Professional Documents
Culture Documents
Publ. no UDCF07.01GB
Maintenance Manual in original MAINTENANCE MANUAL
DCF 280–520
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DCF 280–520
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A:6
Machine card.............................................................................................. A:7
Function descriptions ................................................................................. A:7
About the documentation .............................................................................. A:10
The documentation's parts ....................................................................... A:10
Ordering of documentation....................................................................... A:10
Feedback .......................................................................................................A:11
Form for copying .......................................................................................A:11
A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.
Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.
Storage
NOTE
The maintenance manual shall be accessible to service personnel.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Only used equipment approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Reading instructions
Warning information
Warnings inform of potential hazards that, if warnings are not heeded,
may result in personal injury or product damage.
DANGER
Situation that may lead to severe personal injury or
fatality if the rule is not followed.
WARNING
Situation that may lead to personal injury if the rule is
not followed.
CAUTION
Situation that may lead to product damage if the rule
is not followed.
Important information
Important information is indicated by NOTE, and is provided to
facilitate the work process, handling or increase understanding of the
information.
NOTE
Information that is important without being related to safety.
A Foreword General information about the maintenance manual's purpose, content and
reading instructions as well as survey for feedback of views and eventual
inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
Technical description, description of the machine's functions with schematic
5 Steering drawings and explanatory texts for the included components.
6 Suspension Overviews with the components' position on the machine.
7 Load handling Work instructions for preventive maintenance.
8 Control system Work instructions for checking and adjusting.
9 Frame, body, cab and
accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information is found in the Workshop manual and Operator's manual.
E Diagrams Wiring diagrams and hydraulic diagrams are found in the Workshop manual.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanations of terms and abbreviations
that may appear in the manual, index for headings in the manual.
The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
done at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.
The idea is that the function groups are intended to work as a search
term to find different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.
Optional equipment
Machine card
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the first and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.
If the information on the machine card does not help, contact Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.
Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.
T 2
5 3
5 T
014280
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12 12. Radiator
13. Bulb
D790-1 14. Control system, two control units with CAN-bus
13 14 15. Restriction
D797-F 16. Adjustable restriction
17. Inductive position sensor
15 16 18. Electrically controlled servo valve
19. Thermal bypass valve
17 18 20. Temperature-controlled switch
21. Temperature sensor
19 °C 20 °C
22. Pressure sensor
°C Pa
23. Pressure-controlled switch
21 22
24. Hydraulic cylinder
25. Double-acting hydraulic cylinder
23 Pa 24
26. Spring brake cylinder
27. Valve block
25 28. Shuttle valve
29. Non-return valve
26 27
28 29
014726
Ordering of documentation
The documentation is ordered from the dealer for Cargotec.
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Copy this form, write down your views and send it to us. Thanks for
your help!
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
AdBlue........................................................................................................ B:8
Clothing, etc. .............................................................................................. B:9
Several mechanics on the same machine.................................................. B:9
Working under machine ............................................................................. B:9
Lifting heavy components ........................................................................ B:10
Vibrations ................................................................................................. B:10
Noise .........................................................................................................B:11
Solvents ....................................................................................................B:11
Fire and explosion risks............................................................................ B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:16
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:17
Spare parts............................................................................................... B:19
Non-ionised radiation ............................................................................... B:20
Environment.................................................................................................. B:21
General .................................................................................................... B:21
B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions in this manual must
make absolutely sure that the work is performed without risks of
personal injury, without risks of machine damage, or property damage!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and be careful. Do not take any risks!
Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.
Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position, page B:4
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• AdBlue, page B:8
• Clothing, etc., page B:9
• Several mechanics on the same machine, page B:9
• Working under machine, page B:9
• Lifting heavy components, page B:10
• Vibrations, page B:10
• Noise, page B:11
• Solvents, page B:11
• Fire and explosion risks, page B:12
• Fluid or gas under pressure, page B:14
• Coolant, page B:14
• Refrigerant, page B:15
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:16
• Tyres and rims, page B:17
• Lifting equipment, page B:17
• Spare parts, page B:19
• Non-ionised radiation, page B:20
Service position
General
General
007710
3 Turn the start key to position 0 and turn off the system voltage.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
005648
Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
Always completely depressurise the hydraulic and
brake systems before starting to work in these systems.
Hydraulic and brake systems are pressurised and the
oil can cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! Oil may
also be corrosive to mucous membranes in, e.g., eyes,
skin, and throat.
IMPORTANT
Always clean the area around components and
connections before loosening them. Dirt in oil systems
causes increased wear, which results in material
damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also start fires. Waste oils/fluids shall always
be handled and taken care of by companies that are
authorised for this work.
Fuel system
The following safety instructions shall be followed for work when
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces and
may ignite.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.
IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised for
this work.
AdBlue
The following safety instructions shall be followed for work when
handling AdBlue.
CAUTION
AdBlue can irritate the skin and eyes and when inhaled.
Health hazard!
Handle with care and avoid contact with skin, use
gloves. In the event of contact with skin and spillages
on clothing, rinse the skin with large amounts of water
and replace contaminated clothing and gloves. In
the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
CAUTION
AdBlue spilled onto hot components evaporates
quickly.
Irritation of eyes and respiratory system.
Turn your face away. Evaporated AdBlue can harm
mucus membranes in, for example, the eyes and throat.
In the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary. In the event of inhalation, breath fresh air
and seek medical advice if necessary.
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillages on the ground must be absorbed with sand or
other absorbent, non-combustible material.
Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.
WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
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.
A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
• Use axle stands and supports that stand securely.
• Lifting tools should be inspected and type approved for use.
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to
move heavy components. Make sure that the device
is sturdy and intact.
Risks
The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.
A component lifted with lifting equipment can start to turn if the centre
of gravity changes.
Safety actions
Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs. See the workshop
manual for methods.
Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.
Safety actions
• Use heavy gloves to protect against the cold and transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.
Noise
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) is more damaging than low tones at the
same sound level. Noise in the form of impulse sounds may also be
damaging, e.g., hammer blows.
Risks
Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.
Safety actions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.
Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are flammable.
Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
Safety actions
• Avoid inhaling solvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a solvent container without tight-sealing lid.
• Use solvents with a low content of aromatic compounds. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are solvent-resistant.
DANGER
The operator's safety may not be jeopardised in case
of fire.
If possible, take the following actions at the slightest
sign of fire:
1. Stop the machine and turn the start key to stop
position.
2. Leave the cab.
3. Turn off the system voltage with the battery
disconnector.
4. Call the fire department.
5. Try to put out the fire.
If this is not possible, leave the machine and the
danger area.
DANGER
Smoke from a fire may be very toxic.
Smoke anesthetises, suffocates, and kills! Smoke
from fires, even small amounts, can damage lungs and
respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
fire and working with burnt materials.
Risks
Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding flames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.
Special cases
Gas oil with added gasoline has a reduced flash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher than for gasoline.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive fires.
Safety actions
DANGER
Remains of fuel, oils, grease, and other flammable
materials on the engine or in the engine compartment
are fire hazards.
Risk of fire!
Remove remains of flammable materials from the
engine compartment as soon as they are discovered,
be extra thorough with hot surfaces such as the
exhaust system, manifold, or turbo. If leaks of oil, fuel,
or coolant are detected, find the cause and solve the
problem before starting the engine.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall first be drained of pressure
and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.
• Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
Coolant
The coolant in the machine’s cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
Refrigerant is used in the machine’s air conditioning system.
Risks
Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
Risks
Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.
Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Risks
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in
the machine.
Safety actions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or pant legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
DANGER
Tyres are to be considered as pressurised containers.
Handling incorrectly, they are a fatal hazard.
Parts can be thrown with explosive force and may
cause severe injuries.
Never repair damaged tyres, rims, or lock rings. Tyre
changes shall be performed by authorised personnel.
Risks
Safety actions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regard 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
Safety actions
Do not start work until the carriage is fully lowered. If the type of work
requires raised carriage then it must be secured in some way.
Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Solid wheels
• Control valve, hydraulic servo
• Mast, carriage
• Lift cylinder incl. load control valve
• Separate load control valve
• Lifting chains
• Chain tightener and shaft
• Forks, fork carrier
• Lift cylinder
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Emergency stop
• Hydraulic cylinder, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units
Non-ionised radiation
WARNING
Extra equipment such as two-way radio, RMI, telephone,
etc. may emit non-ionised radiation.
Risk of interference with active or non-active medical
products.
Use a two-way radio, RMI, telephone, etc., when no
persons with active or non-active medical products
are nearby.
NOTE
When persons with active or non-active medical products are not
nearby, then telephone and two-way radio may be used in the cab.
Equipment should not be used when operating or load handling
since this reduces your concentration as operator.
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.
Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.
Recycling
Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.
The refrigerant in the air conditioning unit for the cab contributes to
the greenhouse effect if it escapes into the open air. Special training
is required for all service work on the air conditioning unit. Many
countries also require certification by an authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
Declarations
C Preventive maintenance
C Preventive maintenance
Preventive maintenance, general
It’s very important that preventive maintenance is performed according
to recommended intervals.
CAUTION
Service intervals shall be followed.
This is to maintain the machine's safety and to fulfil
warranty and service agreements!
Use spare parts and fluids approved by Cargotec to
fulfil the warranty.
Completed maintenance
Oper-
ating Operating
hours Actions hours Date Signature
50h 50h-check
500h 500h service
1000h 1000 service
1500h 500h service
2000h 2000h service
2500h 500h service
3000h 1000 service
3500h 500h service
4000h 2000h service
4500h 500h service
5000h 1000 service
5500h 500h service
6000h 2000h service
6500h 500h service
7000h 1000 service
7500h 500h service
8000h 2000h service
8500h 500h service
9000h 1000 service
9500h 500h service
10000h 2000h service
50h-check
On a new machine, the following checks shall be performed after 50
operating hours. The checks are performed to increase reliability and
safety.
1 Engine Reference
Bolted joints, attachments, mountings, hose clamps,
wear and chafing of hoses, cable harnesses, etc.
Sealing check oil, coolant, exhaust system
Fuel prefilter, water draining Section 1 Engine, group 1.2.3 Fuel prefilter
Air filter indicator, check Section 1 Engine, group 1.6.1 Air cleaning system
Air filter main cartridge, inspection
Air filter safety cartridge, inspection
Drive belt tension, checking Section 1 Engine, group 1.7.5 Cooling fan
Coolant level, check Section 1 Engine, group 1.7.7 Coolant
Oil and oil filter, change Section 1 Engine, group 1.8 Lubrication system
Oil pressure
2 Transmission
Leakage check
Oil level, check Section 2 Transmission, group 2.6 Lubrication system
Transmission oil filter, changing Section 2 Transmission, group 2.6 Lubrication system
3 Driveline/Axle
Mounting propeller shaft, check-tightening Section 3 Driveline/Axle, group 3.2 Propeller shaft
Mounting drive axle, inspection Section 3 Driveline/Axle, group 3.3 Drive axle
4 Brakes
Leakage check
Power-assisted brake, function check Section 4 Brakes, group 4.3.4 Accumulator
Parking brake, function check Section 4 Brakes, group 4.5.4 Parking brake unit
5 Steering
No action
6 Suspension
Tyres and rims, check Section 6 Suspension, group 6.3 Tyres and rims
Wheel nuts, check-tightening Section 6 Suspension, group 6.3 Tyres and rims
7 Load handling
Hose connections, check-tightening
Bolted joints, check-tightening
Slide plates and support rollers, function check
Lifting chains, checking and adjusting Section 7 Load handling, group 7.2.9 Mast
Section 7 Load handling, group 7.10.5.1 Spreading
Chain tension spreading, checking and adjusting
8 Control system
Check that there are no active error codes Section 8 Control system, group 8.3 Error codes
9 Frame, body, cab and accessories
No action
10 Common hydraulics
Leakage check, check-tightening as required
Oil level, check Section 10 Common hydraulics, group 10.6.8 Hydraulic oil
Fine filter hydraulic oil, changing Section 10 Common hydraulics, group 10.6.9 Fine filter hydraulic
oil
11 Common electrics
Batteries, check Section 11 Common electrics, group 11.3.1 Start battery
Service schedule
Service shall be performed every 500 operating hours. Actions are
divided into 500h, 1000h and 2000h service.
Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.
After service is performed, make a note in the check and service log,
see Check and service log, page C:4.
In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hours
Air filter main cartridge C/R C/R C/R Checking indicators, change Section 1 Engine, group
when indicated. 1.6.1 Air cleaning system
Air filter safety cartridge C C/R C/R Changed every other time
main cartridge is changed.
Exhaust system C C C Sealing check Section 1 Engine, group
1.6.3 Exhaust system
Charge-air hoses C C Sealing check Section 1 Engine, group
1.6.4 Intercooler
Radiator C C C External check and cleaning. Section 1 Engine, group
1.7.4 Radiator and
expansion tank
NOTE
Do not use high pressure
wash.
Engine oil R R R For volume and quality, see Section 1 Engine, group
section F F Technical data. 1.8 Lubrication system
Engine oil filter R R R
1 Engine (engine alternative Volvo TAD1360VE)
Bolted joints, attachments, C C C
mountings, etc.
Fuel tank C Clean if necessary. Section 1 Engine, group
1.2.1 Fuel tank
Fuel prefilter C R R Drain water/impurities. Section 1 Engine, group
1.2.3 Fuel prefilter
Change filter earlier if error
code is displayed.
Fuel filter R R Change filter earlier if error Section 1 Engine, group
code is displayed. 1.2.4 Fuel filter
Air filter main cartridge C/R C/R C/R Checking indicators, change Section 1 Engine, group
when indicated. 1.6.1 Air cleaning system
Air filter safety cartridge C C/R C/R Changed every other time
main cartridge is changed.
Exhaust system C C C Sealing check Section 1 Engine, group
1.6.3 Exhaust system
Charge-air hoses C C Sealing check Section 1 Engine, group
1.6.4 Intercooler
Radiator C C C External check and cleaning. Section 1 Engine, group
1.7.4 Radiator and
expansion tank
NOTE
Do not use high pressure
wash.
Engine oil R R R For volume and quality, see Section 1 Engine, group
section F F Technical data. 1.8 Lubrication system
Engine oil filter R R R
2 Transmission
Breather filter C C Clean if necessary Section 2 Transmission,
group 2.2 Torque
converter
NOTE
Do not use high pressure
wash.
6 Suspension
Steering axle suspension C C Section 6 Suspension,
group 6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel Section 6 Suspension,
suspension shall be checked. group 6.2.2 Wheel spindle
Wheel hub steering axle, C Check bearing pre-load. Section 6 Suspension,
check group 6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and pressure, Section 6 Suspension,
change as needed. group 6.3 Tyres and rims
Wheel nuts C C Check-tightening. Section 6 Suspension,
group 6.3 Tyres and rims
Rim C* * Checking for cracks, every Section 6 Suspension,
2000 h or in connection with group 6.3.2 Rim
tyre changes.
