling magnet can
lead to compressor damage caused by incorrect refrigerant
quantity.
Turn off the cock on the suction side and then the cock on the
tube. Loosen the service hoses from the compressor and fit the
protective caps. Conduct leakage detection in accordance with
step 11 or with a separate leakage detector.
20. In the event of overfilling the pressure and the temperature in-
crease slowly until the high pressure switch stops the current to
the compressor’s electromagnet. This is because the refrigerant
is flowing around in the system without being either evaporated or
condensed in the condenser. As a result, there is no cooling in the
cooling element and excessive heat is formed in the condenser.
In addition, a plentiful flow of bubbles is visible in the sight glass.
Return to step 2.
21. In the event of underfilling or a lack of refrigerant, bubbles appear
in the sight glass - return to step 2.
Compressor cooling oil

1. The compressor is filled with cooling oil on delivery. Under normal
conditions the oil should not be changed or refilled. In the event of
suspected incorrect oil quantity, see the instruction: "When replac-
ing the compressor".
2. In the event of refrigerant loss there may also be oil loss, because
about 25% of the oil volume is taken up by the refrigerant.
Recommended oil types that may be used are shown in the
When replacing the compressor

The compressor is filled with cooling oil on delivery. When replacing
the cooling compressor the oil should be replaced as follows:
• Drain the defective compressor of oil and measure the quantity.
• Then drain the new compressor of oil and refill it with the same
quantity drained from the defective compressor. With regard to
the oil volume in the system, see section F Technical data.

9 Frame, body, cab and accessories – 9.4.4 Fresh air filter 35
9.4.4 Fresh air filter

Fresh air filter (Spirit Delta cab), cleaning and
page
–
replacement
The fresh air filter is also available as an option for the Spirit Delta cab
with AC or ECC .

2 Remove the filter insert.
3 Wash the filter insert with hot water and dishwashing detergent or
replace the filter when necessary.
4 Fit the filter.
Fine filter, air conditioning unit (Spirit Delta cab),

page
–
replacement.
. Fine filter is always available in combination with AC or ECC.

2 Loosen the bolts and remove the air conditioning unit’s front cov-
er (under the wiper motor).

4 Replace the filter when necessary.
5 Fit the filter insert.
NOTE
Make sure that the filter insert is fitted in accordance with the ar-
row marking.
6 Fit the front cover.

36 9 Frame, body, cab and accessories – 9.4.9 Condenser unit
9.4.9 Condenser unit

Condenser unit (Spirit Delta), checking
page
–

2 Check that the condenser battery’s fins are not clogged with dust
that prevents air flow. (A sign that the condenser needs cleaning
can be low or non-existent cooling output, in combination with the
condenser fans continuously working in the highest speed range.
If the condenser fans stop (cycling from stationary to maximum
speed) then the cause may be an electrical failure on the built-in
resistor for the condenser unit’s fans).
3 Clean the roof-mounted condenser as follows (rear-mounted is
accessible without removal)
4 Check that the fans are rotating.
5 Remove the condenser’s outer protective cover, 4 x M6 bolts.
6 Remove the M8 nuts for the condenser’s two front rubber

dampers.

9 Frame, body, cab and accessories – 9.4.9 Condenser unit 37
7 Carefully lift the condenser up at the front edge and support it with
appropriate support.
8 Clean the fins with compressed air.

38 9 Frame, body, cab and accessories – 9.4.9 Condenser unit
Condenser unit (FlexCab), checking

–

2 Check that the condenser’s fins are not clogged with dust that
prevents air flow. (A sign that the condenser needs cleaning can
be low or non-existent cooling output despite the condenser fans
working normally).
3 Loosen the front rubber mountings.
4 Carefully lift the condenser up at the front edge and support it with
appropriate support.
5 Clean the fins with compressed air.

9 Frame, body, cab and accessories – 9.5 Wiping and cleaning of windows 39
9.5 Wiping and cleaning of

windows
Wiping and cleaning of windows, description
page
–
On the cab there are wipers for front, rear and roof windows. Its func-
3 tion is to clean the windows and to maintain good visibility from
the cab.
The wiper arm is attached to the wiper motor’s shaft over a splined ta-
per. The shaft is made of hardened steel and the wiper arm’s bracket
is made of mild diecast material.
When installing it is important to make sure that the splines are free
from metal filings and similar. In addition, the nuts must be tightened
2 so hard that the splines are pressed into the bracket and act as drivers.
Counterhold the wiper arm when installing so that the torque is not
transmitted to the motor, which may be damaged (16–20 Nm tighten-
ing torque).
1
001878
1. Wiper, front
2. Wiper, roof
3. Wiper, rear
Wipers, checking
–
Check that:
1. the motors are operating normally and without noise.
2. the wiper arms are pressing the wiper blades against the win-
dows. Replace them if they have damage or significant wear.
3. the wiper blades are intact. Replace them if they are damaged
or worn.
4. the washer function distributes washer fluid over the windows sat-
isfactorily. If necessary, fill the washer fluid and adjust the washer
nozzles.

40 9 Frame, body, cab and accessories – 9.6 Lighting system
9.6 Lighting system

Lighting system, component location
page
–
The function of the lighting is to increase safety during operation and

load handling.
NOTE
It is important that the right type of bulb is used for each area. See
The following lighting is available:
5 9, 11, 14 7 6 8 12
10, 13
1, 2, 3 15
3, 4
009545
1. Rear light, red 9. Extra work lights, cab roof, rear edge, 2 lamps
2. Brake lights 10. Mast work lights, 2 lamps
3. Direction indicators 11. Extra work lights, cab roof, rear edge, 2, 4 or 6 lamps
4. Headlights 12. Extra work lights, cab roof, front edge, 2 lamps
5. Back-up light, white 13. Extra work lights mast, 2 lamps
6. Adjustable searchlight 14. Extra work lights for container handling, 4 lamps
7. Revolving beacon 15. Extra work light between the tilt cylinders, 1 lamp
8. Interior lighting

9 Frame, body, cab and accessories – 9.7 Signalling system 41
9.7 Signalling system

Signalling system, component location
page
–
The function of the signals is to increase safety during operation and

load handling. This can be via light and sound. The following signal
systems are fitted to the machine:
NOTE
It is important that the right type of bulb is used for each area. See
7 4
5, 6
3, 5
007790
1
1. Horn 5. Direction indicators
2. Electrically powered loud horn 6. Reverse alarm

3. Flashing hazard lights 7. Back-up lights
4. Revolving beacon 8. Buzzer in cab

42 9 Frame, body, cab and accessories – 9.8 Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, description
page
–
For information and description of equipment, see supplier’s docu-

mentation for each product.

9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors 43
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
B
A
007792
E
Overview, glass windows on the Spirit Delta cab.
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Side windows, front
Hardened glass is standard on all machines with the Spirit Delta cab
C and FlexCab. Tinted windows and laminated glass are optional. Roof
windows for the Spirit Delta are a safety feature and are therefore al-
ways made of polycarbonate plastic. For the FlexGuard cab and Flex-
D Cab the roof window is hardened glass (not a safety feature).
The mirrors are all convex type. The inner rear view mirror is fitted in
B E all machines. Outer rear view mirrors are available, both with (only ap-
plies to the Spirit Delta cab) and without electrical heating.
A As an option the machine can be equipped with a back-up

(reversing) camera and a screen in the cab to improve visibility.
007793
Overview, glass windows on the FlexCab cab.

A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Side windows, rear

44 9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors
Roof window (Spirit Delta cab), checking

–
Check that the roof window does not have cracks or damage. Promptly
change defective roof windows.
DANGER
Applies to the Spirit Delta cab alternative.
The strength of the roof window can be substantially

reduced by exposure to substances that contain aro-
matic hydrocarbons, ketones, esters and chlorinated
hydrocarbons.
Low strength! Fatal danger!
Check the outside surface of the roof window at reg-

ular intervals. Clean only with windscreen washer flu-
id or a mild cleaning agent. Replace a damaged roof
window immediately if it is cracked or scratched!

9 Frame, body, cab and accessories – 9.10 Construction and suspension of cab 45
9.10 Construction and suspension

of cab
Design and suspension, description
page
–
The cab has a flat floor with a bracket for the driver’s seat. It is mount-
ed on a cab undercarriage via strong rubber dampers located on the
underside of the cab. This is designed to minimise vibration from the
1 frame to the cab. Each damper has a rubber bushing and a bolt.
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.1 Cab frame

Cab frame, checking
page
–

2. Check the cab frame with regard to rust damage, deformation or
cracks. Rectify if necessary.

46 9 Frame, body, cab and accessories – 9.10.2 Doors
9.10.2 Doors
Doors, checking
page
–
006914
Spirit Delta

2 Visually inspect the door’s mounting points.
3 Check the door’s locking mechanism with regard to function
and wear.
FlexCab and FlexGuard

9 Frame, body, cab and accessories – 9.10.3 Cab undercarriage 47
9.10.3 Cab undercarriage

Cab undercarriage, checking
page
–

2. Check that the welding seams at the cab’s mounting points are in-
tact and free of visible cracks.
3. Check that the dampers are intact. Replace damaged dampers.