7 Load handling
Servo filter R R R Section 7 Load handling,
group 7.2.2 Servo filter
Lifting chains C C C Check damage, tension chain Section 7 Load handling,
when needed. group 7.2.9 Mast
Mast suspension C C
Slide plates mast C C C
Support rollers mast C C C
Tilt cylinder C C C Section 7 Load handling,
group 7.7.7 Tilt cylinder
Lifting forks C C C Section 7 Load handling,
group7.9.1 Lifting forks
Test-run
Test-run the machine and check:
• Instruments
• Brakes
• Gearshifting
• All load handling functions
• Steering
• Any noise
After test-run
Check the following after test-run:
• Sealing (no leakage)
• Fluid levels
Washing
CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,
battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.
Lubricating 500h
1 Turn off the engine and turn off the system voltage.
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.
13 9 7 10 6 8 11 8 6 10 7 9 13
14 1 1 14
16 16
12 12
010625
3 2 4 5 6 6 5 15 4 2 3
Grease points, lubricating grease
NOTE
Be careful so that the seal is not damaged.
NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.
Link arms
6 Lubricate the link arm bearings (position 2 and 3) with lubricating
grease.
Brake pedal
7 Lubricate the brake pedal's hinge with grease.
8 Wipe off excess grease.
Mast
9 Start the machine and raise the mast to facilitate access to grease
4 3 points.
10 Turn off the engine.
4 11 Secure the mast in a way that ensures safety.
12 Lubricate slide plate (position 1), support rollers (position 2), chain
wheel (position 4) and mast wheel (position 5), as well as top
support rollers (position 3) if applicable, with lubricating grease,
see section F Technical data.
For lowered grease points, lubricate the top support rollers and the
chain wheel down on the mast .
1
13 Spray the chains with chain oil; see section F Technical data.
Make sure the chains are well lubricated.
2
5
007275
Fork wheel
14 Lubricate rollers and wheel with lubricating grease.
007325
Fork carriage
15 Lubricate the rollers and wheel of the fork carriage with lubricating
grease.
007292
Rotation cylinders.
16 Lubricate the rotation cylinders' mounts with lubricating grease.
007233
Tilt cylinder
18 Grease the tilt cylinder axles with lubricating grease.
NOTE
Unload the mast when lubricating.
007322
Grease points on tilt cylinder (diagram shows DCF
280-330).
007277
Cab lock
19 Tilt the cab.
20 Lubricate the cab locks with lubricating grease.
007278
Lubricating 1000h
2 Turn off the engine and turn off the system voltage.
6 2, 3 6
4 4
007235
5 5
Grease points, lubricating grease
Attachment
1 Brush slide surfaces on the attachment with white lubrication
paste as shown on the diagram below, see section F Technical
data.
007271
NOTE
The upper slide surfaces in the outer boom should be lubricated
at the same time as the other slide surfaces.
IMPORTANT
Wipe off excess lubrication paste.
Twistlocks
4 Lubricate the lift pins' bearing with lubricating grease.
Universal joint
5 Grease universal joints with lubricating grease.
DANGER
Welds in areas of high stress concentration must be
checked in accordance with recommended intervals.
The interval is calculated according to the machine
being used for normal handling and on a level, smooth
ground surface. For other handling or, e. g., rough
surface, the interval should be shortened.
If the welds show signs of cracking, take the machine
out of operation immediately and contact Cargotec
Support.
1 Turn off the engine and turn off the system voltage.
3 Visually inspect for damage and cracks in the areas with high
stress concentration, see Checkpoints, page C:27. Check the
whole length of every weld.
Welds where cracks are suspected following visual inspection are
tested with magnetic particle inspection and liquid penetrant if
appropriate in accordance with the following:
a. The magnetic particle method is used to determine if there's a
crack or not, and where it is. See Magnetic particle method,
page C:25.
b. Confirmed cracks are investigated further with penetrating
fluid. See Checking cracks with penetrating fluid, page C:26.
001704
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
Rim any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
Examples of cracks
1. Linear crack
2. Pointed crack
Checkpoints
1 Check the following welds carefully:
1 8 7 6
009782
2
Checking for cracks
009664
009785
d) Tilt mount in tilt frame
009527
009668
Mast mount
5
009486 a) Mast mount in chassis.
009523
NOTE
There may be other variants of top lift attachment than the one
shown here.
009786
Lifting equipment
7
NOTE
There may be other variants of trolleys than those shown here.
009792
009790
e) The wheel pin welds in the trolley.
Check the inner mast wheel pins as well.
009793
Lifting forks
9
NOTE
There may be other variants of forks than those shown here.
009788
0 Complete machine
Complete machine, description
The Kalmar DCF 280-520 is a forklift truck. The machine has a lifting
capacity of 28-52 tonnes depending on model.
The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the type
disc brake and acts on the drive axle's input shaft.
The wheels are fastened on the hubs using clamps. The drive axle has
twin wheels, the steering axle has single wheels.
The frame supports the machine. The engine, transmission, drive axle,
and steering axle are installed in the frame. On the sides of the frame
there are tanks for fuel, hydraulic oil, and oil for the brake system. The
cab is centrally located. As an option the cab can be moved laterally.
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.2 Fuel system.................................................................................................... 1:11
1.2.1 Fuel tank ...................................................................................................1:13
1.2.3 Fuel prefilter ..............................................................................................1:13
1.2.4 Fuel filter ...................................................................................................1:17
1.2.12 AdBlue tank ...............................................................................................1:19
1.2.13 AdBlue filter ...............................................................................................1:22
1.6 Air intake and exhaust outlet..........................................................................1:25
1.6.1 Air cleaning system ...................................................................................1:28
1.6.3 Exhaust system .........................................................................................1:30
1.6.4 Intercooler .................................................................................................1:30
1.7 Cooling system ..............................................................................................1:32
1.7.4 Radiator and expansion tank ....................................................................1:32
1.7.5 Cooling fan ................................................................................................1:32
1.7.7 Coolant ......................................................................................................1:35
1.8 Lubrication system .........................................................................................1:40
1.9 Control system engine ...................................................................................1:45
1.10 Ignition/heating...............................................................................................1:46
1.11 Start/stop........................................................................................................1:47
1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.
The engines are low emission engines and meet emission regulations
from the USA (California) and Europe. The new engines provide
considerable improvement, not only for exhaust emissions but also
for the power and torque curve.
°C
. bar
0 rpm
P I kph
II
III D5
1, 5
7 <°
D
D
D
3 15 8 2
D794 UDS D790-1 D790-2
14 D
D793 D797-1 D795
12 10
D
D
D
D D
17
SENSORS H2O M M
13 4 18 19 11
6 9 5 16
014285
1. Ignition (S150) 11. Control unit KID (D795)
2. Control unit KIT (D790-2) 12. Sensor fuel level (B757)
3. Control unit engine (D794) 13. Control unit frame (D797-1)
4. Glow plug (E800-1) 14. Sensor output shaft speed (B758)
5. Starter relay 15. Control unit, transmission (D793)
6. Starter motor (M654) 16. Control unit SCR (UDS)
7. Electric components engine 17. Pump unit AdBlue
8. Accelerator pedal (B690) 18. Water valve
9. Control unit cab (D790-1) 19. Level and temperature sensor AdBlue
10. Make-contact (closing switch) coolant level (B759) 20. Sensor exhaust temperature
°C
. bar
0
P I
rpm
kph
II
III
1
8 <°
3 15 2 5
D794 UDS D790-1 D790-2
13
D793 D797-1 D795
11 12
7 6
H2O
SENSORS M M
19 4 9 17 18
14 16
10
014281
1. Ignition (S150) 11. Control unit frame (D797-1)
2. Control unit cab (D790-1) 12. Control unit KID (D795)
3. Control unit engine (D794) 13. Control unit, transmission (D793)
4. Preheating coil (E800) 14. Pump unit AdBlue
5. Control unit KIT (D790-2) 15. Control unit SCR (UDS)
6. Starter motor (M654) 16. Water valve
7. Electric components engine 17. Level and temperature sensor AdBlue
8. Accelerator pedal (B690) 18. Sensor exhaust temperature
9. Make-contact (closing switch) coolant level (B759) 19. Output shaft sensor (B758)
10. Sensor fuel level (B757)
7
6
5
4 8
9
3
2
10
11
12
13
14
15
16
17
18
19
20
014776
21
22
Volvo TAD762VE, left side (in the machine's direction of travel)
1. Sensor RPM flywheel 12. Fuel pump
2. Crankcase ventilation 13. Oil filter
3. Filling point engine oil 14. Sensor oil pressure
4. Injector and preheating (6 pcs.) 15. Fuel filter
5. Dipstick 16. Control unit engine (D794)
6. Preheating of air after intercooler 17. Sensor fuel pressure
7. Sensor coolant level (B757) 18. Oil plug
8. Sensor coolant temperature 19. Fuel prefilter
9. Thermostat housing 20. Sensor water in fuel
10. Alternator 21. Water trap
11. Water pump 22. Sensor camshaft rpm
2
1
4
10
014777
8
7
Volvo TAD762VE, right side (in the machine's direction of travel)
1. Expansion tank 6. Starter motor
2. Filling point coolant 7. Intercooler
3. Sensor boost pressure and temperature 8. Condenser
4. Sensor fuel pressure (fuel distribution pipe) 9. Transmission oil cooler
5. Turbo 10. Radiator engine
5
4
3 7
8
2
1 9
10
11
12
13
14
15
16
014774
Engine right side (in machine's direction of travel)
1. Transmission oil cooler 9. Fuel prefilter
2. Water cooler 10. Water trap
3. Intercooler 11. Sensor water in fuel
4. Preheating coil 12. Fuel filter
5. Sensor boost pressure and boost temperature 13. Oil dipstick
6. Sensor oil pressure 14. Sensor oil level/oil temperature
7. Sensor crankcase pressure 15. Drain plug engine oil
8. Make-contact fuel pressure 16. Alternator
6
5
4
3
7
8
2
9
10
014775
11
12
Engine left side (in machine's direction of travel)
1. RPM sensor camshaft 7. Sensor coolant temperature
2. Sensor RPM flywheel 8. Water pump
3. Oil filling engine oil 9. Turbo
4. Expansion tank 10. Oil filter (full-flow)
5. Sensor coolant level 11. Oil filter (bypass)
6. Thermostat 12. Starter motor
0
P I
2 II
III
014283
11 10 9 8 7
Electric components machine
1. Accelerator pedal (B690) 7. Control unit, transmission (D793)
2. Ignition (S150) 8. Fuel tank
3. Control unit, cab KIT (D790-2) 9. Sensor fuel level (B757)
4. Control unit KID (D795) 10. Control unit frame (D797-1)
5. Control unit cab (D790-1) 11. Control unit frame option (D797-2)
6. Control unit engine (D794)
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.
1 1 Machine in service position, see section B Safety.
2 Open the hand pump (position 1) by pressing it in and turning
anticlockwise.
3 Bleed the fuel system by pumping the hand pump at least 250
times.
Pump quickly to maintain the pressure in the pump.
NOTE
Bleeding is not complete until there is no resistance in the pump.
Volvo TAD762VE
1. Hand pump
1
014098
Volvo TAD1360VE
1. Hand pump
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
2
014211
3
1. Fuel filler
2. Drain plug, under tank
3. Fuel tank
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.
4 Open the drain cock (position 1) on the underneath and allow the
condensation water to flow out. Close the cock when clean fuel
without water runs out.
5 Remove the water trap (position 2) from the fuel prefilter by turning
it clockwise.
6 Clean the water trap and refit it on the filter cartridge.
7 Close the drain cock and open the fuel cock.
8 Bleed the fuel system, see Fuel system, bleeding, page 1:12.
9 Turn on the system voltage and start the engine. Check that the
filter seals tight.
1
014216
1. Drain cock
2. Water trap
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.
3 Open the drain cock on the underneath and allow the condensation
water to flow out. Close the cock when clean fuel without water
runs out.
014045
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
3
014214
1. Wiring
2. Fuel prefilter
3. Water trap
3
014215
1. Wiring
2. Fuel prefilter
3. Water trap
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
2 7 Install a new O-ring on the water trap and lubricate with diesel oil.
Install the water trap on the new fuel prefilter.
8 Lubricate the O-ring on the new fuel filter with diesel oil.
3 9 Install the new fuel prefilter on the filter holder.
Tighten the O-ring by hand until it just touches the filter holder.
Then tighten a further half turn, no more.
014213
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Do not fill the fuel filter with fuel prior to installation. There is a risk
of contaminants entering the fuel system and causing malfunctions
or damage.
NOTE
The fuel filter is self-draining. Wait a few seconds after the engine
has been switched off before the filter cover and filter insert are
removed.
3
014217
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
Do not fill the fuel filter with fuel prior to installation. There is a risk
of contaminants entering the fuel system and causing malfunctions
or damage.
014218
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
NOTE
Only use gaskets that can withstand AdBlue.
1
014224
014225
5 Lower the filler cap and filler pipe in a water bath. Let them remain
for at least two minutes.
014226
NOTE
Always replace a damaged strainer.
014228
8 Flush the tank with hot water for at least ten minutes.
014229 Then check that the tank is completely drained of water.
014231
NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.
CAUTION
Wait at least two minutes after switching the engine off
before removing the hoses for AdBlue so that the SCR
system has time to drain and depressurise.
2 Remove the plate covering the pump unit from below. The plate is
placed under the battery compartment on the machine's left-hand
side.
NOTE
Pull the connection straight out.
014232
014233
5 Remove the hose from the filter holder by pressing in the catches.
014234
6 Remove the filter holder (position 1) from the pump unit. Remove
the filter insert (position 3).
NOTE
If the filter has been detached, it must be removed completely
before being reinstalled, even if it is to be reused.
8 Install the hose to the filter holder. Check that the locks lock
1 securely.
NOTE
Ensure that the connection is connected straight.
014236
AdBlue contains deionised water mixed with 32.5% urea. The urea is
broken down into ammonia, which reacts with NOx to create harmless
nitrogen and water vapour.
3
2
1
8
6
7
11
9
10
014783
Exhaust outlet DCF 280-330 6. Injector unit
1. Control unit NOx 7. Level and temperature sensor AdBlue
2. Silencer with integrated SCR catalyst 8. Exhaust pipe
3. Catalytic converter 9. AdBlue tank
4. End-pipe 10. Pump unit
5. Heat shield 11. Heating valve
10 9 6 8
014286
1
A
D
C B
010110
NOTE
The filter cartridge should be changed, not cleaned.
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, or muffler when the
machine is in operation or has recently been turned off!
1.6.4 Intercooler
Intercooler, checking
1 Machine in service position, see section B Safety.
NOTE
Do not use high pressure wash.
4 Check the sealing and check that the intercooler's hoses and
clamps are in good condition.
2 Check the charge air pipes for visible cracks and other external
damage. If the pipes are damaged or if connections leak, the
boost pressure will be too low and engine power is reduced.
014249
Radiator, cleaning
1 Machine in service position, see section B Safety.
NOTE
Do not use high pressure wash.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
IMPORTANT
Always change an alternator belt that looks to be worn
or has cracks.
2 Loosen the belt tensioner and lock it with a drift (position 1).
3 Remove the belt from the coolant pump first (position 2).
4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves and is tensioned correctly.
1
014242
Volvo TAD762VE
2 Remove the protective screen and the outer fan ring around the
cooling fan.