4. Check that the bolted joints are tightened, that the locking devices
function (are not damaged) and that the brackets are undamaged.
Take appropriate action if necessary.
006913

48 9 Frame, body, cab and accessories – 9.10.4 Cab tilting
9.10.4 Cab tilting

Cab tilting, description
page
–
The cab can be tilted up to a certain inclination, above its equilibrium

position, articulated around the suspension on the left-hand side, by
means of a hydraulic cylinder. The hydraulic oil pressure is generated
by a hand-operated pump with an integrated switch valve for up or
down tilting.
There are locking devices on the mounting on the right-hand side
which secure the cab to the frame and they can be easily released for
tilting the cab.
Electric tilting of the cab is available as an option.
A-C D Cab tilting, operating instructions
WARNING
D Never work underneath a cab that is not tilted over its
balance point or secured in another way.
Risk of crushing injury.
Always tilt the cap as far as possible. At maximum tilt-

ing angle (on horizontal surface) arrange the cab’s
centre of gravity so that it does not risk tilting back.
The cab must always be tilted past the centre of gravity position. If
space sideways is insufficient, the cab must always be secured with a
stay to prevent accidental lowering.
Preparation:
• Set the gear and travel direction selector in neutral.
• Tilt the mast forward and lower the forks.
• Apply the parking brake.
• Check that there is nothing loose in the cab.
• Close the doors.
Tilting
1. Turn both lock handles (position D) so that they reach their outer
position to loosen the cab from the frame.
2. Set the pump valve (position C) in the right-hand position.
000859
3. Fit the pump rod in its bracket (position B).

A B C
4. Pump until the cab has reached the end-position.
A. Button for electric tilting
B. Pump rod bracket
C. Pump valve
D. Lock handle (figure shows open position)

9 Frame, body, cab and accessories – 9.10.5 Door stop 49
Lowering
1. Set the pump valve (position C) in the left-hand position.
2. Fit the pump rod in its bracket (position B).
3. Pump all the way until the cab rests on the frame.
4. Turn both lock handles (position D) so that they reach their inner
position to lock the cab to the frame.
Electric tilting
1. Open the hatch for cab tilting.

2. Turn both lock handles (position D) so that they reach their outer
position to loosen the cab from the frame.
3. Set the pump valve (position C) in the right-hand position.
4. Use the control buttons (position A) to raise the cab to end posi-
tion. Press both buttons simultaneously.
Electric lowering
1. Set the pump valve (position C) in the left-hand position.

2. Use the control buttons (position A) to lower the cab to contact
with the frame. Press both buttons simultaneously.
3. Turn both lock handles (position D) so that they reach their inner
position to lock the cab to the frame.
4. Close the hatch.
9.10.5 Door stop

Door stop with gas strut damping, checking
page
–
Check the door stop’s mounting points and joints in terms of wear and
the door stop’s (gas strut) function.
010243

50 9 Frame, body, cab and accessories – 9.11 Cab interior
9.11 Cab interior

Cab interior, description
page
–
The cab is designed for optimal operator comfort. Switches, controls,

warning and indicator lights are grouped on the instrument panels to
provide the operator with a good operating environment.
Recyclable material is used for all parts.
• Dashboard panels
• Interior plastic parts
• Interior textile/fabric parts
• Insulation

9 Frame, body, cab and accessories – 9.12 Frame 51
9.12 Frame
Frame, description
page
–
The frame consists of two longitudinal frame sides cut from steel plate.
Fenders, footsteps, tanks and counterweights are bolted to the frame.
There are mounting points in the frame for steering axle and cab. Bolt-
ed to the frame are brackets for engine, transmission, drive axle and
the fuel and hydraulic tanks, see under each respective function. The
fenders are bolted or welded to the frame, depending on machine
model.
The space in the frame’s rear part is used for counterweights, the
number and size of which are adapted to the machine in question.
11
10 13
11 6
10 13
12
7
3
8
2
6 13
1 4 9
10
000674
1. Frame front section
2. Frame rear section
3. Beam pair
4. Mounting, front fenders
5. Mounting, rear fenders
6. Engine mounting
7. Drive axle mount
8. Steering axle mounts
9. Mast mount
10. Cab mounting
11. Fuel tank mountings
12. Hydraulic oil tank mountings
13. Hood mountings

52 9 Frame, body, cab and accessories – 9.12 Frame
Frame, checking
page
–

2. Look for deformation and rust damage as well as cracks in the
welded joints. Rectify as necessary. See section C Preventive
maintenance.

9 Frame, body, cab and accessories – 9.13 Body structure 53
9.13 Body structure

Body, safety
page
–
WARNING
The hood may be slippery.
Danger of slipping.
It is forbidden to walk on the hood when it has no anti-

slip protection or is not flat.
Body, description
page
–
The function of the body is to be part of the chassis. There are fenders
to deflect dirt, footsteps and handrail to facilitate access to the chassis,
engine hood to deflect dirt and objects from the engine compartment
and a counterweight to balance the machine’s lifting capacity.
3
4
2 011924
1. Fenders, front
2. Fenders, rear
3. Hood
4. Counterweight
5. Battery compartment

54 9 Frame, body, cab and accessories – 9.13.4 Counterweights
9.13.4 Counterweights
Counterweights, checking
page
–
WARNING
Counterweights are factory fitted and are adapted ac-
cording to the machine’s characteristics.
The machine’s operating characteristics are changed.
Never change the number of counterweights.

wheels.
2 Visually inspect that the counterweights are positioned properly
and that the mounts and welding seams are intact and free of vis-
ible cracks.
3 Check the bolted joints.

9 Frame, body, cab and accessories – 9.14 Central lubrication 55
9.14 Central lubrication

Central lubrication, description
page
–
Central lubrication (replaces manual lubrication) is available in differ-

ent variants. The alternatives are:
• Manual central lubrication, hand pumping lubricant at a lubrication
point which is then spread to all selected lubrication points.
• Automatic central lubrication lubricates selected lubrication points
automatically during operation at pre-programmed time intervals.
It is also possible to select the number of lubrication points as follows:
• Total 14 lubrication points: 8 on the steering and 6 on the mast
(the only alternative with manual central lubrication).
and 4 on the carriage.
and 9 on the carriage (with central levelling carriage).
Automatic central lubrication is built up of the following components:
• Pump unit, with lubricant reservoir.
• Distribution block, that distributes and portions the grease be-
tween the different lubrication points.
The distribution blocks lubricate one point at a time. If one point
cannot be lubricated correctly, e.g., in case of stop in a line, then
the following points will not be lubricated. The grease will be
forced out through the safety valve on the pump unit.
1
• Lines, between main unit and distribution block as well as distribu-
tion block and grease nipples.
2
• Grease nipples, at lubrication points.
On the pump unit it is possible to adjust the lubrication interval’s fre-
quency and duration.
3 The central lubrication is supplied with voltage when the parking brake
is released.
007794
NOTE
1. Pump unit
Central lubrication does not lubricate all lubrication points, some
2. Safety valve
still need to be lubricated during preventive maintenance.
3. Distribution block

56 9 Frame, body, cab and accessories – 9.14 Central lubrication
Central lubrication, checking

page
–
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
1 by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
2
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
3 bution block.
4 2 Turn the start key to position I.

3 Operate the pump manually and check that the indicator pin (po-
sition 3) moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in switch man-
5 ual operation (position 5).
If the indicator pins do not move even when the pump is running,
007795
troubleshoot the pump unit.
Overview, central lubrication. Example illustration. NOTE

1. Lubricant nipple, filling point, lubricating grease The system can be lubricated manually through the grease
2. Safety valve nipple on the distribution block (position 4).
3. Indicator pin
4 Fill grease in the pump unit through the filler nipple (position 1),
4. Lubricant nipple, manual lubrication of the system
see section F Technical data.
5. Switch, manual operation

9 Frame, body, cab and accessories – 9.15 Paint/coatings 57
9.15 Paint/coatings
Paint/surface finish, description
page
–
The machine is painted with paint that is applied with a brush or a

sprayer. For paint codes (RAL), see machine card.
Check the machine often for stone-chips, dings and scratches in the
paint and repair them promptly to prevent corrosion of the metal un-
derneath. Use touch-up paint only on small stone-chips and scratches,
larger damage to the paint should be repaired at a paint shop.
NOTE
Before touch-ups are made, the surface area must be thoroughly
cleaned.
For information on other surface and material colours, contact
Cargotec.

58 9 Frame, body, cab and accessories – 9.15 Paint/coatings

10 Common hydraulics 1
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 5
10.3 Tanks and accumulators ............................................................................ 6
10.3.2 Accumulator ........................................................................................... 7
10.4 Pumps ........................................................................................................ 8
10.5 Hoses, pipes and valves ............................................................................ 9
10.5.2 Main valve ............................................................................................ 11
10.6 Temperature control, cleaning and hydraulic oil ....................................... 13
10.6.2 Hydraulic oil cooler .............................................................................. 14
10.6.7 Breather filter hydraulic oil tank ........................................................... 15
10.6.8 High-pressure filter .............................................................................. 16
10.6.9 Hydraulic oil ......................................................................................... 18

2 10 Common hydraulics

10 Common hydraulics 3
mm mm mm mm mm mm
Common hydraulics, description

page
–
The common hydraulics function includes hydraulic functions that are

common to several of the machine’s main functions. For example, hy-
draulic oil pumps that supply load handling, steering, the brake system
and certain cab functions with hydraulic pressure.

4 10 Common hydraulics
Pressure plate
There is a pressure plate on the machine, stamped with the most im-
portant pressures. The pressure plate is located on the right-hand side
of the frame in front of the steps.
Pressure levels vary with the equipment and are therefore unique to
each machine. When checking pressure, the pressures should match
the pressure plate.
1 2 3
5 4 014018
011940
1. Max. pressure lift cylinders 4. Servo pressure, load handling functions

2. Steering pressure 5. Gas pressure servo accumulator
3. Max. brake pressure

10 Common hydraulics – 10.2 Safety valves 5
10.2 Safety valves

Safety valves, component location
page
–
An accumulator drain valve is fitted in the valve block. The accumula-

tor must be drained before work on the hydraulic system using its con-
trols. To drain the hydraulic system, see section B Safety.
To verify that the accumulator pressure has been released, measure
with a pressure gauge at the pressure test outlet for the accumulator
charging valve (see Measuring nipples, component location page 11).
008845
Accumulator drain valve’s controls

6 10 Common hydraulics – 10.3 Tanks and accumulators
10.3 Tanks and accumulators

Tanks and accumulators, component location
page
–
A. Sight glass
B. Breather filter
C. Filling point
B A C
A B C
007520

10 Common hydraulics – 10.3.2 Accumulator 7
10.3.2 Accumulator
Accumulator, checking
page
–
1 Start the machine and allow it to idle (until the accumulator charg-
ing valve switches to cooling).
2 Switch off the engine and turn the start key to position l.
3 Depress the brake pedal with long pumping brake pedal applica-
tions, with a slight delay between each braking action. Count the
number of brake pedal applications until the accumulator is
drained, i.e. when the depression resistance of the pedal has
disappeared.
It must be possible to brake six times before the accumulator is
drained.
4 Start the engine, let the accumulator charge and repeat the test
a couple of times.
If it is not possible to brake six times before the accumulator is drained
then there is a fault in the accumulator. Contact service as soon as
possible for troubleshooting and action.
WARNING
The machine’s hydraulic system contains a high-
pressure accumulator.
Risk of personal injury!
Always be very careful when working with the hydrau-

lic system, and avoid standing close to hydraulic
components or hoses. Before working on the hydrau-
lic system, the accumulator must be drained
(see Maintenance manual).

8 10 Common hydraulics – 10.4 Pumps
10.4 Pumps
Pumps (fixed displacement), general information
page
–
The machine’s hydraulics are supplied as standard from three gear

3 pumps with fixed displacement. They are driven by splines from the
engine. The pump shafts are journalled with slide bearings which are
lubricated by the oil flowing through. The pumps have the following
functions:
1. Pump 1 supplies the steering system and load handling. A priority
valve in the valve block ensures that there is always pressure for
the steering system, the residual flow goes to load handling.
2. Pump 2 supplies lift and tilt.
1
3. Pump 3 supplies the brake system’s brake and cooling circuit over
2 an accumulator charging valve as well as the servo circuit for load
handling.
The pumps are assembled into 2 pump banks which are mounted to
007788
the transmission’s power take-off.
Hydraulic oil pumps in standard version, A hydraulic oil pump is added for Optimum lift .
transmission alternative Dana.
1. Hydraulic oil pump for steering and load handling A hydraulic oil pump is added for joystick control/mini-wheel .
2. Hydraulic oil pump for lift and tilt
3. Hydraulic oil pump for brake system and servo cir-
cuit for load handling
2
014753
1
3
Hydraulic oil pumps in standard version,
transmission alternative ZF.
1. Hydraulic oil pump for steering and load handling
2. Hydraulic oil pump for lift and tilt
3. Hydraulic oil pump for brake system and servo cir-

10 Common hydraulics – 10.5 Hoses, pipes and valves 9
10.5 Hoses, pipes and valves

Hoses, pipes and valves (main valve),
page
–
component location
The main valve (made up of a valve block and two control sections,
with directional control valves) is actuated in standard version over hy-
draulic servo from the operator’s station.
Main valve controlled via hydraulic servo

1. Valve block
2. Directional control valve (lifting/lowering and tilt)
3. Directional control valve (side shift, spreading and levelling)
4. Lifting/lowering section
5. Tilt section
6. Side shift section
1 7. Spreading section
8. Levelling section
9. Inlet section
8
7
6
3
9
5
008310
4 2

10 10 Common hydraulics – 10.5 Hoses, pipes and valves
Main valve controlled via electric servo
1. Valve block
2. Directional control valve (lifting/lowering and tilt)
3. Directional control valve (side shift, spreading and levelling)
4. Lifting/lowering section
5. Tilt section
18
16 6. Side shift section
14
7. Spreading section
1 8. Levelling section
13 9. Inlet section
12
11 8 10. Solenoid valve, lower (Y6004)
10
7 3 11. Solenoid valve, lift (Y6005)
6 12. Solenoid valve, tilt out (Y6010)
19 13. Solenoid valve, tilt in (Y6011)
17
15 14. Solenoid valve side shift left (Y6020)
15. Solenoid valve side shift right (Y6021)
9
5 16. Solenoid valve, spreading in (Y6019)
008311
4 17. Solenoid valve, spreading out (Y6018)

2
18. Solenoid valve, levelling up (Y6022)
19. Solenoid valve, levelling down (Y6023)

10 Common hydraulics – 10.5.2 Main valve 11
10.5.2 Main valve

Measuring nipples, component location
page
–
On the main valve there are a number of measuring nipples and ad-
justment options for certain functions. Most measuring nipples are lo-
cated on the valve block and one or two on the directional control
valves.
For the pressure value for the different measuring nipples, see the
pressure plate (located beside the cab tilting control for the machine).
3
2
1
5
10
9
8
7
008312
6
4
1. Pressure limiting valve for lift and tilt

2. Measuring nipple, pressure for side shift and spreading (PM)
3. Accumulator drain valve
4. Measuring nipple, pressure for lift and tilt (P2)
5. Measuring nipple, pressure for steering (LSM)
6. Pressure limiting valve for steering
7. Measuring nipple, pressure for servo control levers (PPM)
8. Adjusting the pressure for servo control levers (PP)
9. Measuring nipple, pressure for accumulator (ACCM)
10. Accumulator charging valve (adjustment of max. pressure for
accumulator)

12 10 Common hydraulics – 10.5.2 Main valve
Hydraulic pressure, checking

page
–
NOTE
section B Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, approx. 50 C.
2 Turn off the engine.
3 Connect a pressure gauge to the measuring outlet in question on
the main valve, see the figure under Measuring nipples, compo-
nent location page 11 for positioning of the measuring nipples.
4 Start the engine. Check each of the functions in accordance with
below.
Accumulator charging (ACCM)
– Allow the accumulator to charge until its charging changes
over to cooling the brakes. Read the pressure and compare
with the permissible pressure on the pressure plate.
– Brake repeatedly and read the pressure at which the accumu-
lator starts charging again, should be approx. 13.5 MPa.
Steering (LSM)
– Increase engine speed to approx. 1100 rpm.
– Turn to max. steering right or left and continue to activate the
function.
– Read the pressure and compare with the permitted pressure
on the pressure plate.
– Increase engine speed to approx. 1800 rpm. Read the pres-
sure again, the difference should be max. ±1.0 MPa.
Lift and tilt (P2)
– Activate tilt in to its end position and continue to activate the
function.
– Increase engine speed to approx. 1800 rpm. Read the pres-
Sign with pressure data sure again, the difference should be max. ±1.0 MPa.
Side shift, spreading (PM)
– Activate side shift or spreading to an end position and contin-
ue to activate the function.
– Read the pressure and compare with the permissible pres-
sure on the pressure plate, the difference should be max.
±1.0 MPa
Servo pressure for control levers (PPM)
5 To adjust the hydraulic pressure, see Workshop Manual
DCE 90-180.

10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 13
10.6 Temperature control,

cleaning and hydraulic oil
page
–
The hydraulic system’s oil is cleaned through high pressure filters lo-
cated after each hydraulic oil pump.
The cooling system lowers the temperature of the machine’s hydraulic

oil. The cooling system consists of a hydraulic oil cooler with separate
temperature-controlled electric fan fitted in the wheel brakes’ cooling
circuit.
The hydraulic oil pump pumps oil (from the tank) via the high-pressure
filter and the valve block and it is cooled in the hydraulic oil cooler. An
electric cooling fan increases the air flow through the cooler when the
temperature needs to be reduced. A thermal bypass valve leads the
hydraulic oil past the cooler directly to the tank if the temperature is be-
low 55 °C. When the oil temperature above 65 °C all the oil is led
through the cooler.
The temperature sensor starts the electric fan if the oil temperature is
above than 60 °C and switches off the fan when it is below 50 °C.
˚C 5
7
3 4 8
M
COOL
6
PA
TA
C 9
2 C
1
007462
1. Hydraulic oil pump 3 for brake system and servo cir- 6. Relay (K359)
2. High-pressure filter 7. Cooling fan (M668)
3. Valve block 8. Radiator
4. Thermal bypass valve 9. Wheel brake
5. Make-contact (closing switch) hydraulic oil tempera-
ture (S240-1)

14 10 Common hydraulics – 10.6.2 Hydraulic oil cooler

page
–
component location
3
4
5
2
7 6
007700
1. Thermal bypass valve 5. Tank heater
2. Make-contact (closing switch) cooling fan 6. High-pressure filter

3. 7. Hydraulic oil pump 3 for brake system and servo circuit
Hydraulic oil cooler
for load handling
4. Cooling fan 8. Breather filter hydraulic oil tank
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, cleaning
page
–

2 Clean the hydraulic oil cooler (position A) using compressed air.
Blow away dust and other loose dirt.
A
001990

10 Common hydraulics – 10.6.7 Breather filter hydraulic oil tank 15
10.6.7 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, changing
page
–

2 Clean the area around the breather filter.
3 Remove the breather filter.
4 Fit the new breather filter.

16 10 Common hydraulics – 10.6.8 High-pressure filter
10.6.8 High-pressure filter

High-pressure filter, changing
page
–
There are three hydraulic oil filters located in the engine compartment.
Two large and one small (a large filter is added for the mini-wheel/joy-
stick control option). The method describes changing one filter, but it
applies to all filters.
NOTE
section B Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
Equipment: Receptacle for hydraulic oil (5 l)

Consumables: Universal grease EP2.
2 Depressurise the hydraulic system, see section B Safety.
3 Tilt the cab.
4 Clean the filter cover externally.
5 Place a receptacle under the hydraulic oil filters.
6 Remove the drain plugs in the bottom of the filters.
Let the oil drain. Wait a while since the oil drains slowly.
7 Remove the filter cover.
NOTE
The filter cover is heavy, loosen it carefully.
9 Fit the small O-ring, which is located in the packaging, onto the
new filter.
In case of doubt, compare with the old filter insert.