4 Insert a 1/2" wrench in the belt tensioner (position 1). Lift the
wrench up and remove the drive belt.
5 Slip the drive belt around the fan blade and remove it.
6 Check that the pulleys are clean and undamaged.
7 Run the new drive belt over the fan.
8 Lift up the 1/2" wrench and install the new drive belt.
9 Install the protective covers around the drive belts.
10 Install the protective screen and the outer fan ring around the
cooling fan.
11 Start the engine and perform function check.
1
014243
2 Remove the protective screen and the outer fan ring around the
cooling fan.
4 Insert a 1/2" wrench in the belt tensioner (position 1). Lift up the
wrench and lift off the water pump drive belt.
5 Insert a 1/2" wrench in the belt tensioner (position 2). Depress the
2 wrench and remove the alternator belt.
6 Check that the pulleys are clean and undamaged.
7 Push the 1/2" wrench down on the belt tensioner (position 2) and
install the new alternator belt.
8 Lift up the 1/2" wrench on the belt tensioner (position 1) and
reinstall the water pump drive belt.
9 Install the protective covers around the drive belts.
10 Install the protective screen and the outer fan ring around the
1 cooling fan.
11 Start the engine and perform function check.
014244
1.7.7 Coolant
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
C B A
DCF 280-330
DCF 370–520
NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
A When changing and topping up coolant, only use
coolant of the same type that was used before.
IMPORTANT
On machines with ECC or AC, it is of the utmost
importance that the engine's cooling system be refilled
with coolant that contains the correct mixture of
anti-freeze fluid; otherwise there is a risk that the air
conditioning will freeze up and fail during use.
012535
B C D
DCF 370–520
A Position for coolant reservoir (expansion tank)
B Pressure cap
C Filling point
D Level marking, MIN and MAX
Coolant, changing
Radiator performance is reduced due to deposits in the radiator and
radiator ducts. Clean the system in conjunction with changing the
coolant.
WARNING
The cooling system is pressurised. Steam or hot fluid
may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid contact with skin, use
protective goggles and protective gloves. In the event
of skin contact, wash the skin.
IMPORTANT
Cleaning may not be performed if there can be a risk
of freezing in the cooling system since the cleaning
solution does not have anti-freeze properties.
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system's expansion tank.
C B A
A
014061
DCF 280-330
A Position for coolant reservoir (expansion tank)
B Filling point
012535
C Sight glass B C D
DCF 370–520
A Position for coolant reservoir (expansion tank)
B Pressure cap
C Filling point
D Level marking, MIN and MAX
2 Open all drain points. Drain the coolant from the radiator and
engine block with drain hose. The drain nipples are under the
radiator and on the right-hand side of the engine block.
3 Check that all coolant drains.
NOTE
There may be deposits inside the cock or the plug that must
be cleaned; otherwise there is a risk that coolant may remain
and cause freezing damage.
the coolant line's lowest points. Allow the drain cocks or plugs to
remain open and ensure that the heating knob is set to full heat
during cleaning.
Drain point engine.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If there still are impurities after flushing for some time, cleaning
with coolant can be performed. Otherwise continue with Cleaning
with coolant, page 1:39.
NOTE
In order to avoid dissolved materials getting into the cooling
system, drain quickly, within 10 minutes, without the engine
having been stationary for a long time.
Remove the filler cap from the expansion tank and any lower
radiator hose to increase the drain speed.
NOTE
Use only cleaning agent approved by the engine manufacturer.
Carefully follow the instructions on the packaging.
Filling point
1 When the cooling system is completely free from impurities, close
the drain cocks.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
NOTE
Only use recommended coolant.
2 Add coolant so that the level lies between the MIN and MAX
markings. The engine must not be started until the system
has been bled and filled fully.
3 Start the engine when the system is bled and completely filled.
Open any bleed cocks some time after start, so that the trapped
air can escape.
Open all heat controls on the heater unit so that it is bled.
4 Stop the engine after about one hour and check the coolant level,
top up if needed.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
3 Remove the drain plug from the engine and drain the engine of oil.
4 Place a container under the oil filter.
5 Clean around the oil filter.
014238
2 Allow the oil to drain from the filter into the container.
8 Fit the new filter insert and a new O-ring.
3
9 Fit the filter cover and tighten to a torque of 40+10 Nm.
10 When the oil has run out fit the oil plug with a new gasket. Tighten
to a maximum torque of 55±10 Nm.
NOTE
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
11 Fill with engine oil to the correct level. Do not fill over MAX-level.
For volume and quality, see section F F Technical data.
12 Start the engine, let it idle. Check that the oil pressure is normal.
13 Turn off the engine and check the oil level, see Oil level, checking
(engine alternative Volvo TAD762VE), page 1:42. Top up as
needed.
014237
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
3 Remove the drain plug from the engine and drain the engine of oil.
007317
9 Fill engine oil. For volume and quality, see section F F Technical
014240
data.
10 Start the engine, let it idle. Check that the oil pressure is normal.
1. Filter holder
2. Bypass filter 11 Switch off the engine and check the oil level, see Oil level,
checking (engine alternative Volvo TAD1360VE), page 1:43. Fill if
3. Full flow filter necessary.
4. Full flow filter
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The engine's filler pipe (position B) and dipstick (position C) are located
under the hood.
1 Machine in service position, see section B Safety.
2 Check the oil level when the engine has been warmed up. Wipe
off the dipstick before checking.
The dipstick has two markings, MAX and MIN, and the oil level
should be between them.
NOTE
On certain machines the oil dipstick is long. Wear gloves.
3 Top up with new engine oil if necessary (position B). For volume
A and quality, see section F Technical data).
C 4 Fill - wait awhile - check on the dipstick.
B NOTE
Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
014785
DCF 280-330
A Location for filling and dipstick for engine oil
B Filling point
C Dipstick
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The engine's oil filling pipe (position B) is located under the hood. The
oil dipstick is on the right-hand side of the engine.
1 Machine in service position, see section B Safety.
2 The oil level can be checked both when the oil is cold and hot.
The STOP side of the dipstick is used for cold engine and the
OPERATING side is used for hot engine.
The dipstick has two marks between which the oil level should lie.
S TO
P
OP
ER A
TIN
G 014239
3 Top up with new engine oil if necessary (position B). For volume
and quality, see section F Technical data).
Do not fill over MAX-level.
4 Fill - wait awhile - check on the dipstick.
NOTE
Work carefully when filling to prevent other fluids or particles
from contaminating the oil, which means risk of engine damage.
B A
014059
DCF 370–520
A Position for filling
B Filling point
The control unit controls the amount of fuel to the unit injectors by
opening and closing a fuel valve by each injector. The unit injectors are
activated by an extra cam lobe on the camshaft, which compresses the
injector so that fuel is injected into the cylinder.
The fuel quantity is calculated by the control unit based on signals from
the sensors on the engine and a CAN message about the desired
engine speed (from the accelerator pedal via the cab control unit
(D790-1)).
1.10 Ignition/heating
Ignition/heating, description
The engine features preheating of the induction air, for faster start at
low temperatures. Preheating is activated when the ignition key is in
position II. When preheating is activated the preheating indicator light
comes on. The ignition sends signals to Control unit KIT (D790-2)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794).
1.11 Start/stop
Start/stop, description
The engine is started and stopped with the ignition. The ignition sends
signals to Control unit KIT (D790-2) and Control unit cab (D790-1)
which sends messages via CAN-bus drivetrain to Control unit engine
(D794). Starter motor and stop device are controlled by Control unit
engine (D794).
There is a stop button on the engine that can be used to stop the engine
in an emergency, e.g. if the engine cannot be stopped by other means.
2 Transmission
Contents 2 Transmission
2 Transmission ......................................................................................................2:3
2.2 Torque converter/Clutch system ......................................................................2:9
2.3 Mechanical transmission................................................................................2:10
2.6 Lubrication system ......................................................................................... 2:11
2.7 Cooling system ..............................................................................................2:16
2.8 Control system transmission..........................................................................2:17
2 Transmission
Transmission, general information
The transmission converts the engine power to the drive wheels (drive
axle) via the propeller shaft and also power to drive the hydraulic oil
pumps for the hydraulic system and the brake system.
The torque converter and the transmission work together via a common
hydraulic system. The torque converter is a hydraulic clutch located
between the engine's output shaft and the transmission's input shaft.
The hydraulic oil pumps and the oil pump for control and lubrication
of the transmission are connected to the torque converter via power
take-offs on the transmission.
F
R
<˚ 1
18 5
17 6 2
D794 D790-1 D790-2
8
˚C Pa
7 11 12 13 14
Pa ˚C 19
4 15
10
3
010113
1. Gear selector (S162) 11. Sensor turbine speed (B751)
2. Control unit KIT (D790-2) 12. Sensor drum speed (B752)
3. Oil pump transmission 13. Sensor output shaft speed (B758)
4. Oil filter transmission 14. Temperature monitor torque converter (S221)
5. Accelerator pedal (B690) 15. Oil cooler
6. Control unit cab (D790-1) 16. Control unit KID (D795)
7. Sensor oil pressure 17. Control unit engine (D794)
8. Sensor engine speed and oil temperature (B758/766) 18. Declutch pedal (S220-1)
9. Control unit, transmission (D793) 19. Break contact declutch (S220-2)
10. Solenoid valves for travel direction and gear position 20. Control unit frame (D797-1)
3 4 5 6
1 2 7 8
11
10
010282
12 13 14 9
1. Transmission 8. Oil filling
2. Sensor turbine speed (B751) 9. Oil filter transmission
3. Torque converter 10. Sensor output shaft speed (B758)
4. Sensor temperature output to oil cooler 11. Cross flange (for connection to propeller shaft)
5. Sensor oil pressure 12. Hoses cooling
6. Sensor engine speed (input shaft) incl. temperature 13. Thermostat
in oil pan (B758/766)
14. Transmission oil cooler
7. Sensor drum speed (B752)
F 1
R
4
3
26
5 2
D 7 9 0 -1 D 7 9 0 -2
27 D 794
6 D 793 D 795 D 7 9 7 -1
25 29
P a
16 17 18 19 20 21
P a P a 28
22
8 15
14 23
13
7 12
11 24
10
013393
9
1 2 3 4 5 6 7 8 9
20
19
18
17
16
15
14
013397
10 25 24 23 11 22 21 13 12 11 10
1. Sensor oil temperature (B7660) (from cooler to sump) 14. Solenoid valve gear selection 2/4 (Y6074)
2. Pressure line oil filter 15. Solenoid valve gear selection 1/3 (Y6075)
3. Temperature monitor torque converter (S2210) 16. Servo valve gear 1/3 (Y6067)
4. Dipstick 17. Servo valve gear 2/4 (Y6069)
5. Sensor engine rpm (B7530) 18. Servo valve gear forward/reverse (Y6300)
6. Torque converter 19. Solenoid valve drive reverse (Y6066R)
7. Power take-off 20. Solenoid valve drive forward (Y6066F)
8. Oil pump transmission 21. Transmission oil cooler
9. Transmission 22. Thermostat
10. Output shaft 23. Sensor rpm turbine (B7510)
11. Oil filter transmission 24. Sensor rpm drum (B7520)
12. Pressure sensor gear 1/3 (B6067) 25. Sensor rpm output shaft (B7580)
13. Pressure sensor gear 2/4 (B6069)
3 4 5
2
11
10 9
8
014272
1. Accelerator pedal (B690) 7. Control unit, transmission (D793)
2. Multi-function lever (S162) 8. Control unit engine (D794)
3. Control unit KIT (D790-2) 9. Declutch pedal (S220-1)
4. Control unit KID (D795) 10. Control unit frame (D797-1)
5. Control unit cab (D790-1) 11. Break contact declutch (S220-2)
6. Sensor operator in seat (S230)
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
NOTE
Do not over-fill the transmission!
4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the drain plug's washer seal is also removed.
NOTE
Make sure that the drain plug's washer seal is also removed.
A
B
012538
DCF 280-330
A Position for filling and level checking
B Dipstick and filling point
A
014060
C B
DCF 370-520
A Position for filling and level checking
B Filling point
C Dipstick
000356
b 14 Calibrate the transmission, see Transmission, calibration, page
2:18.
Operating menu oil temperature
a Transmission oil temperature
b Hydraulic oil temperature
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The transmission's oil filling pipe and oil dipstick are located under
the hood.
1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 82-93°C on the
display). The oil dipstick has two markings, MAX and MIN, the oil
level should be at MAX.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means risk
012538 of transmission damage.
DCF 280-330
A Position for filling and level checking
B Dipstick and filling point
A
014060
C B
DCF 370-520
A Position for filling and level checking
B Filling point
C Dipstick
Mode Limp-Home
In case of:
• a malfunction of a control output from the transmission is detected.
• a malfunction connected to a sensor for “engine speed” is detected.
• two of three “vehicle speed” sensors are defective.
In the event that any of the above situations arise the transmission will
be placed in neutral. To be able to continue operation a gear must be
selected with the gear selector.
In this mode the operator can use the transmission's two first gears in
each direction. If the malfunction occurs in a higher gear, the operator
has to downshift manually to first or second gear to continue.
Mode Shutdown
When the control unit gives the control signal for “Shutdown”, the oil
pressure drops in all pressure modulators. This takes place in the
event of a serious malfunction.
Transmission, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
1 Stop the machine on level ground, select neutral, and apply the
parking brake. Let the engine idle.
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION DRIVETRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000062
TARGET TEMP XXX A. Apply the footbrake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position and apply full throttle for 10 seconds,
run the engine at idle speed.
D. Repeat steps B and C until the oil is warm.
Towards the end of heating the engine speed may decrease
because the oil out from the transmission is too hot. If this occurs,
leave the gear in neutral and keep the engine speed at 1200 rpm
for 20 seconds.
When the temperature is correct MODE changes from 0 to 1.
005148
ACTION X XXXXrpm
NOTE
If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.
IMPORTANT
Calibration can be aborted at any time by selecting
travel direction reverse.
3 Driveline/Axle
Contents 3 Driveline/Axle
3 Driveline/Axle......................................................................................................3:3
3.2 Propeller shaft..................................................................................................3:4
3.3 Drive axle .........................................................................................................3:5
3 Driveline/Axle
Driveline/Axle, description
The machine's power transmission consists of propeller shaft and drive
axle with differential and hub reduction.
005193
1 2 3 4 1 1
3
4
2
009743 1
009744
DCF 280-330
DCF 370-520
1. Hub reduction
2. Insert shaft
3. Differential
4. Drive axle housing
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1 Position the machine so that the hub reductions' drain plugs at the
wheels are in the lowest position.
This applies to both drive wheels.
Wheel 1: move forwards or backwards to obtain the correct
position.
Wheel 2: lift the wheel from the ground (raise the machine under
the mast) and rotate the wheel into the correct position. Lower
1 the machine.
2 Machine in service position, see section B Safety.
2
008058
NOTE
Check that the seals are intact, clean and in the correct position.
7 Fill oil in the hubs until the oil level is flush with the filling and level
holes. For volume and quality, see section F F Technical data.
NOTE
The oil is very viscous, fill the oil slowly. Check the level in
stages so that the oil has time to settle.