10 Common hydraulics – 10.6.8 High-pressure filter 17
10 Fit the new filter insert in the filter holder.
NOTE
Use only original filters.
11 Fit a new support ring (white) and O-ring (black), which are locat-
ed in the packaging with the new filter, in the groove on the top of
the filter cover.
NOTE
It is important to fit the support ring under the O-ring as illustrated.
12 Lubricate the top of the filter cover (on the side) with universal
grease EP2.
13 Fit the filter cover.
14 Start the engine and check that there are no leaks.
15 Turn off the engine.
16 Check the hydraulic oil level, see Hydraulic oil, level check
page 18.

18 10 Common hydraulics – 10.6.9 Hydraulic oil
10.6.9 Hydraulic oil

Hydraulic oil, level check
page
–
NOTE
Check the hydraulic oil level with the trolley completely lowered
and the mast tilted completely inward.
1 Machine in service position, section B Safety.

2 Check the oil level in the hydraulic tank. The oil level should be
visible in the level glass. Top up with oil when needed. For oil
grade, see section F Technical data.
Hydraulic oil, checking

page
–
The condition of the hydraulic oil must be checked with oil tests aimed
at avoiding unnecessary wear and unnecessary oil changes. The in-
tervals for oil tests are advised in the service schedule. Oil tests are
carried out as per instructions from the relevant institution or oil
supplier.
Threshold value for efficient oil is 18/14 according to SS-ISO 4406
"Hydraulic equipment - fluids - Method for classifying impurities
through fixed particles".
Hydraulic oil, changing

page
–
NOTE
section B Safety.
IMPORTANT
Ensure cleanliness around the filling point when
working on the hydraulic tank.
Dirt particles may cause machine damage.

2 Place a receptacle under the drain plug.

10 Common hydraulics – 10.6.9 Hydraulic oil 19
3 Remove the drain plug.

4 Allow the hydraulic oil to run out into the container.
5 Fit the drain plug.
NOTE
6 Clean the area around the filler cap.

7 Remove the filler cap.
8 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see High-pressure filter, changing
page 16.
9 Fill with new hydraulic oil until the oil level is in the centre of the
sight glass.
10 Fit the filler cap.
NOTE

20 10 Common hydraulics – 10.6.9 Hydraulic oil

11 Common electrics 1
11 Common electrics
Table of Contents 11 Common electrical

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2 Electrical protection .................................................................................... 4
11.2.2 Fuses ..................................................................................................... 5
11.3 Batteries ..................................................................................................... 8
11.3.1 Start battery ........................................................................................... 8
11.4 Alternator .................................................................................................. 11
11.5 Distribution of electricity ........................................................................... 12
11.5.1 Voltage feed ......................................................................................... 12
11.5.2 Electronic box ...................................................................................... 13
11.5.3 Control units ......................................................................................... 15
11.6 Communication ........................................................................................ 17
11.6.1 CAN bus .............................................................................................. 17
11.6.2 Redundant CAN-bus ............................................................................ 17
11.6.3 CAN-bus drivetrain .............................................................................. 17

2 11 Common electrics

11 Common electrics 3
11 Common electrics
mm mm mm mm mm mm
Common electrics, general

page
–
The function group common electrical includes electrical functions that

are common to several of the machine’s main functions. For example,
voltage feed and CAN-bus.

4 11 Common electrics – 11.2 Electrical protection
11.2 Electrical protection

Electrical protection, component location
page
–
1. Circuit fuses, electrical distribution box cab

2. Circuit fuses, engine alternative Cummins
3. Circuit fuses, engine alternative Caterpillar
1 4. Main fuses
5. Battery disconnector
6. Control switch
6 2
5 4 3
009370

11 Common electrics – 11.2.2 Fuses 5
11.2.2 Fuses
Fuses, checking
page
–
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
The electrical system has two main circuits (30 and 15-voltage), see
Distribution of electricity, general page 12. The main circuits are fused
several times with main fuses and circuit fuses.
Main fuses
The main fuses divide the machine’s voltage feed into smaller parts to
maintain as many functions as possible in case of damage to cables
harnesses.
The machine’s electrical system has main fuses in the battery com-
partment on the frame, 4 x 25 A. They disconnect all electrical power,
except fuse number 7 in fuse holder F58-3 and fuse number 8 in fuse
holder F58-4.
When checking and replacing the main fuse:
1. Disconnect the main electric power with the battery disconnector
(position 2).
2. Remove the plastic cover.
3. Check and replace fuses if necessary. Fuses are 25 A.
4. Reconnect the main electric power again.
1
007703
1. Main fuses (25 A)

2. Battery disconnector

6 11 Common electrics – 11.2.2 Fuses
Circuit fuses
The circuit fuses are grouped in fuse holders which are located in the
electronic box in the cab. The electronic box is located behind the driv-
er’s seat in the cab.
Adjacent to the electronic box is a fuse plate describing the
various fuses.
A B C D
007482
Fuses
A. Fuse holder F58-1
E B. Fuse holder F58-2

C. Fuse holder F58-3
D. Fuse holder F58-4
E. Fuse holder F56 (engine alternatives Cummins)
007938

11 Common electrics – 11.2.2 Fuses 7
F. Fuse holder F52 (engine alternative Caterpillar)

F
009114
When checking and replacing fuses:
1. Disconnect the main electric power with the battery disconnector.
2. Remove the cover of the electronic box.
3. Remove the cover from the fuse holder.
4. Check that fuses are intact, change if needed.
Measure and check if necessary.
The fuse plate provides information on each fuse.

8 11 Common electrics – 11.3 Batteries
11.3 Batteries
11.3.1 Start battery
Battery, component location
page
–
The batteries, two connected in series, are located behind a cover lid
on the machine’s rear left-hand side (by the fuel tank).
The battery’s negative terminal is connected to the frame and the pos-
itive terminal is connected to the battery disconnector.
001387

11 Common electrics – 11.3.1 Start battery 9
Start battery, checking

page
–
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use goggles and gloves when working with the bat-

teries. Immediately remove electrolyte from the skin.
Wash with soap and plenty of water. If electrolyte gets
in the eyes, rinse with plenty of water and seek medi-
cal attention immediately.
1. Check the battery’s acid gravity with a hydrometer or optical bat-

tery indicator if the battery is equipped with one. In a fully charged
battery the acid gravity should be 1.28 g/cm3.
If the acid value is lower than 1.24 at +20 C then the battery must
be charged.
NOTE
A discharged battery freezes at -5 C.
NOTE
If the acid gravity differs between the batteries they must be
charged separately.
2. The fluid level should be level with the top of the round white plas-
tic ring that is visible down in the battery when the cover is
unscrewed.
NOTE
Use only distilled water if topping up is necessary.
3. Check that the batteries are clean on the top to prevent leakage
currents between cells, which can cause reduced battery
capacity.
Wipe clean with a cloth and clean warm water without detergent.
4. Check that the battery terminals are free from dirt. When needed,
lubricate the battery terminals with terminal grease.

10 11 Common electrics – 11.3.1 Start battery
Battery cables, checking

page
–
WARNING
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of serious injury!
Repair or replace damaged clamps and check that no

machine parts wear or chafe against the battery ca-
bles. Replace damaged battery cables.
The following battery cables must be checked for clamping, risk of

chafing and damage to the battery cables. Rectify incorrect clamping
and risks of chafing. Replace battery cables that show signs of
damage.
Diesel-powered machines
• Plus-cable between battery and battery disconnector.
• Plus-cable between battery and starter motor.
• Plus-cable between starter motor and alternator.
• Plus-cable between battery disconnector and main fuses.
• Plus-cable between starter motor and preheating relay.
• Plus-cable between preheating relay and preheating coil.
• Ground cable between battery and frame.
• Ground cable between engine and frame.

11 Common electrics – 11.4 Alternator 11
11.4 Alternator
Alternator, component location
page
–
The alternator is fitted on the engine. Location is dependent on engine

alternative.
007767
Volvo TAD650VE, TAD660VE, TAD750VE and

TAD760VE
009546
Caterpillar C6.6
007767
Cummings QSB6.7

12 11 Common electrics – 11.5 Distribution of electricity
11.5 Distribution of electricity

Distribution of electricity, general
page
–
This section describes distribution of electric power and communica-

tion between the control units. Distribution of electricity describes the
foundation of the electrical system and the network of control units
The system’s communication has three main parts:
• Voltage feed of control units
• Redundant CAN bus communication (no control unit can drop out
without the system losing all function)
See CAN-bus, description page 17.
• CAN bus communication for drivetrain (the drivetrain has its own
communication system)
See CAN-bus drivetrain, description page 17.
11.5.1 Voltage feed

11.5.1.1 Battery voltage, 30-voltage
Battery voltage, 30-voltage, description
page
–
The voltage before the ignition key lock is normally called 30-voltage.
This is always approx. 24 V, even if the ignition is switched off
(ignition key in position 0).
11.5.1.2 Ignition voltage, 15 volts

Ignition voltage, 15 volts, description
page
–
The voltage after the ignition key lock is normally called 15-voltage.
This is at 24 V, only if the ignition is switched on (ignition key in
position 1). Otherwise this voltage is 0 V.
11.5.1.3 Frame connections

Frame connections, description
page
–
Power supply takes place with cable harnesses (cables) which are
routed across the machine.
Communication takes place via twinned pair signal cable (30 rpm).
Grounding points, description

page
–
A grounding point in the frame acts as main ground, including for the
starter motor. From there the ground is routed to a common point in
the electronic box to which all current consumers’ grounds are
connected.

11 Common electrics – 11.5.2 Electronic box 13
11.5.2 Electronic box

Electronic box, component location
page
–
1 2 3 4 5 6 7
9 10 11 12 13 14 15
007759
16 17
Electronic box

14 11 Common electrics – 11.5.2 Electronic box
1 2 3 4 5 6 7
9 10 11 12 13 14 15
008571
16 17
Electronic box, machine with turnable driver’s seat.
1. Relay, intermittent wipers 10. Bolts, holders and straps
2. Relay, ignition 11. Socket, relay 5-pin
3. Relays 12. Socket, relay 9-pin
4. Fuse holder F58-2 13. Flasher unit, 200 W, 24 V
5. Fuse holder F58-3 14. Mini relay
6. Fuse holder F58-4 15. Fuse holder F58-1
7. Fuse holder 16. Cable terminal, washer and screw
8. Sleeve block with 9 pins 17. Fitting plate
9. Circuit board with diodes

11 Common electrics – 11.5.3 Control units 15
11.5.3 Control units

Control units, general
page
–
Part of the machine’s different functions is managed by the control

system KCS, see section 8 Control system, where each control unit is
allotted responsibility for a number of functions.
Control units ECU 790, ECU 792 and ECU 796 have indicator lights
that can be used to check basic information on control unit status.
Indicator lights have the following significations:
Table 1. Indicator lights ECU 790 and ECU 792
A B C D
Green Battery voltage OK.
(Power)
Green Internal 5 VDC OK

ECU 792 ECU 796 ECU 790 (System)
Yellow (Mode) Software check, flashes 0.5 Hz if the program is

OK, flashes 5 Hz if no program is loaded, fixed
light if in setup mode
0007760
Red (Status) Illuminates if a fault arises.

A. ECU 792
B. ECU 796 Table 2. Indicator lamps ECU 796
C. ECU 790
All LEDs illuminate with fixed light for 3 seconds when starting up.
D. Electronic box
Green Power, fixed light at 22-28 VDC, flashing if out-
side limits
Yellow CAN bus communication and application OK
Red Flashes if the supply voltage for the PWM card is

under 12 VDC.

16 11 Common electrics – 11.5.3 Control units
Control units, position

page
–
1 2 3 4
9 8 7 6 5
009547
1. Control unit, steering (ECU 792) 6. Control unit, transmission ZF (ECU 793)
2. Control unit, hydraulics (ECU 796) 7. Control unit Volvo engine (ECU 794)
3. Control unit general (ECU 790) 8. Control unit Cummins engine (ECU 794)
4. Control unit terminal (EDU 795) 9. Control unit Caterpillar engine (ECU 794)
5. Control unit, transmission Dana (ECU 793)

11 Common electrics – 11.6 Communication 17
11.6 Communication
Communication, general
page
–
The machine’s communication is handled by a so-called CAN-bus

ECU 792 system. The CAN-bus system consists of control units connected to
1 form a network.
The idea with a network is to share the information. Signal values are
sent out by the control unit that, e.g., is connected to a sensor, other
ECU 790 EDU 795 ECU 796 control units can use the signal for their functions.
The network consists of control units and segments. Segment is the
2 CAN-bus between the control units.
007764
ECU 794 ECU 793
1. Segment
2. CAN-bus drivetrain
11.6.1 CAN bus

CAN-bus, description
page
–
The CAN-bus consists of two twisted cables (twisted pair).
11.6.2 Redundant CAN-bus

Redundant CAN-bus, description
page
–
Redundant CAN-bus means that every control unit has two connec-
ECU 790 EDU 795 ECU 796 tions for communication. The CAN-bus is connected in series between
CAN R CAN L CAN R CAN L CAN R CAN L
the control units. This means that the CAN-bus can handle loss of a
segment. If several segments fail, some or a few control units lose
contact with the network and work independently often with limited ca-
High+/Low- pacity to perform its task.
007765
ECU 792
Signals can be checked with diagnostic menu.
Principle illustration redundant CAN-bus
11.6.3 CAN-bus drivetrain

CAN-bus drivetrain, description
page
–
The communication with Control unit engine (ECU 794) and Control
EDU 795 unit transmission (ECU 793) is separated from the redundant
CAN-bus.
Signals can be checked with diagnostic menu.
007766
ECU 794 ECU 793
Principle illustration CAN-bus drivetrain

18 11 Common electrics – 11.6.3 CAN-bus drivetrain

D Error codes – Error codes 1
D Error codes
Error codes
mm mm mm mm mm mm
Information is found in the

page
–
Workshop manual
Information is found in the Workshop manual.
For information how to order Workshop manual, see
section A Foreword.

2 D Error codes – Error codes

E Schematics – Diagrams 1
E Schematics
Diagrams
mm mm mm mm mm mm
Information is found in the

page
–
Workshop manual
Information is found in the Workshop manual.
For information how to order Workshop manual, see
section A Foreword.

2 E Schematics – Diagrams

F Technical data 1
F Technical data
Table of Contents F Technical data

mm mm mm mm mm mm
Technical data ................................................................................................ 3

Specifications for data and volume ........................................................................ 3
Specifications for lifting capacity and dimensions .................................................. 8
Oils and lubricants, recommendation ................................................................... 11
Tightening torques, recommendations ................................................................. 14
Tightening torque, ORFS connections ................................................................. 15
Tightening torque, connections for air conditioning unit ....................................... 17
Unit explanations .................................................................................................. 17
Conversion table, SI units .................................................................................... 18
Conversion table, length ....................................................................................... 19
Conversion table, area ......................................................................................... 19
Conversion table, volume ..................................................................................... 19
Conversion table, mass ........................................................................................ 20
Conversion table, pressure .................................................................................. 21

2 F Technical data

F Technical data – Technical data 3
Technical data
mm mm mm mm mm mm
Specifications for data and volume

page
–
Data
1 Engine Volvo Volvo Volvo Volvo Cummings Caterpillar

TAD650VE TAD660VE TAD750VE TAD760VE QSB6.7 C6.6
Power acc. to ISO 3046 (net 147 kW at 147 kW at 181 kW at 181 kW at 164 kW at 136 kW at
power) 2300 rpm 2300 rpm 2300 rpm 2300 rpm 2200 rpm 2200 rpm
136 kW at 145 kW at 181 kW at 184 kW at or
2000 rpm 2000 rpm 2000 rpm 2000 rpm 129 kW at
2200 rpm
Torque ISO 3046 750 Nm at 800 Nm at 1050 Nm at 1100 Nm at 949 Nm at 802 Nm at

1600 rpm 1600 rpm 1500 rpm 1500 rpm 1500 rpm 1400 rpm
or
799 Nm at
1400 rpm
Alternator 2240 W 1960 W 2100 W
Battery 2 x 12 V - 140 Ah
1.3 Engine, device for additional exhaust cleaning system

Particle filter K 18 S 18
Voltage 400 V 400 V
Output 3.3 kW 13.5 kW
2 Transmission Dana-Spicer Off Highway ZF
TE13000 TE17000 3WG161
No. of gears, forward - reverse 3–3 3–3 3–3
Stall speed 1805 rpm (engine: 1914 rpm (engine: 1964 rpm (engine:
TAD650VE, TAD660VE) TAD750VE, TAD760VE) TAD650VE, TAD660VE)
1926 rpm (engine: C6.6) 1879 rpm (engine:
1891 rpm (engine: QSB6.7, 164 kW)
QSB6.7, 129 kW)
3.3 Driveline/Axle, drive DCE90-180/DCE70-32E3 DCE70-35E4

axle
Drive axle, type Kessler D81 Kessler D81
Drive axle, mounting Tightening torque 650 Nm
Propeller shaft, mounting Tightening torque 98 Nm

4 F Technical data – Technical data
4 Brakes
Footbrake system - wheels Wet Disc Brake - Drive wheel

affected
Parking brake system - wheels Spring brake - Drive wheels

affected
Brake pedal – pedal pressure 27 bar (with half depressed pedal)