NOTE
Check that the seals are intact, clean and in the correct position.
9 Fill oil in the differential until the oil level is flush with the filler and
level hole.
10 Install the level and filler plug on the differential.
NOTE
Check that the seal is intact, clean and in the correct position.
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:4
4.1.1 Brake pedal .................................................................................................4:4
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Oil pump brake system................................................................................4:8
4.3.4 Accumulator ..............................................................................................4:10
4.3.9 Wheel brake ..............................................................................................4:10
4.5 Parking brake system ....................................................................................4:12
4.5.4 Parking brake unit .....................................................................................4:14
4.8 Temperature control, cleaning and oil brake system......................................4:17
4.8.11 Breather filter.............................................................................................4:19
4.8.12 Oil filter, brake system ...............................................................................4:19
4.8.14 Oil brake system .......................................................................................4:20
4 Brakes
Brakes, general
There are brakes to stop the machine. The brakes act on the drive axle
(steering axle does not have brakes).
1 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
2 Check that the brake pedal returns all the way and that the
clearance between the brake pedal and brake valve is 1–1.5 mm.
If needed, adjust the brake pedal's stop bolt so that the clearance
becomes correct.
3 Check that the pedal's travel is smooth.
Oil pump brake system pumps oil (from the tank) which is cleaned in
the oil filter. The accumulator charging valve directs pressure to the
accumulators that store the pressure or direct the oil through the wheel
brake for cooling of the brake discs. The brake valve directs pressure
from the accumulators to the brake cylinder. The brake cylinder
compresses the discs in the brake units that brake the machine.
Make-contact (closing switch) for brake pressure emits a signal so that
the brake light is switched on when the brake cylinder is pressurised.
The oil for cooling the multiple-disc brakes then passes through the
cooler on the way back to the tank. An electric cooling fan increases
the air flow through the cooler when the temperature needs to be
reduced. A thermal bypass valve leads the hydraulic oil past the cooler
if the oil's temperature is too low. The temperature sensor controls
activation of the fan and temperature warning in the display.
5
12
B
D790-2 P
T
D
D797-1
9
D
10
8
C Pa
D
4 11 14 7
Pa
6
B C
ACC
C
3
P
2 13 T
P
B
010568
1. Oil pump brake system 8. Make-contact brake lights (S216)
2. Oil filter, brake system 9. Control unit frame (D797-1)
3. Accumulator charging valve 10. Brake light lamps
4. Accumulators 11. Break contact (opening switch) (S204)
5. Brake valve 12. Control unit KIT (D790-2)
6. Brake cylinder 13. Brake valve for double brake pedals
7. Wheel brakes 14. Shuttle valve double brake pedals
1
7 9 2
6b
6a
5
007197
1. Make-contact brake lights (S216) 6. a. Accumulator brake system (DCF 280-330)
2. Oil pump brake system b. Accumulator brake system (DCF 370-520)
3. Brake valve 7. Oil filter, brake system
4. Wheel brake 8. Accumulator charging valve
5. Shuttle valve double brake pedals 9. Break contact (opening switch) (S204)
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
4 Connect a pressure gauge (0–25 MPa) to the test outlet for pump
pressure on the accumulator charging valve.
5 Start the engine and let it idle.
005146
004791
10 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
Close the accumulator charging valve
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
004791
19 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
Close the accumulator charging valve
20 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
4.3.4 Accumulator
Accumulator, checking
1 Start the engine and let it idle for approx. 1 minute (until the
accumulator charging valve switches to cooling).
2 Turn off the engine and turn the start key to position I.
3 Apply and release the brake several times, and count the number
of times that the brake can be applied before the warning lamp for
low brake pressure is activated.
It should be possible to apply the brake at least 8 times before
the warning lamp is activated.
If the warning light for low brake pressure is activated earlier, one
of the brake system's accumulators is probably defective and
these should therefore be checked further.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Brake cylinder
1 Machine in service position, see section B Safety.
NOTE
The hydraulic hose between the brake pedal and brake is long.
For this reason allow at least two litres of oil pass through the
breather nipple during bleeding to ensure that no air pockets
remain in the system.
Breather nipple brake cylinder, top side of drive axle at 6 Move the wrench and the hose and collection container and repeat
the wheel hub's inner short side (left side). steps 2-5 on the other side.
Cooling circuit
NOTE
Bleeding the cooling circuit is very important to correctly cool the
discs.
3 Start the engine and let it idle. Wait until the brake accumulators
are fully charged and the accumulating charging valve has
switched to brake cooling.
4 Loosen the breather nipple (do not remove it) and let the oil run
out until it is free from air bubbles.
5 Move the receptacle and the sheet metal to the other wheel.
Repeat steps 1–4 on the other wheel.
Oil pump brake system pumps oil (from the tank) which is cleaned
in the oil filter. The accumulator charging valve directs pressure to
the accumulators that store the pressure. The parking brake unit is
released with pressure from the accumulators by the parking brake
valve in the accumulator charging valve pressurising the parking brake
caliper. Make-contact (closing switch) parking brake emits a signal
so that indicator light parking brake is switched on when the parking
brake is applied.
5
6 11
D790-1 D790-2
D797-1
7
C D D
4
8
Pa 10 9
C ACC
3
H
P
T
2
B
010569
1 2 3
007199
1. Accumulator charging valve 4. Oil pump brake system
2. Solenoid valve, parking brake (Y642) 5. Oil filter, brake system
3. Make-contact (closing switch) parking brake (S200) 6. Parking brake unit
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
2 Turn off the engine and turn the start key to position I.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is clean from oil and dirt.
NOTE
To avoid turning the adjustment screw as well, it must be held
still when tightening the lock nut.
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
6 Pull out the attaching bolt so that the brake pads can be twisted
out and removed.
NOTE
The bolt does not have to be removed.
The temperature control system consists of hydraulic oil tank, oil pump
brake system, oil filter brake system, accumulator charging valve and
wheel brake units.
Oil pump brake system pumps oil (from the tank) which is cleaned in
the oil filter. When the accumulators are charged, the accumulator
charging valve directs oil through the drive axle's brake units, which
cools the brakes and then returns to the tank.
If the temperature in the brake system becomes too high, the machine's
speed is limited to protect the brakes.
Brake system with separate oil tank and cooler
The brake system is cooled with oil that is circulated through a cooler.
The cooler has a temperature-controlled electric fan that counteracts
overheating.
The temperature control system consists of oil tank brake system, oil
pump brake system, oil filter brake system, accumulator charging
valve, wheel brake units, radiator, cooling fan, temperature sensor oil
brake system and thermal bypass valve.
Oil pump brake system pumps oil (from the tank) which is cleaned in
the oil filter. When the accumulators are charged, the accumulator
charging valve directs oil through the drive axle's brake units and cools
the brakes. The oil passes through the cooler back to the tank. An
electric cooling fan increases the air flow through the cooler when the
temperature needs to be reduced. A thermal bypass valve leads the
hydraulic oil past the cooler if the oil's temperature is too low. The
temperature sensor controls activation of the fan and temperature
warning in the display.
11
D795
D797-1
D 9 D
C
C
3 4
P T
2 5
6 10
1 M
7
010570
8 ˚C ˚C
2 3
5
7
4
007200
NOTE
1 Work carefully so that contaminants do not enter the tank.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
The filter protects the brake system from impurities. It
is very important that new impurities do not enter the
brake system when changing filter.
NOTE
Leave the valves open when changing.
3 Remove the cover plates over the area next to the transmission.
NOTE
The filter holder is heavy, loosen it carefully.
NOTE
Note the position of the O-rings.
NOTE
007201
12 Start the engine and check that the filter holder does not leak.
13 Fit the cover plates over the space next to the transmission.
14 Bleed the wheel brakes, see Wheel brake, bleeding, page 4:10.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
3 Remove the filler cap and drain the brake system's oil tank.
4 Remove the drain plug and let the last of the oil drain into a
2 receptacle.
5 Fit the drain plug, use a new sealing washer.
6 Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F F Technical data.
1 7 Fit the filler cap.
8 Bleed the brake cylinders and cooling circuit, see section 4
Brakes, group 4.3.9 Wheel brake.
005255
1. Filling oil brake system
2. Breather filter oil tank
5 Steering
Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.2 Power assisted system ....................................................................................5:4
5.2.6 Link arm ......................................................................................................5:9
5.2.12 Sensor steering wheel reading....................................................................5:9
5 Steering
Steering, general
The function steering means to steer the machine while operating. The
machine is steered with the rear wheels by a power-assisted steering
system.
The steering wheel acts (via the steering shaft) on the steering valve
which in turn directs oil pressure from the hydraulic oil pump to the
steering cylinder. The priority valve, located between the hydraulic oil
pump and the steering valve, gives priority to oil supply of the steering
valve before other functions, e.g. load handling. The steering cylinder
acts on the wheel spindles. The link arms are located between the
steering cylinder and wheel spindles.
4
C PP
P
P CF
LS 3
T LS T
L R
1 C
010733
1. Hydraulic oil pump 4. Priority valve
2. Steering wheel 5. Steering cylinder
3. Steering valve
D790-1
4 D797-2 D
P 3 6
PP
C
LS
D
CF
P T
L R
LS T
8 5 5
1
D
7 7
010571
1. Hydraulic oil pump 6. Control unit frame option (D797-2)
2. Steering wheel 7. Solenoid valve steering forward (Y636-1) or steering
backward (Y636-2)
3. Steering valve
8. Directional control valve turnable operator's station
4. Priority valve
9. Steering cylinder
5. Sensor turnable operator's station forward (S720-F)
or backward (S720-R)
Joystick control and mini-wheel function in the same way, the difference
is in the design of the control.
NOTE
The standard steering wheel always has priority over joystick control
or mini-wheel steering. Joystick control or mini-wheel steering are
disabled as soon as a steering wheel movement is made.
10
D D
2
12 3
D790-2 D790-1
11 D797-2
4
D 5 D
8
C PP
P
LS
P CF P
TP
6, 7
LS
T1
T LS A B
T
L R
007205
1. Hydraulic oil pump 7. Control valve joystick steering or mini-wheel
2. Switch joystick or Switch mini-wheel 8. Priority valve
3. Control unit cab (D790-1) 9. Steering cylinder
4. Control unit frame (D797-2) 10. Steering wheel
5. Solenoid valve steering right (Y636-3) or Solenoid 11. Sensor steering wheel reading (B770)
steering left (Y636-4)
12. Control unit, cab KIT (D790-2)
6. Control slide
5
4
6
007206
1. Steering valve 5. Hydraulic oil pump
2. Directional control valve turnable operator's station 6. Steering axle with steering cylinder
7. Control valve mini-wheel/joystick steering
3. Make-contact (closing switch) turnable operator's
8. Priority valve
station forward (S720-F)
4. Make-contact (closing switch) turnable operator's
station backward (S720-R)
007918
5.2.12 Sensor steering wheel reading
Sensor steering wheel reading, checking
Also check that the sensor for the steering wheel reading is secure in
its bracket and that the multi-function levers are secure by unfastening
the bottom of the steering wheel panel.
002628
1. Indicator ring
2. Sensor steering wheel reading (B770)
6 Suspension
Contents 6 Suspension
6 Suspension .........................................................................................................6:3
6.2 Suspension ......................................................................................................6:4
6.2.1 Steering axle cradle ....................................................................................6:6
6.2.2 Wheel spindle..............................................................................................6:7
6.2.3 Wheel hub ...................................................................................................6:7
6.3 Tyres and rims .................................................................................................6:9
6.3.1 Tyres .........................................................................................................6:18
6.3.2 Rim ............................................................................................................6:19
6 Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the driveline/axle, see section 3 Driveline/Axle, group3.3 Drive axle.
6.2 Suspension
Suspension, description
The steering axle cradle is mounted to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journaled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journaled wheel hubs where
the wheels are mounted.
010114
DCF 280-330
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. Spindle bolt / bearing
1 2 3 5 4 6 7 8
007575
DCF 370–520
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Front suspension
6. Steering cylinder
7. Rear suspension
8. Counterweight
3 Measure the distance between the frame and the steering axle
cradle. Note the measurement.
4 Lift the machine under the rear counterweight.
NOTE
Do not lift under the steering axle.
5 Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
6 Calculate the difference between the two measurements. The
difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.
007842
2 Lift and lower the machine under the steering axle with a jack
at the wheel in question, and check that there is no play in the
spindle joint.
4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
NOTE
Be careful so that the seal is not damaged.
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.
CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
When removing drive wheels, make sure that the
wheels are secured when removing the spacer rings.
If the wheels move they may move the spacer rings,
which may result in crushing injuries.
When installing drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,
pieces of wood, metal filings, etc.
Check if tyre wear is abnormal, this could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.
The drive axle is exposed to high forces during operation, if the drive
wheels' rolling circumference is different the stresses increase on
the drive axle. It is important that the tyres on the drive axle are the
same model, type and make, and have equal wear and proper inflation
pressure.
DANGER
Never stand in front of the tyre when deflating or
inflating! Lock ring and lock lugs may release and
shoot off when the pressure changes.
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Do not exceed prescribed air pressure! When changing
tyre or rim version, another air pressure may apply,
contact Cargotec.
1. Lock ring
2. Side ring
3. Lock ring
2 Check the air pressure in the tyres, see section Tyres, inflating,
page 6:18.
The pressure must be 1.0 MPa, inflate if necessary.
3 Check the tyres.
• Check for uneven and fast wear, this is caused by mechanical
defects such as, e.g., uneven brake action. Make sure that
such defects are repaired immediately.
• Remove penetrating objects such as crushed glass, pieces of
wood, metal filings, etc.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change, page 6:19.
4 If the tyres and rims have no defects, check-tighten the wheel nuts.
Tighten crosswise to a torque of:
• 400 Nm oiled screw.
007268
2 Lift the machine under the drive axle by the relevant wheel.
Support under the drive axle in a secure way.
DANGER
With double wheel fitting both tyres must be deflated
otherwise the inner may explode when the outer is
removed.
Risk of tyre explosion! Fatal danger!
Empty both tyres of air.
b) If this does not work, undo the valve in the rim and release the air.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
005124
NOTE
The spacer ring is heavy.
7 Lift the wheel away and position it safely so that it does not fall or
move.
8 Secure the inner drive wheel with lifting equipment.
9 Remove the spacer ring between the outer and inner wheels.
NOTE
The spacer ring is heavy.
10 Remove the inner drive wheel and position it safely so that it does
not fall or move.
Installing
11 Fit the inner drive wheel. Turn the wheel so that the guide lug
enters the groove on the hub.
NOTE
The inner spacer ring is not split.
13 Install the outer drive wheel. Turn the wheel so that the guide lug
enters the groove on the hub.
NOTE
The outer spacer ring is spit. Turn the ring so that the opening
ends up directly opposite the groove on the hub.
15 Fit clamps and nuts on the wheel studs. Fit washers too where
applicable.
NOTE
Don not forget the bracket for the inner tyre's valve extender.
16 Fit the wheel nuts. Tighten the wheel nuts crosswise successively
with increasing torque to 400 Nm oiled screw.