100 bar (with fully depressed pedal)
4.3 Power-assisted brake

system Accumulator
Pre-charge pressure nitrogen 70 bar

gas
Max. accumulator pressure 165 bar
5 Steering
Steering system Hydraulic servo
Mini-wheel 2-channel potentiometer
Joystick – Resistance 5 kohm
6 Suspension DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE
90- 100- 120- 140- 150- 100- 120- 150- 160- 160- 160- 180- 70- 70-
6 6 6 6 6 12 12 12 6 9 12 6 32E3 35E4
Dimension, front 11.00 - 20/16PR 12.00 - 20/20PR 12.00 12.00 - 20/

and rear - 20/ 20PR
20PR
HD
Tyre pressure, 0.9 MPa 1.0 MPa 0.9 MPa

also see pressure
NB! Michelin tyres must have 1.0 MPa tyre pressure.
plate
Tyre type, front Air-inflated. Spare and replacement tyres must be of a brand approved by Kalmar Industries.
and rear
Wheel nuts, tight- 650 Nm

ening torque

9 Frame, body, cab and Spirit Delta FlexCab FlexGuard

accessories
Equivalent sound pressure level max 73 dB(A) max 78 dB(A) max 85 dB(A)
in cab in accordance with
EN12053. LpAz (Internal).
9.4 Frame, body, cab and ac- Spirit Delta FlexCab FlexGuard
cessories, heating, ventilation
and air conditioning.
Specified heat input 10 kW at -10 °C 5.5 kW at -10 °C -
9.6 Lighting system
Light Rating (W) Socket

Instruments 3 Ba7s
Control lights 1.2 W2x4.6d
Interior lighting 10 S8.5
Rear light, red 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Running lights 5 SV8,5
Headlights (high, low beam) 75/70 P43t-38 (H4)
Back-up light, white 70 PK22s (H3)
Work light 70 PK22s (H3)
35 D1S Xenon tube. Insert and ballast

Work light, Xenon
replaced complete.
Revolving beacon 70 PK22s (H1)

Volumes
For oil types see Oils and lubricants, recommendation page 11.
1.2 Engine, fuel DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE
system 90- 100- 120- 140- 150- 100- 120- 150- 160- 160- 160- 180- 70- 70-
6 6 6 6 6 12 12 12 6 9 12 6 32E3 35E4
Fuel tank, volume 140 l 200 l
Fuel quality Diesel, in accordance with EN590

WARNING!
It is important that only fuel in accordance with specified standards is used.
1.7 Engine, cooling system Volvo TAD650VE Volvo TAD750VE Cummings QSB6.7 Caterpillar C6.6
Coolant volume 35 l 40 l 40 l (164kW) 40 l

40 l (129kW)
Coolant, filling and changing Volvo Penta Coolant VCS, ready-mixed ES Compleat, Cat ELC 50/50
Premix Premix
BEWARE!
Risk of engine damage if different types of coolant are mixed.
When changing and topping up coolant, only use coolant of the same type that was used
before.
1.8 Engine, lubrication Volvo TAD660VE Volvo TAD760VE Cummings QSB6.7 Caterpillar C6.6
system
Oil type, quality See Oils and lubricants, recommendation page 11.
Oil volume 15,5 l for change 21,5 l for change 20 l 15.5 l when
(16 l total) (23 l total) changing
(17.4 l total)
2.6 Transmission, Dana TE13FF Dana TE17FF ZF 3WG161

lubrication system
Oil type, quality See Oils and lubricants, recommendation page 11
Oil volume 35 l 33 l
3.3 Driveline/Axle, drive DCE90-180/DCE70-32E3 DCE70-35E4

axle
Oil grade See Oils and lubricants, recommendation page 11.
Oil volume, differential 17.5 l 18.5 l
Oil volume, hub reduction 2x2 l

9 Frame, body, cab and FlexCab Spirit Delta

accessories
Refrigerant air conditioning R134a
Volume refrigerant 1200 g (see sign for air conditioning) 2200 g (see sign for air conditioning)
Lubricant in air conditioning ZXL100PG ZXL100PG
Volume, lubricant 0.15 l 0.32 l
Volume, washer fluid 2.0 l
10 Common DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE
hydraulics 90- 100- 120- 140- 150- 100- 120- 150- 160- 160- 160- 180- 70- 70-
6 6 6 6 6 12 12 12 6 9 12 6 32E3 35E4
Oil grade See Oils and lubricants, recommendation page 11.
Oil additive Lubrizol 3%
Hydraulic system 205 l 225 l

volume

Specifications for lifting capacity

page
–
and dimensions
DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE DCE
90- 6 100- 120- 140- 150- 100- 120- 150- 160- 160- 160- 180- 70- 70-
6 6 6 6 12 12 12 6 9 12 6 32E3 35E4
Lifting capacity
Classification 9 10 12 14 15 10 12 15 16 16 16 18 7 7
(kg x 103)
Centre of 600 1200 600 900 1200 600 1220

gravity
distance
(L4 [mm])
Dimensions
Truck length 4470 4720 4725 4985 5055 5065 5315 5325 530 5315 5575 5065 5595 5845
without forks 5
(L [mm])
Truck width 2480 2540 2900

(B [mm])
Height, base 2895 2920

machine,
Spirit Delta
(H6 [mm])
Height, base 2995 3020

machine,
FlexCab (H6
[mm])
Seat height 1770 1790

(H8 [mm])
Axle distance 2750 3000 3250 3500 3750 3250 3500

(L3 [mm])

90- 6 100- 120- 140- 150- 100- 120- 150- 160- 160- 160- 180- 70- 70-
6 6 6 6 12 12 12 6 9 12 6 32E3 35E4
Distance 895 900 910 980 990 1000 980 990 1000 990 1265 1265
drive axle -
fork front
shank surface
(L2 [mm])
Track (front - 1840 - 1960 1855 - 1960 2210 -

rear) (T [mm]) 1960
Minimum 3950 4180 4360 4785 5175 4360 4785

turning radi-
us, outer
(R1 [mm])
Slewing radi- 75 125 420 600 125 420

us, inner
(R2 [mm])
Ground clear- 250 250

ance, min
[mm]
Height for cab 3370 (3450) 3395 (3475)

tilting, max.
(OHG)
(T1 [mm])
Width for cab 3350 (3440) 3380 (3470)

tilting, max.
(OHG)
(T2 [mm])
Minimum 6240 6470 6475 6665 6735 7945 8370 8380 716 8160 8770 6745 8900 9200
track width for 0
90 stacking
with forks
(A1 [mm])
Kerb weight 15.2 15.6 16.2 16.9 19.8 18, 6 19.7 21.4 19.2 20.6 22.4 21,1 22.9 23.9
[kg x 103]
Axle load 7800 8100 8300 8400 1030 1000 1010 9400 100 9600 1050 9800 14700 15600
pressure 0 0 0 00 0
front, (with-
out load) [kg]
Axle load 2170 2310 2650 2890 3265 2670 2960 3380 332 3420 3580 3660 27100 27600
pressure 0 0 0 0 0 0 0 0 00 0 0 0
front, (with
classified
load) [kg]

90- 6 100- 120- 140- 150- 100- 120- 150- 160- 160- 160- 180- 70- 70-
6 6 6 6 12 12 12 6 9 12 6 32E3 35E4
Axle load 7400 7500 7900 8500 9500 8600 9600 1200 920 1100 1190 1130 8200 8300
pressure rear, 0 0 0 0 0
(without load)
[kg]
Axle load 2500 2500 1900 2000 2150 1900 2100 2600 200 2400 2600 2500 2800 3300
pressure rear, 0
(with classi-
fied load) [kg]

Oils and lubricants,

page
–
recommendation
The service intervals specified by Cargotec in the maintenance man-
ual only apply if oils are selected according to the table below. The ta-
ble indicates recommended viscosity for different oil types and grades
depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
C -30 -20 -10 0 +10 +20 +30 +40 +50

Oil type, quality F -22 -4 +14 +32 +50 +68 +86 +104 +122
1.8 Engine, lubrication system *)
Volvo: VDS-2, VDS-3 -15 C SAE 15W/40
API: CH-4, CI-4
-25 C SAE 10W/30
ACEA: E4-99, E4-99 (Synthetic),
SAE 5W/30
E5, E7
Cummins: CES-20071,
CES-20072, CES-20076, -15 C SAE 15W/40
CES-20077, CES-20078
-25 C SAE 10W/30
API: CH-4/SJ, CI-4/SK
SAE 5W/30
ACEA: E5, E7
Caterpillar: **)
EMA: DHD-1 SAE 15W/40
SAE 10W/30
SAE 5W/30
2.6 Transmission, lubrication

system
Dana: Transmission oil ATF DEXRON III (trademark)
ZF:
API: CD/CE/CF-4/CF/CG-4/ SAE 10W, 10W/30, 10W/40
CH-4/CI-4/SF/SG/SH/SJ/SL
-25 C SAE 15W/30, 15W/40
ACEA: Categories A, B, E
SAE 20W/20, 20W/40
SAE 30
3.3 Driveline/Axle, drive axle

Hypoid oil, API GL-5 and SAE 80W140
MIL-L-2105B SAE 80W90
SAE 90
SAE 85W140

Hydraulic oil AV 32
SS 155434 AV 46
Hydraulic oil HVLP 46

DIN 51524 HLP 68
Hydraulic oil ISO - LHV 46

ISO 6743/4 ISO - LHM 68
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
*) API CH-4 or CI-4 are approved for markets outside the EU/EES.
**) API CH-4 and CI-4 oils are acceptable, if the requirements in Cat-
erpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are fulfilled.
CH-4 and CI-4 oils that do not meet the requirements in Caterpillar’s
ECF-1 specification may result in shortened service life of the engine.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
CES = Cummins Engine Standard
EMA = Engine Manufacturer’s Association
VDS = Volvo Drain Specification
Grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for
all grease points except for slide plates lifting equipment and slide
plates.
For lifting equipment, use a universal grease type EP according to
NLGI Grade 2 (EP2) with 3.5% Molybdenum disulfide intermix.
Cargotec approved lubricant must be used for slide plates.
Obtained from Cargotec Spare Parts Dept. 0.65 kg cartridge for
grease gun part no. 923110.0360, and 5 kg can part no. 923595.0003
Electrical connector grease

Use electrical contact grease part no. 923836.0552.
Sealant silicone
Use silicone part no. 923107.0308.
Silicone adhesive
Use silicone adhesive part no. 923854.0100.