17 Inflate the tyres, see Tyres, inflating, page 6:18.
18 Lower the machine and remove the jack.
19 Test-drive the machine and check that the wheels are secure.
20 Check-tighten the wheel nuts crosswise with 400 Nm oiled bolt.
2 Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.
014571
b) If this does not work, undo the valve in the rim and release the air.
014573
c) If this does not work, break off, cut or saw off the valve pipe.
014572
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill bit of a max. Ø 5 mm.
005123
4 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5 Remove wheel nuts and clamps.
6 Remove the wheel and position it safely so that it does not fall or
move.
005124
Installing
7 Fit the wheel.
Adjust the position of the wheel so that the steering pin passes
over the notch in the hub and so that the wheel is lying against
the hub.
8 Install clamps and wheel nuts. Tighten the wheel nuts crosswise
successively with increasing torque to 400 Nm oiled screw.
9 Inflate the tyre, see Tyres, inflating, page 6:18.
10 Lower the machine and remove the jack.
11 Test-drive the machine and check that the wheels are secure.
12 Check-tighten the wheel nuts crosswise with 400 Nm oiled bolt.
000383
6.3.1 Tyres
Tyres, inflating
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:9.
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must
be dismantled and the rim checked for damage.
Never install rim components by striking with a
hammer while inflating. Never strike fully or partly
inflated tyres or rim sets.
Never inflate tyres before all parts are in place.
Wheels shall be inflated on the machine or in a
protective device, designed and dimensioned so that
it can handle or dissipate a shock wave from a tyre
explosion as well as catch the ejected parts.
Do not exceed the prescribed tyre pressures which
must be checked at ambient temperature. When
007268
NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1 Make sure that the lock ring and lock lugs are in the correct
position before inflating.
3 Stand at an angle behind the tyre and remain there until inflating
has been completed in order to prevent being hit by rim parts in
the event of an explosion.
Tyre, change
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre company.
Check the rim in connection with tyre change, see Rim, check, page
6:19.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimise risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and size.
Overdimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
2 Carefully clean the outside of the rim edge with a steel brush.
001703
Max 0,5 mm
001715
O. Circumference 001701
D. Diameter
3 Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
Rim any remaining cleaning fluid evaporate.
4 Spray detection fluid part no. 923626.0670 on the area.
5 Let the sprayed area dry 1-2 hours.
001705
Examples of cracks
1. Linear crack
2. Pointed crack
7 Load handling
7 Load handling
Load handling, general
Load handling function refers to, for example, lifting/lowering the
carriage, tilting mast forward and back, side shifting, changing
distance between and levelling the forks, and rotating separate top
lift attachment.
Load handling is divided into different sub-functions.
• Lifting/lowering
012513
• Side shift
006950
• Spreading
007910
• Tilt
012514
• Rotation
• Load carrier
• Separate top lift attachment
012515
7.2 Lifting/lowering
Lifting/lowering, function description
Lifting/lowering means that the mast's components are raised and
lowered so that the fork carriage and lifting forks are raised and
lowered.
During lifting, the inner mast is raised with the lift cylinders. The lifting
chain that is secured in the carriage (and in the outer mast) runs over
the chain wheel at the top of the inner mast, and by these means the
carriage is also lifted at the same time as the inner mast.
012513
The machine can be equipped with a special free-lift mast . The
fork carriage is raised in two steps, first the free-lift stage (i.e. the
carriage is raised to full height in the inner mast with the aid of the
free-lift cylinders) and then with the two lift cylinders, which lift
the inner mast to full lifting height.
8
C 7
3
A 4
2 B2
T H
P
C
P2
P1 8
T A2 7
6
C EF
P
1 1 T
007243
1. Hydraulic oil pumps 5. Control lever lifting/lowering
2. Pressure reducer 6. Lifting/lowering slide in control valve load handling
3. Accumulator servo circuit 7. Load control valves
4. Servo filter 8. Lift cylinders
D
5b
5a
6
D790-1
D797-1
7
11
3 10
C
D 8
2 A 4
H
T 9
P
C
P2
C P1
11
T 10
8
C C EF
P
1 1 T
014792
1. Hydraulic oil pumps 7. Control unit frame (D797-1)
2. Pressure reducer 8. Solenoid valve lift mast (Y6005) or solenoid valve
lower mast (Y6004)
3. Accumulator servo circuit
9. Lifting/lowering slide in control valve load handling
4. Servo filter
10. Load control valves
5. a. Control lever lifting/lowering (R8071)
11. Lift cylinders
b. Control lever (S815-P1)
6. Control unit cab (D790-1)
9b
D
9a
10
D790-1
D797-1 D797-2
3 4 D
D
16
7 15
C
12
D C 14 13
11 2
6 A 8
T H A2
P
C
P2
16 1
C P1
T 15
11
14
C C EF
P
5 5 T
014793
11
10 1
9
3
8
5a
5b
6
009838
1. Pressure reducer 6. Hydraulic oil pump
2. Accumulator servo circuit 7. Load control valve
3. Test outlet servo circuit 8. Position sensor fork carriage up (B260)
4. Servo filter 9. Lift cylinder
5. a. Control valve load handling, hydraulic servo 10. Position sensor mast down (B261)
b. Control valve load handling, electric servo 11. Mast
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
5 Start the engine and check the servo pressure. Compare to the
pressure plate.
MPa Turn the steering wheel or activate a load handling function in
order to activate the hydraulic oil pumps. The servo pressure is
higher than the standby pressure of the hydraulic oil pumps.
6 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
MPa
MPa
MPa
MPa
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
3 Turn the start key to position 0 and turn off the system voltage.
8 Check that the O-ring on the filter holder is intact and in place.
9 Fit the filter and filter holder.
10 Check the oil level in the hydraulic oil tank when all of the hydraulic
pistons are in retracted position. The oil should be at the top
of the sight glass. Top up as needed, for quality see section F
Technical data.
NOTE
Hydraulic oil level is checked when all hydraulic oil pistons are
pushed in.
7.2.9 Mast
WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.
4 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
009673
2 Check that the slide surfaces in the inner mast have a normal
1 appearance and do not show signs of damage or unevenness.
3 Check the clearance between the outer and inner mast with
the mast in the fully lowered position. The clearance should be
between 0-5 mm.
2 4 If the play between the outer and inner masts exceeds 5 mm,
reduce clearance by shimming.
NOTE
Do not over-shim; this will increase the wear on the slide plates.
010289
1. Slide plate
2. Shim
2 Check that the support rollers are correctly run and that all
surfaces of the support rollers and contact faces against the mast
have normal appearances.
NOTE
Support rollers and mast wheels are also located in the mast's
upper component.
2
010288
1. Support roller
2. Mast wheels
The chains must be thoroughly cleaned over their whole length. The
checking is performed without a load on the forks.
Wear checking
1 The chain must not have extended more than 3%. Measure the
length of the 25 links that during lifting first (and most often) travel
over the chain wheel. This is where the extension is greatest.
Compare with the values in the table. If the 3% limit is exceeded,
the chains must be replaced.
Adjusting
3 Check that the pins for the outer washers are securely fastened.
7 Check that the chain bends easily over the pulley (does not jam
when bending).
8 Place the machine on level surface with the mast vertical (0° tilt).
NOTE
If the chain is slack when the carriage is in its lowest position,
the chain must be tightened.
11 Adjust the chains so that the carriage is lifted evenly in the mast.
• Loosen the locking washers (position 1) and remove the lower
nut (position 2).
• Lift the chain tightener (position 4) out of the carriage and
remove the old locking washer.
• Reinstall with new locking washer, chain tightener, locking
washer and lower nut. Repeat on the other side.
NOTE
Reinstall only new locking washers.
3
• Adjust the nuts on each side to balance the carriage so that
1 the distance between the carriage and mast is 10-20 mm.
• Tighten the nuts with 2000 Nm and lock them with locking
washers.
• Test lift and check that the lifting chain stretches equally on
each side so that the carriage is balanced.
Repeat adjustments as needed.
12 Lubricate the chains after completed inspection.
1
2
005669
1. Locking washer
2. Lower nut
3. Upper nut
4. Chain tightener
Side shift is controlled and activated with control lever, side shift.
The piston side of one of the side shift and spreading cylinders is
006950
pressurised during side shifting. The pressure from the piston side of
the first cylinder is directed to the other cylinder's push rod side and
compresses the second cylinder together.
There are two versions of side shift, depending on how the function is
controlled.
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the side shift.
•
Electric servo means that the control levers are electric and send
voltage signals to the control system to control the side shift.
C
3
A 4
2 A1 A1
7
T H
P C
P2
P1
T B1 B1
6 7
C EF
P
1 1 T
007245
1. Hydraulic oil pumps 5. Control lever side shift
2. Pressure reducer 6. Side shift slide in control valve load handling
3. Accumulator servo circuit 7. Side shift and spreading cylinders
4. Servo filter
D
5b
5a
6
D790-1
D797-2
7
C
3
D 8
A 4
2 A1 A1
9
T H
P C
P2
C P1
T B1 B1
9
8
C EF
P
T
1 1
010606
1. Hydraulic oil pumps 6. Control unit cab (D790-1)
2. Pressure reducer 7. Control unit frame option (D797-2)
3. Accumulator servo circuit 8. Solenoid valve side shift left (Y6020) or solenoid
valve side shift right (Y6021)
4. Servo filter
9. Side shift and spreading cylinders
5. a. Control lever side shift (R8073)
b. Control lever (S815-P3)
1
9
3
5a
5b
009839
1. Pressure reducer b. Control valve load handling, electric servo
2. Accumulator servo circuit 6. Hydraulic oil pump
3. Test outlet servo circuit 7. Side shift and spreading cylinders
4. Servo filter 8. Fork bracket
5. a. Control valve load handling, hydraulic servo 9. Fork carriage
7.5 Spreading
Spreading, function description
Spreading involves changing the relative distance between the
lifting forks. Control valve, load handling, pressurises the spreading
cylinders. Spreading uses the upper of the side shift and spreading
cylinders, this extends the right-hand fork bracket independently of
the left. Spreading is activated with control lever, spreading.
• Spreading with hydraulic servo means that the control levers are
007910
supplied with hydraulic pressure, which controls the spreading of
the forks.
•
Spreading with electric servo means that the control levers are
electric and send voltage signals to the control system to control
the spreading of the forks.
8
7
C
3
A 4 8
2 A1
T H
P C
P2
P1
T B1
6
C EF
P
T
1 1
014786
1. Hydraulic oil pumps 5. Control lever spreading
2. Pressure reducer 6. Spreading slide in control valve load handling
3. Accumulator servo circuit 7. Flow distributor
4. Servo filter 8. Side shift and spreading cylinders
5b D
5a
6
D790-1
D797-2
7 10
C
3 9
D 8
A 4
2 A1 A1
T H
P C 10
P2
C P1
T B1 B1
8
C EF
P
T
1 1
014787
1. Hydraulic oil pumps 6. Control unit cab (D790-1)
2. Pressure reducer 7. Control unit frame option (D797-2)
3. Accumulator servo circuit 8. Solenoid valve spreading in (Y6019) or solenoid
valve spreading out (Y6018)
4. Servo filter
9. Flow distributor
5. a. Control lever spreading (R8074)
10. Side shift and spreading cylinders
b. Control lever (S815-P4)
1
10
3
8 4
5a
5b
6
014790
1. Pressure reducer 6. Hydraulic oil pump
2. Accumulator servo circuit 7. Side shift and spreading cylinders
3. Test outlet servo circuit 8. Flow distributor
4. Servo filter 9. Fork bracket
5. a. Control valve load handling, hydraulic servo 10. Fork carriage
b. Control valve load handling, electric servo
7.7 Tilt
Tilt, function description
Tilt means the angling of the mast in relation to the machine. Control
valve, load handling, pressurises the tilt cylinders which extend/angle
the mast in relation to the machine. Tilt is controlled with control
lever, tilt.
012514
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the tilting.
•
Electric servo means that the control levers are electric and send
voltage signals to the control system to control the tilting.
C
3
A 4 8
2 7
T H A1
P C
P2
P1 8
T B1 7
6
C EF
P
T
1 1
007250
5b D
5a
6
D790-1
D797-1
7
C
3
D 8
A 4 10
2 9
T H A1
P C
P2
C P1 10
T B1 9
8
C EF
P
1 1 T
010576
1. Hydraulic oil pumps 6. Control unit cab (D790-1)
2. Pressure reducer 7. Control unit frame (D797-1)
3. Accumulator servo circuit 8. Solenoid valve tilt in (Y6011) or solenoid valve tilt out
(Y6010)
4. Servo filter
9. Load holding valve
5. a. Control lever tilt (R8072)
10. Tilt cylinders
b. Control lever (S815-P2)
8 1
4
7
5a
5b
009841
1. Pressure reducer b. Control valve load handling, electric servo
2. Accumulator servo circuit 6. Hydraulic oil pump
3. Test outlet servo circuit 7. Mast
4. Servo filter 8. Load holding valve
5. a. Control valve load handling, hydraulic servo 9. Tilt cylinders
5
6
007487
7
1. Lifting fork 5. Lock pin
2. Support roller 6. Mobile lock hook
3. Inverted lifting forks for fork shank system 7. Lower mounting hook
4. Upper mounting hook
DANGER
Damaged lifting forks must be changed.
Repairs to lifting forks change their strength, which
may lead to dropped loads and fatalities.
2 Check the fork arms with regard to blade thickness, cracks and
deformation.
• Blade wear may 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 no longer than 5 mm.
If surface cracks are discovered, grind down approx. 0.5 mm
and test with magnetic particle inspection to see if the crack
is still visible. 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
approved service personnel, who will determine whether the forks
can be repaired.
NOTE
Surface cracks and wear must not be dealt with using welding.
007488
5
014275
Fitted on the top lift attachment is a valve that determines whether
spreading 20"-40", twistlocks or rotation should be activated.
Spreading 20"-40" and twistlocks are activated with a switch. Rotation
is controlled with the control lever for spreading.
7.10.5.1 Spreading
D D
5 6 7
D790-1
D797-2
8
D
C 10 14
3
A 4 9
2 A1
T H 11 12
P C 13
P2
C P1
15
T B1
9
C EF
P
1 1 T
010577
1. Hydraulic oil pumps 9. Solenoid valve spreading out (Y6018) or solenoid
2. Pressure reducer valve spreading in (Y6019)
16 10
2
15
3
17 9 4
8
7
6
5
10
14 M
11
13
12
014794
1. Main beam attachment 10. Spreading motor
2. Electronic box attachment 11. Spreading chains
3. Gearshifting valve, rotation or twistlocks 12. Control valve load handling, electric servo
4. Position sensor spreading 13. Hydraulic oil pump
5. Sensor contact 14. Servo filter
6. Twistlock 15. Pressure reducer
7. Sensor twistlocks 16. Accumulator servo circuit
8. Lock cylinder twistlocks 17. Test outlet servo circuit
9. Extension beam
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
NOTE
Make sure that the drain plug's washer seal is also removed.
1. Filling point
2. Sight glass
3. Drain plug
4 Top up the oil through the filling point (position 1) until the level is
in the middle of the sight glass as shown. For volume and quality,
see section F F Technical data.