Coolant
Use ready-mixed coolant. Choose the mixture of coolant that is adapt-
ed for the correct temperature.
CAUTION
Risk of engine damage if different types of coolant are

mixed.

coolant of the same type that was used before. See
Spare parts catalogue for correct part number.

Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tighten-
ing torque should be reduced by approx. 5%.
For mild surfaces (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, flange bolt or flange nut can
be used.
Tighten to the prescribed torque without stopping.
Recommended tightening torque varies depending on surface treat-
ment. Certain combinations of bolt and nut require lubrication accord-
ing to the table below.
State Screw Nut Lubrication
1 untreated untreated oil
2 bright-galvanised untreated or bright-galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9
State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm

Quality 8.8 10.9 12.9
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
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, ORFS

page
–
connections
Pipe and hose coupling
Pipe diameter Tightening torque
mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"

Pipe diameter Tightening torque
mm inch Nm
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque
mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Goods coupling
UNF-UN Metric-ISO BSSP

Thread Tightening torque (Nm) Thread Tightening torque (Nm) Thread Tightening torque (Nm)
(inch) (mm) (inch)
7/16-20 21 10 x 1 20 1/8-28 20
1/2-20 27 12 x 1.5 35 1/4-19 35
9/16-18 40 14 x 1.5 45 3/8-19 70
3/4-16 78 16 x 1.5 55 1/2-14 100
7/8-14 110 18 x 1.5 68 3/4-14 190
1"1/16-12 180 20 x 1.5 80 1"-11 300
1"3/16-12 230 22 x 1.5 98 1"1/4-11 330
1"5/16-12 285 26 x 1.5 170 1"1/2-11 400
1"5/8-12 320 27 x 2 180
1"7/8-12 400 33 x 2 310
42 x 2 330
48 x 2 400

Tightening torque, connections for

page
–
air conditioning unit

O-ring coupling cooling coils
Hose diameter Thread Tightening torque
mm inch inch Nm
6 1/4" 7/16" 7-14 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-27 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-47 Nm
Pressure switch 3/8" 7-14 Nm
The above values should be considered guidelines and may vary de-
pending on installation.
Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kilopond metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Meter m
Kilometre km

Conversion table, SI units

page
–
SI-unit Conversion factor Non-SI Conversion factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm2 x 14.22 = psi x 0.070 = kp/cm2
N/mm2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 =W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 =J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm = TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3/min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table, length

page
–
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 mm
Conversion table, area

page
–
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a - 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume

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

Conversion table, mass

page
–
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

page
–
Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735,56 Dry (mmHg) = 0.96784 atm


G Terminology and index 1
G Terminology and index
Table of Contents G Terminology and index

mm mm mm mm mm mm
Terminology and index.................................................................................. 3

Terminology ............................................................................................................ 3
Index ....................................................................................................................... 6

2 G Terminology and index

G Terminology and index – Terminology and index 3
Terminology and index

mm mm mm mm mm mm
Terminology
page
–
Term Description
AC Air Conditioning. Heater unit with manual control of heating, cooling, dehumidifying and
air flow.
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grabs the load when lifting.
Axle distance Distance between drive axle and steering axle.
Bar Unit for measuring pressure.
Battery disconnector Cuts off current from battery.
Buzzer Audible alarm to catch the operator’s attention.
Central lubrication An automatic system for the lubrication of a preset number of lubrication points.
Control valve Valves that can be used to control something, e.g. release pressure and thus lower a mast
or a fork. See also control valve.
Counterweight Weights adapted to the machine’s lifting capacity to provide a balancing load during lifting.
Daily inspection The actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of the machine’s lifting capacity.
Displacement The oil volume that the pump can supply per pump revolution.
Display "Window" showing digital information on steering wheel panel in cab (for KCS).
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, emptied automatically dur-
ing operation.
ECC Electric Climate Control. Air conditioning with automatic control of heating, cooling, dehu-
midifying and air flow.
ECU Electronic Control Unit
EDU Electronic Display Unit
Electric servo Load handling hydraulic components receive control signals from electro-mechanical
controls.
Electrolyte level Fluid level in battery cells.
End-positions The farthest distance the object can be moved out or away; for example, the end-position
for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Tank for coolant.
Fixed displacement Pump with fixed pump volume.
FlexCab Safety cage with a strong frame structure. Lagged.

4 G Terminology and index – Terminology and index
Term Description
FlexGuard Safety cage with a strong frame structure. Open.
FMI Fault Message Identifier.
Fork bracket Brackets for forks, mounted on the trolley.
Forks Lifting gear that lifts the load.
Frame beam Supporting beams in the frame.
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque from
the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in the operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic servo Load handling hydraulic components receive control signals from mechanical controls.
Hydraulic system System that uses oil pressure to transmit power to different functions.
Indicator Manual "sensor", shows for example that a filter is clogged and needs to be replaced.
KCS Kalmar Control System. An electronic control system that monitors and regulates certain
systems in the machine that require KCS, e.g. certain engine and transmission
alternatives.
Levelling Forks tilted, e.g. if a load is standing on an uneven surface.
Lifting capacity Indicates machine’s maximum lifting capacity.
Lifting point Attaching point for lift device when lifting an object.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance with
regulations.
Machine model Machine type. Indicated, for example: DCE 90-180. See also type designation.
Main fuse Located by battery. Cuts off current all systems in machine.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
Mast Carrier of the attachment and the load.
Operating hours Number of hours machine has been in operation, shown on hour meter in cab.
Optimum drive Function for simulated hydrostatic control.
Optimum rev KCS function that optimises the lift speed using an extra variable hydraulic pump, while at
the same time the engine speed is as low as possible.
Optimum speed KCS function that increases lift speed using an extra variable hydraulic pump.
Option Optional equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Piston rod Rod that is inserted into the piston’s cylinder barrel and is acted on by hydraulic pressure.
Planetary gear Type of transmission with gears in constant mesh.
Product alternatives One of several alternatives is selected for a machine, e.g., engine alternative.
Progressive steering Rapid steering wheel movements give larger steering deflection.
Proportional valve An electromagnetically controlled valve. If a current is applied, the valve is activated in
proportion to the current’s amplitude. In simple terms, infinitely variable valve, as opposed
to on/off valve. For example, on the transmission valve housing.
Recirculation Circulation in a closed system.

Term Description
Refrigerant Fluid/gas in the air conditioning system. Must only be handled by authorised trained
personnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small user movement results in a big machine movement, e.g. power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Forks moved sidewards in parallel.
SmartLink Software for operating the KCS (Kalmar Control System).
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Spreading the forks, e.g. changing the relative distance between the forks.
Steering axle Wheel axle with steering.
Tilt The mast is leaned forward or backward.
Top lift Attachment. See attachment.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for transmission and torque converter. See specifications.
Trolley Lifts the load, located on the mast.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding holes
in container and twisted to lock the container for lifting.
Type designation Indicates machine type and capacity. See also machine model.
Valve slide Movable part in valve. Determines oil’s path.
Variable displacement Adjustable volume (capacity) of a pump.
Variable pump Pump with adjustable flow rate.
Wet brakes Brake discs in oil-bath.
Working hydraulics All load handling functions, e.g. lift and lower, tilt, side shift, spreader and levelling.

Index
page
–
Designation Section Function group

A near accident is a warning! B Safety -
About the documentation A Foreword -
About the machine version A Foreword -
About the maintenance manual A Foreword -
Accumulator 10 Common hydraulics 10.3.2
Additional exhaust cleaning system 1 Engine 1.3
Air cleaning system 1 Engine 1.6.1
Air intake and exhaust outlet 1 Engine 1.6
Air pollution B Safety -
Alternator 11 Common electrics 11.4
Batteries 11 Common electrics 11.3
Body structure 9 Frame, body, cab and accessories 9.13
Brake pedal 4 Brakes 4.1.1
Brakes 4 Brakes 4
Breather filter hydraulic oil tank 10 Common hydraulics 10.6.7
Cab frame 9 Frame, body, cab and accessories 9.10.1
Cab interior 9 Frame, body, cab and accessories 9.11
Cab tilting 9 Frame, body, cab and accessories 9.10.4
Cab undercarriage 9 Frame, body, cab and accessories 9.10.3
CAN bus 11 Common electrics 11.6.1
CAN-bus drivetrain 11 Common electrics 11.6.3
Central lubrication 9 Frame, body, cab and accessories 9.14
Chains 7 Load handling 7.2.8
Chassis 9 Frame, body, cab and accessories 9.12
Check and service log C Preventive maintenance -
Checking for cracks C Preventive maintenance -
Clothing, etc. B Safety -
Common electrics 11 Common electrics 11
Common hydraulics 10 Common hydraulics 10
Communication 11 Common electrics 11.6
Communication system 9 Frame, body, cab and accessories 9.7
Complete machine 0 complete machine -


Complete machine, description 0 complete machine -
Condenser unit 9 Frame, body, cab and accessories 9.4.9
Conditions A Foreword -
Construction and suspension of cab 9 Frame, body, cab and accessories 9.10
Control and monitoring system engine 1 Engine 1.9
Control and monitoring system transmission 2 Transmission 2.8
Control system 8 Control system 8
Control units 11 Common electrics 11.5.3
Controls and instruments 4 Brakes 4.1
Controls and instruments 9 Frame, body, cab and accessories 9.1
Conversion table, area F Technical data -
Conversion table, length F Technical data -
Conversion table, mass F Technical data -
Conversion table, pressure F Technical data -
Conversion table, SI units F Technical data -
Conversion table, volume F Technical data -
Coolant 1 Engine 1.7.7
Coolant B Safety -
Coolant pump 1 Engine 1.7.1
Cooling fan 1 Engine 1.7.5
Cooling system 1 Engine 1.7
Cooling system 2 Transmission 2.7
Copyright A Foreword -
Counterweights 9 Frame, body, cab and accessories 9.13.4
Crank mechanism 1 Engine 1.5.6
Diagnostics 8 Control system 8.4
Distribution block 4 Brakes 4.3.6
Doors 9 Frame, body, cab and accessories 9.10.2
Drive axle 3 Driveline/Axle 3.3
Driveline/Axle 3 Driveline/Axle 3
ECU 790 8 Control system 8.4.1


Electric motors B Safety -
Electric scales 7 Load handling 7.10.1
Electrical distribution 11 Common electrics 11.5
Electrical distribution box 11 Common electrics 11.5.2
Electrical protection 11 Common electrics 11.2
Engine 1 Engine 1
Engine’s mechanical parts 1 Engine 1.5
Entertainment and communication 9 Frame, body, cab and accessories 9.8
Environment B Safety -
Error codes 8 Control system 8.3
Exhaust system 1 Engine 1.6.3
Feedback A Foreword -
Fire and explosion risks B Safety -
Fluid or gas under pressure B Safety -
Foreword A Foreword -
Form for copying A Foreword -
Frame, body, cab and accessories 9 Frame, body, cab and accessories 9
Fresh air filter 9 Frame, body, cab and accessories 9.4.4
Fuel filter 1 Engine 1.2.2
Fuel pre-filter 1 Engine 1.2.3
Fuel system 1 Engine 1.2
Fuel system B Safety -
Fuel tank 1 Engine 1.2.1
Function descriptions A Foreword -
Function group structure A Foreword -
Fuses 11 Common electrics 11.2.2
General A Foreword -
General B Safety -
General B Safety -
General safety information B Safety -
Glass/windows/mirrors 9 Frame, body, cab and accessories 9.9
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
High-pressure filter 10 Common hydraulics 10.6.8
Hydraulic oil 10 Common hydraulics 10.6.9


Hydraulic oil cooler 10 Common hydraulics 10.6.2
Hydraulic system, depressurising B Safety -
Ignition/heating 1 Engine 1.10
Important information A Foreword -
Intercooler 1 Engine 1.6.4
Levelling 7 Load handling 7.8
Lift and lower 7 Load handling 7.2
Lifting equipment B Safety -
Lifting forks 7 Load handling 7.9.1
Lifting heavy components B Safety -
Lifting height presets 7 Load handling 7.10.2
Lighting system 9 Frame, body, cab and accessories 9.6
Link arm 5 Steering 5.2.6
Load alarms (latest alarm) 8 Control system 8.4.5
Load carrier 7 Load handling 7.9
Load handling 7 Load handling 7
Lubricating 1000h C Preventive maintenance -
Lubricating 500h C Preventive maintenance -
Lubrication system 1 Engine 1.8
Lubrication system 2 Transmission 2.6
Machine card A Foreword -
Main valve 10 Common hydraulics 10.5.2
Maintenance manual’s content A Foreword -
Mast 7 Load handling 7.2.6
Mechanical transmission 2 Transmission 2.3
Monitoring 8 Control system 8.2
Noise B Safety -
Oil filter 1 Engine 1.8.4
Oil filter 2 Transmission 2.6.4
Oils B Safety -
Oils and lubricants, recommendation F Technical data -
Optimum speed, Optimum rev and Optimum drive 7 Load handling 7.10.4
Ordering of documentation A Foreword -
Other functions 7 Load handling 7.10


Paint/coatings 9 Frame, body, cab and accessories 9.15
Parking brake system 4 Brakes 4.5
Parking brake unit 4 Brakes 4.5.4
Particle filter 1 Engine 1.3.1
Pipes, hoses and valves 10 Common hydraulics 10.5
Power-assisted brake system 4 Brakes 4.3
Power-assisted steering system 5 Steering 5.2
Preventive maintenance C Preventive maintenance -
Preventive maintenance, general C Preventive maintenance -
Preventive maintenance, work instructions C Preventive maintenance -
Product alternatives and optional equipment A Foreword -
Propeller shaft 3 Driveline/Axle 3.2
Pumps 10 Common hydraulics 10.4
Radiator and expansion tank 1 Engine 1.7.4
Read maintenance manual A Foreword -
Read operator’s manual A Foreword -
Reading instructions A Foreword -
Redundant CAN-bus 11 Common electrics 11.6.2
Refrigerant B Safety -
Rim 6 Suspension 6.3.2
Rotating components and tools B Safety -
Safety B Safety -
Safety and emergency equipment 9 Frame, body, cab and accessories 9.2
Safety concerns everyone! B Safety -
Safety instructions B Safety -
Safety valves 10 Common hydraulics 10.2
Seats 9 Frame, body, cab and accessories 9.3
Sensor coolant temperature 1 Engine 1.7.9
Sensor oil pressure 1 Engine 1.8.3
Sensor steering wheel reading 5 Steering 5.2.11
Sensor, wheel angle 5 Steering 5.2.9
Service indicator 8 Control system 8.2.4
Service position B Safety -
Service schedule C Preventive maintenance -


Several mechanics on the same machine B Safety -
Side lift attachment 7 Load handling 7.10.5
Side shift 7 Load handling 7.4
Side shift cylinder 7 Load handling 7.4.4
Solvents B Safety -
Specifications for data and volume F Technical data -
Specifications for lift capacity and dimensions F Technical data -
Speed limitation 8 Control system 8.2.3
Spreading 7 Load handling 7.5
Start battery 11 Common electrics 11.3.1
Start/stop 1 Engine 1.11
Starter motor 1 Engine 1.11.1
Steering 5 Steering 5
Steering axle cradle 6 Suspension 6.2.1
Steering spindle 6 Suspension 6.2.2
Storage A Foreword -
Suspension 6 Suspension 6
Suspension 6 Suspension 6.2
Tanks and accumulators 10 Common hydraulics 10.3
Technical data F Technical data -
Temperature control, cleaning and hydraulic oil 10 Common hydraulics 10.6
Temperature control, cleaning and hydraulic oil 4 Brakes 4.8
Tensioned springs B Safety -
The documentation’s parts A Foreword -
Tightening torque, ORFS connections F Technical data -
Tightening torques, recommendations F Technical data -
Tilt 7 Load handling 7.7
Tilt cylinder 7 Load handling 7.7.5
Transmission 2 Transmission 2
Turbo 1 Engine 1.6.2
Tyre system 6 Suspension 6.3
Tyre system B Safety -
Tyres 6 Suspension 6.3.1
Unit explanations F Technical data -


Valve mechanism 1 Engine 1.5.4
Vertical holding 7 Load handling 7.10.3
Vibrations B Safety -
Voltage feed 11 Common electrics 11.5.1
Warning information A Foreword -
Washing C Preventive maintenance -
Wheel hub 6 Suspension 6.2.3
Wiping and cleaning of windows 9 Frame, body, cab and accessories 9.5
Working under machine B Safety -

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A Foreword

9 Frame, body, cab and accessories

G Terminologi och Index

Table of Contents A Foreword

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

About the maintenance manual

Thank you for choosing Kalmar Industries as your machine supplier.

The instructions are based on the use of generally available standard

About the machine version

The information in this publication corresponds to the machine’s de-

Risk of fatal accidents and property damage!

Only used equipment approved by Cargotec.

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

Warnings inform of potential hazards that, if warnings are not heeded,

Important information is indicated by NOTE, and is provided to facili-

Read operator’s manual

Read the operator’s manual

Read maintenance manual

Read the maintenance manual

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

Maintenance manual’s content

The information in the maintenance manual is divided in function

B Safety Keep in mind for your safety.

C Preventive maintenance General information about preventive maintenance of the machine.

9 Frame, body, cab and

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

Function group structure

The information in the manual is divided in a structure of functions at

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

Product alternatives and optional equipment

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

Optional equipment comprises options that can be added to the stand-

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

The machine card indicates of which drawings the machine consists,

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

Function descriptions are schematic overviews that describe how a

Example of function description

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

1. Hydraulic force (solid double line)

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

Symbol explanation function descriptions

D790-1 13. Bulb

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

About the documentation

The documentation for the machine consists of the following parts:

The documentation is ordered from the dealer for Cargotec.

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

Cargotec’s ambition is that you who work with maintenance of Kalmar

To: Cargotec Sweden AB

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

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

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

Table of Contents B Safety

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

General safety information

A near accident is a warning!

A near accident is an unanticipated event where neither any person is

Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006 UDCE08.05GB

UDCE08.05GB Maintenance manual DCE 90–180, DCE 70-32E3–70-35E4 2006

• Machine parked, that is, applied parking brake.