013674
20-foot position
2 Start the engine, move in the spreading to the 20-foot position
and turn off the engine.
3 Check that both spreading beams move toward the 20-foot stop
and that the distance between the spreading beam and the
spreading motor's mount is at least 3 mm.
NOTE
Note the distance that the stop is adjusted to.
CAUTION
20-foot stop
Incorrect chain tension.
Risk of damage to the attachment.
If the 20-foot stop is adjusted, the spreader chains must
be adjusted by an equal amount.
NOTE
Check the vertical position of the chain tensioner to ensure that
the chain runs straight against the chain wheel.
005105
40-foot position
8 Start the engine and move out the spreading to the 40-foot position
and turn off the engine.
9 Check the C-C measurement between the twistlocks.
C-C 40 foot: 11985±3 mm.
If the 20-foot setting is correct, go to step 11.
10 If needed, adjust the 40-foot stop.
005106
40-foot stop
0 N
010486
100 N
X
NOTE
Adjust the chain on the chain tightener max 2 mm at a time.
IMPORTANT
Check the distance of the stop from both 20\q and 40\q.
1 Park the machine with the attachment as far down as possible and
spreading run inward so that 40 cm remain to the 20-foot position.
2 Turn off the engine and turn off the main electric power.
6 Pull out the slide plate together with spacer plates and console.
7 Measure the thickness of the slide plate, replace if needed.
NOTE
The thickness of the slide plate should be at least 10 mm.
NOTE
Excessive clearance may result in damage to the spreader
beam during load handling.
7.10.5.2 Rotation
Rotation, description
5a D
5b
6
D790-1
D797-2
7
C
3
D 8 10
A 4
2 A1 9
T H
P C
P2
C P1
T B1
10
8
C EF
P
1 1 T
010578
1. Hydraulic oil pumps 6. Control unit cab (D790-1)
2. Pressure reducer 7. Control unit frame option (D797-2)
3. Accumulator servo circuit 8. Solenoid valve spreading in (Y6019) or solenoid
4. Servo filter valve spreading out (Y6018)
5. a. Control lever (R8074) 9. Gearshifting valve, rotation or twistlocks
b. Control lever (S815-P4) 10. Rotation cylinders
8
2
10
3
7 4
009843
1. Main beam attachment 6. Hydraulic oil pump
2. Gearshifting valve, rotation or twistlocks 7. Servo filter
3. Rotation cylinders 8. Pressure reducer
4. Rotation carriage 9. Accumulator servo circuit
5. Control valve load handling, electric servo 10. Test outlet servo circuit
7.10.5.3 Twistlocks
Twistlocks, description
Electric servo
007502
Twistlocks secure the container to the attachment. Twistlocks are
operated with hydraulic cylinders that are controlled by the control
valve for load handling.
D
5
11 6 19 10 19
D790-2 D790-1
D797-2
12
D
7
14
D
4 17 17
C 16 8
13 D
3 A
2 18
C
P2 9
15 16 18
P1
T B
ACC
13 D
P
17 17
T
EF
P
1 1 1 010579
13 1
12 15 5
2
14
3
4
11 6 7 6 8
10
9
009844
1. Lock mechanism 9. Control valve load handling, electric servo
2. Sensor contact 10. Hydraulic oil pump
3. Contact pin 11. Servo filter
4. Lift pin 12. Pressure reducer
5. Lock guide 13. Accumulator servo circuit
6. Sensor twistlocks 14. Test outlet servo circuit
7. Lock mechanism 15. Gearshifting valve, rotation or twistlocks
8. Lock cylinder
Twistlocks, checking
WARNING
Dropped load.
Fatal danger!
Twistlocks hold the load during load handling and
therefore it is crucial that twistlocks are checked
according to instructions and replaced at the slightest
sign of damage or wear.
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
5 5 Press in the alignment pin so that the head is flush with the
spreader beam's underside. Check the distance to sensor
alignment, the distance should be 3-4 mm. Adjust when needed.
NOTE
4 The contact pin should move easily and spring back completely.
000633
3 6 Check that the lock guide and lift pin can move freely.
7 Fit a pry bar between the lift pin (position 4) and the lock guide
1. Lock mechanism (position 5) and check the clearance, max. clearance: 1.5–2 mm.
2. Sensor contact
3. Contact pin
4. Lift pin
5. Lock guide
8 Turn twistlocks to locked position and check wear of the lift pin.
Change the lift pin as needed.
m Max. 4 mm
m
70
.
in
M
002311
Wear limits lift pin.
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.
NOTE
Twistlocks are heavy, be careful when removing.
2 Check for cracks within the marked area on the lift pins without
causing damage.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
002313
WARNING
Dropped component.
Risk of crushing, product damage.
Twistlock weighs approx. 30 kg.
1,5-2 mm
012582
2
1. Nut
2. Twistlocks
3. Adjusting shims
WARNING
In the event of irregular horizontal movement twistlocks
are exposed to fatigue.
Shortened life of twistlocks.
Check the float position every 500 hours of operation.
1 Check that the tightening torque on the nut (position A) is 700 Nm.
2 Move the lift pin around in the opening and check that the lift pin
A reaches all four corners and that the edges of the lift pin and the
opening are in contact with each other at the same time.
3 Adjust the vertical movement if the float position is not correct.
1 2
3 4
012583
000635
4 Lower the attachment over a container and lock twistlocks.
5 Check that the light indicator on the sensor is on for the sensors
1. Sensor twistlocks with the indicator plate in position in front of the sensor. On the
2. Lock mechanism other two, the light indicator should not be lit.
3. Lock cylinder If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is 5±1 mm.
6 Check that indicator light twistlocks locked is lit.
8 Control system
8 Control system
Control system, general
In many cases the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator or
limit the machine's functions in case of certain dangerous situations or
if there are malfunctions in the machine.
Settings is the tool for setting and adapting the machine’s functions.
The function keys are used to navigate in the display menus for
service and troubleshooting, for example.
000053
A
A Function keys (KIT)
B Warning and indicator lights
C Display (KID)
D Alarm indicator
Function keys
Function keys
The function keys (A) are used to navigate in the menu system.
Also used to enter values in the system, change light contrast in the
keys/indicator panel, and to acknowledge warning.
000055
Operating menus
Operating menus
014251
• Operating menu heating and air conditioning
Examples of available operating menus • Operating menu statistics
• Operating menu scale
• Operating menu service interval
• Operating menu code lock
Event-controlled information
8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
• Bypass
• Speed limitation
• Service indicator
8.2.2 Bypass
Bypass, description
Bypass is activated with the bypass switch.
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
000056
3 Enter code for resetting service indicator.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
PRESENT XXXXh
Height warning alerts when the set maximum lifting height is reached.
Height warning is adjustable according to customer requirements.
Error code is indicated with activate Indicator for active error codes
(position 36). Error codes are divided into three error code levels,
depending on how serious they are.
When the error code has been acknowledged the display returns
to previously selected menu. If the error code is active, it is stored
in the error code list under operating menu for service.
Example of automatic display figure
If the error code is active it is repeated to remind the operator
of the error status, stop every 3rd minute, warnings every 5th
minute.
001998
Example of display in error code list
NOTE
If error code isn’t included in the error code list, it may be due
to the following:
– condition for error detection no longer exists, e.g.,
control lever is released or engine is off.
– loose connection/poor contact.
8.4 Diagnostics
Diagnostics, general
The machine has built-in functions for troubleshooting called diagnostic
test. The diagnostic test consists of several menus that are shown in
the display. The menus are grouped for faster access.
005592
FEEDBACK 0 and ammeters that measure the signal on the connectors out to
components or in from components.
1. DIAG = Diagnostic menus Output signals are control of solenoid valves, lights, relays, etc.
2. Menu group (CAB = cab functions)
Input signals are sensor signals, signals from controls and switches,
3. Menu number feedback control signals, etc.
4. Total number of menus in the loop. The number
of menus depends on how the machine is The figure shows an example of a menu, here for diagnostics of
equipped, which is why the number of menus is windshield wiper. The table below indicates what you can read out
indicated by (X) in this manual. from the menu figure.
5. Variable
6. Signal value
7. Menu heading
000056
3 Enter the code for diagnostics.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
4 Select group by scrolling with the arrow keys (1 and 2) and confirm
DIAGNOSIS with Enter.
CAN/POWER LIGHTS CAB
Each group consists of a sequence of numbered menus. The first
CLIMATE HYD ENGINE menu for selected diagnostic menu is shown in the display, use
TRANSM ELSERV ATTACH arrow keys (1 and 2) to change menu.
005263
OLS EXTRA
8.4.1 CAN/POWER
CAN/POWER, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
SEGMENT ERROR X
8.4.2 LIGHTS
LIGHTS, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.3 CAB
CAB, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
007489
8.4.4 CLIMATE
CLIMATE, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.5 HYD
HYD, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
010284
DECLUTCH PRESSURE X VALVE XY PUMP ATTACHMENT XY
8.4.6 ENGINE
ENGINE, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
014712
IND. SEVERITY XX
8.4.7 TRANSM
TRANSM, menu overview
Applies for transmission alternative TE17.
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
013398
TIME AGO XXXXX
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
8.4.9 ATTACH
ATTACH, menu overview
Not used.
8.4.10 OLS
OLS, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
010620
8.4.11 EXTRA
8.4.11.1 VBFS
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
009945
FRONT LE/RI XY FRONT LE XY RI XY DAMP SPEED XY
8.4.11.2 EL-STEERING
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
007652
FEEDBACK XXX FEEDBACK XXX
8.4.11.3 EXT-ATTACH
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
010286
FEEDBACK XXX FEEDBACK XXX
8.4.11.4 FREELIFT
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
8.4.11.5 MOVE-CAB
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
007653
FEEDBACK XXX
8.4.11.6 OPT
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
007654
8.4.11.7 I/O
8.4.11.8 RMI
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
8.5 Settings
Setup, general
Settings offer the option of adapting the properties of the functions
for each unique machine. Settings are entered via the menus in the
display. Settings options are divided into sections such as Initiations
and Calibrations
The body consists of fenders, hood, tanks and other parts mounted on
the frame.
The cab is built separately and isolated from the frame using
heavy-duty rubber dampers. Driver's seat, steering wheel, and control
lever for hydraulics can be adjusted for optimal individual operating
position. Effective insulation gives a minimum of vibrations and a low
sound level. The machine is equipped with heating and ventilation, air
condition is available as an option.
1 2 3 4 5
15
12 13 12 10 11 9 6 8
013922
14
Overview
1. Left instrument panel
2. Gear and multi-function lever (S162)
3. Steering wheel panel
4. Steering wheel
5. Direction indicators (S161)
6. Panel for hydraulic functions
7. Control breaker for hydraulics (S250)
8. Switch for parking brake (S107)
9. Hydraulic control
10. Driver's seat
11. Accelerator pedal (B690)
12. Brake pedals
13. Declutch pedal (S220-1)
14. Electronic box with fuses and relays
15. Hour meter (P708)
A Joystick or mini-wheel
012966
17
Extra working lights mast
16
Left instrument panel 22. Switch for rotating beacon (S110)
23. Switch for hazard lights (S109)
24. Switch for headlights (S100)
25. Switch for seat heating (S143)
(Can be located on the driver's seat)
26. Switch for electrically-heated rearview mirrors (S199-4)
27. Spare
28. Switch for supplemental heater (S199-1)
29. Spare
30. Spare
31. Socket 12 VDC
61 60 59 58 57
56. Switch for windshield wiper roof, continuous
Steering wheel panel 57. Switch for interior lighting
58. Switch for windshield wiper rear, interval
59. Switch for windshield wiper rear, continuous
60. Function keys for control and monitoring system
61. Travel direction indicator, Forward Neutral Reverse
62. Switch for shifting program A, automatic shifting
63. Switch for shifting program 1, locked to 1st gear
64. Switch for shifting program 2, locked to 2nd gear
71
7 75 8 75 73
Panel for hydraulic functions and control lever hydraulic
servo
75
65
66 74
67 75
68
69
70
71 013925
72 8 7 70
73
Panel for hydraulic functions and control lever
74
013924
8 75 7 75
Panel for hydraulic functions and control levers, electric
servo
1 2 3a 3b
9 8 7 6
014276
10 11 12 13
1. Operating menu engine and transmission 7. Operating menu statistics
2. Operating menu scale 8. Operating menu service
3. a. Engine operating menu, for Volvo TAD762VE. 9. Operating menu heating and air conditioning
b. Engine operating menu, for Volvo TAD1360VE 10. Operating menu code lock
4. Operating menu for oil temperature 11. Operating menu statistics, operating hours
5. Operating menu electrical system 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
1 2
009703
4 6,7,8,11 2 1,10 8
012500
5 3
1. Reverse alarm
2. Rotating beacon
3. Horn
4. Electrically powered loud horn
5. Fire extinguisher
If the machine is supplied with a fire extinguisher, it should be of
the type ABE in accordance with EN 3 part 1, 2, 4 and 5. With such
a fire extinguisher, it is possible to extinguish fires in both solid
organic materials and fluids. Adapted fire extinguishing equipment
can be 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 cab without applying the parking brake.
8. Camera with monitor :
Used to give better visibility to the rear when operating the
machine. The monitor is located inside the cab on the left side.
9a
9b 9c
9b
9a
012501
9b 9c
Low-profile model
9b
9a
012502
9c Centrally-positioned cab
9b
007330
High-profile model
10. Blinking brake lights when reversing
11. Control switch for load handling (servo circuits) :
Breaks all transmission of power and control signals to the
hydraulics.
9.3 Seats
Seats, description (product alternative standard
seat)
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
1 2 The seat has the following equipment:
• mechanical adjustment
3 • armrest right
• seat belt
• armrest left
4
• seat heating
• head restraint
8 6
006825
7
Controls for standard seat
1. Adjustable lower back (lumbar) support
2. Adjustable arm rest, right
3. Adjustable arm rest, left
4. Adjustable tilt, backrest
5. Adjustable suspension position
6. Adjustable seat angle
7. Adjustable seat height
8. Longitudinal adjustment
BE-GE 9120 is the same seat as the standard seat but equipped with
1 2 air suspension. The air suspension automatically adapts the seat
height and suspension to the operator's weight. The air suspension
is supplied by a special compressor installed on the underside of
3 the cab.
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
4 several adjustment features and meets high comfort requirements.
8 6 • armrest left
006826
7 • seat heating
Controls BE-GE 9120 • head restraint
1. Adjustable lower back (lumbar) support
2. Adjustable arm rest, right
3. Adjustable arm rest, left
4. Adjustable tilt, backrest
5. Adjustable suspension position
6. Adjustable seat angle
7. Adjustable seat height
8. Longitudinal adjustment
The function of the seat is to give the operator a good sitting position
and contribute to a good working environment. The cab's seat has
several adjustment features and meets high comfort requirements.
11
10
34 567
004691
9 8 2
Controls Isringhausen 6800
1. Longitudinal adjustment
2. Adjustable seat
3. Seat height lowering
4. Seat tilt
5. Seat height raising
6. Backrest tilt
7. Adjustable suspension
8. Seat heating
9. Level damping, On/Off
10. Adjustable lower back (lumbar) support
11. Arm rest
1 8 8
<° <°
2
D790-1
D797-2
3
4 5
A798 7 7
009759
M 6
4 Remove the cover plate and lubricate the chain with grease.
5 Check the play in the chain. It must be a maximum of 1 cm, adjust
if required.
The heating and ventilation system used heat from the engine's
cooling system via a heater to warm the outdoor air. Outdoor air is
forced by the fan through the heater and on through channels in the
cab's interior, and is then directed at, e.g., the windshield (defroster)
or the feet.
At the air inlet before the cab fan there is a filter that cleans the air
before it is forced into the machine.
001839
1 2 3 17
D D 16
D
4 ˚C D
D
˚C
D 6
7 D
D790-1 D790-2 D795
15 D
11
M D794
M
14 D 10
˚C
5 M ˚C 9
D D 8 12
13
M
009891
1. Switch fan (S118) 10. Control unit engine (D794)
2. Switch temperature (S117) 11. Water valve (Y673)
3. Switch air distribution (S139) 12. Heat exchanger
4. Sensor cab temperature (B775-1) 13. Actuator recirculation (M612)
5. Sensor temperature outlet fan (B775-2) 14. Fan motor heat (M657)
6. Sensor outdoor temperature (B774) 15. Damper motor (Y672)
7. Control unit cab (D790-1) 16. Switch defroster on Control unit KIT (D790-2)
8. Engine 17. Operating menu on Control unit KID (D795)
9. Sensor engine temperature
The air conditioning adds the following functions to the heating and
Defroster nozzles ventilation unit:
• dehumidification of the air when it is humid
• cooling of the air when it is warm
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690
1. Switch temperature (S117) 15. Damper motor (Y672)
2. Switch fan (S118) 16. Control unit frame (D797-1)
3. Switch air distribution (S139) 17. Magnetic clutch (M645)
4. Sensor cab temperature (B775-1) 18. Compressor
5. Sensor temperature outlet fan (B775-2) 19. Condenser
6. Sensor outdoor temperature (B774) 20. Moisture filter
7. Control unit cab (D790-1) 21. Pressure switch (S246)
8. Engine 22. Expansion valve
9. Water valve (Y673) 23. Sensor temperature in refrigerant circuit (B775-3)
10. Sensor engine temperature 24. Heat exchanger for cooling
11. Heat exchanger 25. Switch defroster on Control unit KIT (D790-2)
12. Control unit engine (D794) 26. Operating menu on Control unit KID (D795)
13. Actuator recirculation (M612)
14. Fan motor heat (M657)
1 2 3
16
15
14
13
7
12
8
11
010619
10 9
1. Operating menu on Control unit KID (D795) 10. Cab fan (M657)
2. Switch defroster on Control unit KIT (D790-2) 11. Fresh air and recirculation damper (M612)
3. Sensor outdoor temperature (B774) 12. Fresh air filter
4. Control unit cab (D790-1) 13. Heat exchanger (cold and heat)
5. Sensor cab temperature (B775-1) (inside of the left 14. Sensor temperature refrigerant (B775-3)
control panel, behind a grating)
(located the copper pipe inside the expansion valve)
6. Switch air distribution (S139)
15. Air distributor (Y672)
7. Switch temperature (S117)
16. Sensor temperature outlet fan (B775-2) (in air
8. Switch fan (S118) distributor)
9. Expansion valve
1 3
2
014277
1. Compressor 5. Condenser
2. Moisture filter 6. Water valve (Y673)
3. Sight glass 7. Magnetic clutch compressor (M645)
4. Pressure switch (S246)
CAUTION
Authorisation is required to perform repairs on the
climate control unit.
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
WARNING
Electric fans can injure hands.
Risk of personal injury.
Avoid placing hands near the cooling fans when the
engine is running.
NOTE
The air conditioning does not work at temperatures below approx.
0 ºC since the pressure in the refrigerant circuit is too low. If the
pressure in the refrigerant circuit becomes too low the low pressure
switch cuts off power supply to the compressor's magnet clutch,
which means that the air conditioning stops working.
In winter, during cold and dry periods of low operation, the compressor
should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are lubricated.
1 Check that the condenser is not clogged – clean condenser fins
with compressed air as needed.
3 Check that the drain for the cooling element's condensation water
is not clogged.
5 Start the engine and engage the cooling function with setting on
maximum cooling.
Let the engine run at min. 1,500 rpm. (At temperatures below
approx. 0 ºC, the cooling function will not start due to low pressure
in the system.)
013669
NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) can be very hot. Risk of burn injuries.
3 All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
5 Check that the compressor cuts in and out normally. Run the
cab fan at low speed and let the compressor work at high rpm.
When the temperature in the air vents nozzles is close to 0 ºC,
the compressor cuts out via the thermostat or ECC and cuts in
again when the temperature has increased approx. 3-7 ºC. (If the
compressor does not cut out, there is a risk of the evaporator icing
up and cooling performance decreasing.)
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 ºC.
4 Check that no bubbles are visible in the sight glass on the particle
and moisture filter.
Bubbles in the glass means that the quantity of refrigerant is
incorrect or that the condenser is defective, clogged by, e.g., dust,
or that the ambient temperature is very high.
013669
2 Check the cooling plant and pinpoint leaks. For this purpose, use
special leak detection equipment. If there still is refrigerant left,
the remaining refrigerant amount shall be evacuated and then
measured.
7 Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.
9 Connect the yellow filler and vacuum hose to the nitrogen tube.
Open the cock on the tube and then the cock on the pressure
side. Open the valve on the cylinder and then the valve on the
pressure side. Now the gas flows through the system and back
to the suction side of the compressor, which can be seen on the
blue pressure gauge which slowly indicates a pressure equivalent
to the pressure in the cylinder (see red pressure gauge). (If the
blue pressure gauge does not move then there is a stop in the
system.) Close the cock on the pressure side and then the valve
on the cylinder.
10 Now the system contains a mix of nitrogen gas and air. This gas
amount is enough to indicate a leak.
12 Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.
13 Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil is blown out of the vacuum pump.
Then, open the cock on the pressure side, use vacuum suction
for at least 30 minutes. Preferably longer.
14 First close both cocks on the pressure gauge set. Then turn off
the vacuum pump. Work in this order, otherwise the air will rush
back. Wait approx. 15 min and check on the pressure gauges that
the vacuum does not change.
15 Move the yellow hose to the refrigerant cylinder and open the cock
on the cylinder.
17 Open the cock on the suction side and allow the gas to flow
around until the pressure gauges indicate the same pressure as
in the tube.
18 Start the compressor and set the cooling thermostat and fan to
max.
19 Open the cock on the pressure side and let the compressor suck
from the cylinder. Observe the sight glass. At the beginning the
fluid is mixed with a lot of bubbles. The longer the compressor
sucks, there will be less bubbles and the fluid will be clearer.
If the bubbles suddenly disappear the cooling thermostat has
probably cut out. Bypass the thermostat using a cable directly
from the connection 24 V or wait until the thermostat cuts in again.
Continue until the correct refrigerant amount has been reached.
NOTE
Directly bypassing the compressor's coupling magnet can lead
to compressor damage caused by incorrect refrigerant quantity.
Close the cock on the suction side and then the cock on the
cylinder. Disconnect the service hoses from the compressor and
install the protective caps. Check for leaks according to step 11
or with a special leak detector.
20 In case of overfilling, the pressure and temperature increase
slowly until the high-pressure monitor cuts off the current to the
013669
9.4.8 Condenser
Condenser, cleaning
1. Radiator
2. Condenser
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
IMPORTANT
Working on the air conditioning requires special
authorisation.
1
Supplemental heater, an option for the heating unit, uses excess heat
in the engine's cooling system to keep the cab warm.
3 2
004909
The wiper arm is attached to the wiper motor's shaft over a splined
taper. The shaft is made of hardened steel and the wiper arm's
E C bracket is made of a mild die cast material.
When installing it is important to make sure that the splines are free
D from metal burrs or similar. Also, the nuts shall be tightened so tight
that the splines are pressed into the bracket and work like drive
flanges. Counterhold the wiper arm when installing so that the torque
is not transmitted to the motor as it may be damaged (16–20 Nm
002214
A tightening torque).
A Wiper motor front The wipers turn off automatically 2 minutes after the operator has left
the cab. The wipers are activated automatically when the operator sits
B Wiper motor roof in the set, selects a gear, or if the accelerator pedal is pressed down.
C Wiper motor rear
D Washer motor and reservoir
E Wiper, front
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 2 4 3
7
8
11 9
5
15 12 12
13
14 M
D790-1 D790-2
17 6 26 10
D797-1 D797-2
16
Pa
009762
18 19 20 21 22 23 24 25 27 28 29 30 31
1. Switch work lights cab roof (S105-1) 19. Running lights (H416-1, H416-2, H417-1 & H417-2)
2. Switch working lights mast (S105-3) 20. Driving lights low beams (E400L & E400R)
3. Switch headlights (S100) 21. Driving lights high beams (E402L-1 & E402R-1)
4. Switch rotating beacon (S110) 22. Tail lights (H412L & H412R)
5. Break-contact door (S266-LE & S266-RI) 23. Brake lights (H411L & H411R)
6. Control unit cab (D790-1) 24. Working lights mast (E404L-1 & E404R-1)
7. Multi-function lever (S162) 25. Extra work lights mast (E404L-4 & E404R-4)
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 2 3 4 5
6, 7
8, 9, 10, 11, 12
009729
20 19 18 17 16 14, 15 13
1. Rotating beacon (H428) Extra work lights front fender (E404L-4 & E404R-4)
2. Work lights cab roof (E406L-1 E406R-1, E406L-2 &
E406R-2) 13. Make-contact brake lights (S216)
3. Interior lights (E434-1) 14. Control unit frame (D797-2)
4. Control unit KIT (D790-2) 15. Control unit frame (D797-1)
5. Multi-function lever (S162) 16. Break-contact door (S266-LE & S266-RI)
6. Working lights mast (E404L-1 & E404R-1) 17. Switch, see section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments
7. Extra work lights mast (E404L-2 & E404R-2)
18. Control unit cab (D790-1)
Extra work lights mast (E404L-4 & E404R-4)
19. Relay working lights cab roof (K3017-1 & K3017-2)
8. Tail lights front (H413L & H413R)
Brake lights front (H410L & H410R) 20. Headlights low beam rear (E401L & E401R)
9. Direction indicators front (H422 & H423) Headlights high beam rear (E402L-2 & E402R-2)
10. Running lights front (H416-1 & H417-1) 21. Running lights rear (H416-2 & H417-2)
11. Headlights low beams (E400L & E400R) 22. Back-up lights (E405L & E405R), white
Headlights high beams (E402L-1 & E402R-1) 23. Tail lights (H412L & H412R) red
12. Extra work lights front fender (E404L-2 & E404R-2) Brake lights (H411L & H411R)
24. Direction indicators rear (H426 & H427)
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
1 2 3 4
17 6
7
15
16
14 13 18
M
5 8 19
D790-1 D790-2 D795
9
D797-1
10 11
009763
12
1. Switch rotating beacon (S110) 11. Back-up lights (E405L & E405R)
2. Switch hazard lights (Hazard) (S109) 12. Back-up alarm (H965)
3. Switch parking brake (S107) 13. Horn (H850)
4. Control unit, cab KCU (D790-1) 14. Rotating beacon (H428)
5. Switch horn (S149-3) 15. Relay loud horn (K3016)
6. Multi-function lever (S162) 16. Loud horn (H850-1)
7. Lever direction indicator (S161) 17. Make-contact operator in seat (S230)
8. Control unit KIT (D790-2) 18. Buzzer cab (H853)
9. Control unit frame (D797-1) 19. Control unit KID (D795)
10. Direction indicators front (H422 & H423) and rear
(H426 & H427)
NOTE
On machines prepared for or equipped with separate top lift
attachments, the sound signal can also be emitted with button
open twistlock (S1002) on the panel for hydraulic functions or open
twistlock on joystick, providing that the function open twistlocks at
contact is not active.
13, 14 1 2 3 4
007109
11, 12 10 9 8 7 6
1. Rotating beacon (H428) 9. Horn (H850)
2. Control unit KIT (D790-2) 10. Make-contact operator in seat (S230)
3. Buzzer cab (H853) 11. Control unit cab (D790-1)
4. Control unit KID (D795) 12. Relay loud horn (K3016)
5. Direction indicators front (H422 & H423) 13. Direction indicators rear (H426 & H427)
6. Control unit frame (D797-1) 14. Back-up alarm (H965)
7. Loud horn (H850-1)
8. Switch, see section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component location
The function of the window panes is to enclose the cab and to give
C the operator good visibility. Tempered glass windows are standard on
all trucks. Roof windows are a safety feature and are therefore always
D made of polycarbonate plastic.
001512
A E B • Windshield (front window), position B
WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!
9.10.2 Doors
Doors, description
The cab has two doors, the left is the driver's door and the right is the
emergency exit. The doors have:
• handle
• keylock
• opening window (emergency exit door )
There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.2.12 LIGHTS, menu 12.
Doors, checking
1 Machine in service position, see section B Safety.
2 Check that the welding seams at the cab's mounting points are
intact and free of visible cracks.
3 Check that the isolators are intact. Replace any damaged isolator.
4 Check that the bolted joints are tightened, that the locking devices
function (are not damaged) and that the brackets are undamaged.
Take appropriate action if necessary.
007112
The cab's mounting points with dampers, low-built
machines without hydraulic lateral cab sliding.
014788
5
6
D790-1
D797-1 D797-2 D
3 8 7
D D
10 9
2 A 4
T H B1
P
13
C A1
P
B1
P2
T
P1
T A1
12
11
10
EF
P
1 1 T
010580
1. Hydraulic oil pump 8. Solenoid valve shuttle valve sliding cab (Y6080)
2. Pressure reducer 9. Control unit frame (D797-1)
3. Accumulator servo circuit 10. Solenoid valve side shift right (Y6020) or solenoid
valve side shift left (Y6021)
4. Servo filter
11. Solenoid valve load handling
5. Disconnecting switch hydraulic lateral cab sliding
(S1010) 12. Gear valve block lateral shifting
6. Control unit cab (D790-1) 13. Hydraulic cylinder
7. Control unit frame (D797-2)
1 2
3 4 5
007533
7 8
1. Ball bearing mounted wheels 5. Hydraulic cylinder
2. Rails 6. Hydraulic oil pump
3. Carriage 7. Solenoid valve load handling
4. Insulators 8. Shuttle valve lateral cab sliding
9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:
1
2
007108
1. The rear section of the frame with counterweights
2. Engine compartment with engine and transmission mounts
3. The rear section of the frame with drive axle mounts
4. Bracket front fenders
5. Cab mounts (4 points)
6. Steering axle mounts
007107
1. Counterweight
2. Hood with safety catch over engine compartment
3. Fenders
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling the
connections at the distribution block. A blocked hose remains
pressurised and the connection becomes firm.
NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
NOTE
The system can be lubricated manually through the grease
nipple on the distribution block.
Overview of central lubrication. Example figure.
1. Lubricant nipple, filling point, lubricating grease 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
2. Safety valve
3. Lubricant nipple, manual lubrication of the
system
4. Indicator pin
5. Switch, manual operation
9.15 Paint/coatings
Paint and surface finish, description
The machine is finished with an alkyd based single component paint
that is applied by brush or sprayed. For colour code (RAL), see
machine card.
Check the machine often for stone chips, impact damage, and
scratches to the paintwork, repair these immediately to avoid corrosion
on the underlying metal. Only use touch-up paint for minor stone chip
damage and scratches, major damage to paintwork should be repaired
by a paint shop.
NOTE
Before performing touch-ups, the surface area must be carefully
cleaned.
10 Common hydraulics
10 Common hydraulics
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering,
and certain cab functions with hydraulic pressure.
Pressure levels vary with the equipment and therefore they are
unique to each machine. When checking pressure the pressure must
correspond with the pressure plate.
Pressure plate
MPa
2
MPa
3
MPa
MPa
6 5 4
010618
NOTE
The valve shall be closed during operation and is opened to
depressurise the machine.
007210
1 2 1 2 Tank
3
1. Cap for hydraulic oil filter
2. Filler plug hydraulic oil
4 3. Breather filter
4. Sight glass hydraulic oil
5. Drain plugs hydraulic oil
5
007211
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from three pumps mounted on
the transmission's power take-off.
2
The pumps have the following functions:
1. Hydraulic oil pump that feeds the brake system's brake and
cooling circuit over an accumulator charging valve, see section 4
1 Brakes, group 4.3.1 Brake oil pump and 4.8 Temperature control,
cleaning and brake oil.
2. Hydraulic oil pump that feeds load handling.
3 3. Hydraulic oil pump that supplies steering and load handling. The
priority valve ensures that there is always pressure for steering;
the residual pressure goes to load handling.
007216
2
3
007538
1. Priority valve 3. Shuttle valve brake for turnable driver's seat
2. Accumulator charging valve
The hydraulic oil pump for the brake system pumps oil (from the
tank) through the brake system's cooling circuit to be cooled in the
hydraulic oil cooler. A small amount of the oil is filtered by the fine
filter. An electric cooling fan increases the air flow through the cooler
when the temperature needs to be reduced. When the oil is cold, a
thermal bypass valve opens and leads the oil directly to the tank so that
resistance through the cooler and filter does not become too great. The
thermal bypass valve closes when the oil gets hot and then instead
leads the oil through the cooler and filter. The temperature sensor
controls activation of the fan and temperature display in the display.
Return oil from load handling and steering is filtered through the
hydraulic oil filter in the hydraulic oil tank.
°C
°C
P2
P1
T
EF PP
P 12 9
P CF D790-2 D795
LS
T LS
T D797-1
L R
8
2 3 4
10 M
P T
6
11
1 1 1
13 5
007549
°C 7
2
4
3
007213
8 7
010654
1 Turn off the engine and turn off the main electric power.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Turn off the engine and turn off the main electric power.
2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter
cartridge as environmentally hazardous waste. Note position of
the parts.
Magnetic rod
NOTE
Check the hydraulic oil level with the trolley completely lowered and
the mast tilted completely inward.
2 Check the oil level in the hydraulic tank. The oil level should be
visible in the sight glass. Top up with oil as required. For oil grade,
see section F Technical data.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
2 Remove the filler cap and pump out the hydraulic oil in a collection
container.
3 When most possible oil has been pumped out. Place a container
under the hydraulic oil tank's drain plug and drain the last hydraulic
oil.
4 Fit the drain plug when the oil has drained.
NOTE
Make sure that the drain plug's washer seal is also removed.
1. Cover plate for oil filter
5 If the hydraulic oil filters are to be changed, change them before
2. Filling point hydraulic oil filling the tank with oil, see Hydraulic oil filter, changing, page
3. Sight glass hydraulic oil 10:12.
6 Fill new hydraulic oil in the filler holes on the filter's cover
plates. This filters the oil and protects the hydraulic system from
contamination.
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked when all hydraulic
cylinders are in the retracted position.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
11 Common electrics
11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN-bus.
5. Battery disconnector
3
4
F5
93
D7
F5
F5
68
8-1
X1
F5
8-2
K1
8-3
K3 K4
K2
007280
5
4
11.2.2 Fuses
Fuses, description
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
The electrical system has three main circuits (30-, 15-, and
15E-voltage), see Distribution of electricity, description, page 11:12.
The main circuits are fused several times with main fuses and circuit
fuses.
Main fuses
Main fuses
The main fuses divide the machine's voltage feed into smaller parts
to maintain as many functions as possible in case of damage to
cables harnesses.
By the cab's and frame's electrical distribution boxes there are fuse
plates that describe the different fuses.
1
2
3
4
Circuit fuses
Circuit fuses
Circuit fuses are grouped in fuse holders that are located in the
electrical distribution box on the frame and the electrical distribution
box in the cab.
By the fuse holders there are fuse plates with information about fused
function and fuse rating.
A
B
012543
Fuses on frame
A. 30-fuses (battery voltage), F58-1
B. 15-fuses (ignition voltage), F58-2
SUPPLY POWER
A1 10A KCU (KALMAR CAB UNIT)
X2044980 1
B2 5A KCU,START UP (KALMAR CAB UNIT)
F58-4 15
C3 10A SERVICE
CAB
D4 10A OPT CUSTOMER
MAIN POWER
F6 25A OPT SEAT HEATER, TURNABLE SEAT
F58-4 30
G7 15A OPT WORK LIGHT
CAB
H8 15A OPT AIRCUSHIONED SEAT
E5 10A SERVICE
014092
H8 10A OPT COMPRESSOR HORN
014278
Fuses, changing
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
11.3 Batteries
11.3.1 Start battery
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed in
the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
1 Check the battery voltage from the operating menu for electrical
system.
With the engine off, the battery voltage should be 23–25 V.
With engine at max. engine speed (2,000 rpm), the battery voltage
should be 27–29 V.
000354
2 Turn off the engine and turn off the system voltage.
Operating menu for electrical system 3 Check that the batteries are clean on the top to prevent leakage
currents between cells, which can cause reduced battery capacity.
Wipe clean with a cloth and clean warm water without detergent.
4 Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
5 Check the fluid level in the battery cells. Top up with battery water
if needed.
The electrolyte level should be 10 mm above the cells.
NOTE
Use only distilled water if topping up is necessary.
DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no
machine parts wear or chafe against the battery cables.
Change damaged battery cables.
11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. See section 1 Engine.
The first pre-requisite for the machine to be able to perform any action
is to first establish the redundant voltage feed for control units and
then establish CAN-bus communication to administer control signals
for functions.
D797-2 D797-1
(+)
D797-2 D797-1
(+) 4. Control unit cab (D790-1) establishes redundant CAN-bus.
Redundant CAN-bus communication See Redundant CAN-bus, description, page 11:20.
5. Control unit cab (D790-1) activates CAN-bus drivetrain. See
CAN-bus drivetrain, description, page 11:20.
6. Control unit cab (D790-1) activates emergency stop switch
voltage (15E). See Emergency stop switch voltage (15E),
description, page 11:15.
The following takes place when the system goes down in powerless
mode.
1. Cab control unit (D790-1) cuts off emergency stop switch voltage
(15E).
See Emergency stop switch voltage (15E), description, page 11:15.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:14.
3. Redundant voltage feed to control units is cut off.
4. Cab control unit (D790-1) disconnects the redundant CAN bus.
See Redundant CAN-bus, description, page 11:20.
5. Cab control unit (D790-1) disconnects the redundant voltage feed.
See Redundant voltage feed of control units, description, page
11:14.
6. Control unit cab (D790-1) awaits start-up signal. Other electronics
are powerless.
D797-2 D797-1
(+) 3. Control unit cab (D790-1) activates redundant voltage feed to the
other control units, see B in illustration.
A Start-up signal is sent
Control unit cab (D790-1) has four outputs for voltage feed, other
B All control units are supplied with voltage control units have two inputs for redundant voltage feed. In case
of failure of one feed, the control unit is supplied from the other
feed.
D794
5 6
4 7
3
15
2
1 8
16
9 17
10 18
11 19
12
13
14
010279
1. Circuit fuses emergency stop switch voltage (15E) 11. Relay ignition K315-2
F58-3
12. Relay ignition K315-1
2. Circuit fuses ignition voltage (15) F58-2
13. Power relay control switch K3009-1
3. Circuit fuses battery voltage (30) F58-1
14. Power relay control switch K3009-2
4. Diagnostic socket motor, VODIA (engine alternative
15. Diagnostic socket machine
Volvo)
16. Circuit fuses cab battery voltage (30) and ignition
5. Diagnostic socket transmission
voltage (15) F58-4
6. Main fuses
17. Diagnostic socket CAN-Bus drivetrain
7. Control unit, transmission (D793)
18. Circuit fuses cab ignition voltage (15) F58-5
8. Terminal block attachment X168
19. Voltage converter
9. Relay lift/lower K3007
10. Relay tilt in/out K3002
Control unit cab and control units on the frame and attachment have
indicator lamps that can be used to check basic information on the
status of other control units.
1 2 3
014279
7 6 5
1. Control unit KID (D795)
2. Control unit KIT (D790-2)
3. Control unit cab (D790-1)
4. Control unit engine Volvo (D794)
5. Control unit, transmission (D793)
6. Control unit frame (D797-1)
7. Control unit frame option (D797-2)
11.6 Communication
Communication, general
The machine's communication is handled by a so-called CAN bus
D790-1 D790-2 D795 system. The CAN bus system consists of control units connected
together to form a network.
The idea with the network is to share information. Signal values are
D797-2 sent out by the control unit that, e.g., is connected to a sensor, other
1 D797-1
(+) control units can use the signal for their functions.
007290
D794 D793 CAN-bus between control units.
1. Segment
2. CAN-bus drivetrain
D797-2 D797-1
(+)
Signals can be checked with diagnostic menu.
Principle illustration redundant CAN-bus
D794 D793
Principle illustration CAN-bus drivetrain
007443
RMI interface (A911) records communication on the CAN bus and
sends the information to a central RMI server. In the event of a fault
RMI-interface (A911) the control unit in the machine can send information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.
From the RMI server, data from the machine can be analysed and
processed for reading off different values. For example, when it is
time for a service or if there are error codes stored in the machine.
NOTE
RMI only sends data from the machine, but no data can be sent to
the machine. RMI cannot be used to control the machine.
D Error codes
D Error codes
Error codes
See Workshop manual DCF 280–520, section D Error codes.
E Diagrams
E Diagrams
Diagrams
See Workshop manual DCF 280–520, section E Diagrams.
F Technical data
F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.
4. Brakes
Footbrake system - wheels affected Wet Disc Brake - drive wheel
Parking brake system - wheels affected Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, only use coolant of
the same type that was used before.
2.6 Transmission, lubrication Dana-Spicer Off Highway TE17312 Dana-Spicer Off Highway TE32418
system
Oil type See Oils and lubricants, recommendation, page F:9.
Oil volume transmission, total 37 litre 80 litre
Oil volume transmission for changing 27 litre 60 litre
AxleTech AxleTech
3.3 Driveline/Axle, drive axle PRC3806W4H PRC7534W4H Kessler D102
Oil grade See Oils and lubricants, recommendation, page F:9.
Oil volume, differential 33 litre 50 litre 65 litre
Oil volume, hub reduction 2x10.5 litre 2x10 litre 2x12 litre
7 Load handling
Oil grade See Oils and lubricants, recommendation, page F:9.
Oil volume, planetary gear hydraulic motor 1.6 l
Oil volume, multiple-disc brake hydraulic 0.6 l
motor
H5
H4
H3
H6
H8 H2
a
S L3 L2 L4
L L1
55
A1
DCF500 -12
50 100 100
DCF450 -12
45
DCF420 -12
40
b
DCF370 -12 V1 V B
35
DCF330 -12
DCF300 -12
30
DCF280 -12
25
R2
20 R1
010586
15
600 900 1200 1400 1600 1800 2000
Lift capacity
Classed (kg) 28000 30000 33000 37000 42000 45000 50000
Centre of gravity distance
1200
(L4 [mm])
Dimensions, truck
Truck length without forks
6675 6925 7345 7845 7950 8550
(L [mm])
Truck width (B [mm]) 3410 4150
Height, basic machine
3650 3415 3650 3415 3650 3415 3725 3825
(H6 [mm])
Seat height (H8 [mm]) 2300 2350 2450
Distance between centre
of front axle - front of fork 1125 1295 1400 1440
arm (L2 [mm])
Axle distance (L3 [mm]) 4500 4750 5000 5500 6000
4 Brakes (Note 1)
GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Oil planetary gear hydraulic motor, hypoid oil SAE 80W140
API GL-5
SAE 75W90
Disc brake hydraulic motor, See "10 Common
hydraulics" below
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
Note 1: The oil in the brake system must fulfil one of the quality
requirements.
Grease
NOTE
Select grease grade according to relevant climate.
Sealant silicone
Silicone adhesive
Coolant
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
When torquing using a machine, for example, bolt runner, the tightening
torque should be reduced by approx. 5%.
For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Goods coupling
Unit explanations
Unit Abbreviation
Newton metre Nm
Kilopond metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Meter m
Kilometre km
Conversion SI-units
SI-unit Conversion factor Non-SI Conversion factor SI
Torque
Nm x 10.2 = kg cm x 0.8664 = lb in
Nm x 0.74 = lbf ft x 1.36 = Nm
Nm x 0.102 = kg m x 7.22 = lb ft
Pressure (Pa = N/ m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft) TQ x rpm 5252 = bhp
Temperature
°C = (°F – 32)/1.8 °F = (°C x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min
Term Description
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, e.g., release pressure and thus lower
a boom or a fork.
Machine model Machine type. Indicated, for example: DCF 280-520. See also type designation.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant mesh.
Product alternatives One of several alternatives is selected for a machine, e.g., engine alternative.
Progressive steering Rapid steering wheel movements give larger steering deflection.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current's amplitude. In everyday language, a stepless valve, as
opposed to an Off/On valve. On, e.g., the transmission's valve housing.
Frame beam Supporting beams in the frame.
Recirculation Circulates again and again.
Serial number Unique machine designation. Available on machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small user movement results in a big machine movement, e.g. power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Forks / parallel sideways movement of attachment.
Levelling Forks / attachment is tilted, for example, if load stands on uneven surface.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading Spreading of forks (i.e. changes distance between forks in relation to one another) /
Widening of attachment.
Mast Carrier of trolley, forks, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
Steering axle Wheel axle with steering.
Buzzer Audible alarm to catch the operator’s attention.
Option Optional equipment for machine.
Tilting The mast is leaned forward or backward.
Top lift Attachment. See attachment.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Four lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates type of machine and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for long life.
UTTO-oil Universal Tractor Transmission Oil.
Variable pump Pump with adjustable flow rate.
Variable displacement Adjustable volume (capacity) of a pump.
Term Description
Valve slide Moving part in the valve. Decides the oil's path.
Wet brakes Brake discs in oil-bath.
End-positions The farthest distance the object can be moved out or away; for example, the
end-position for tilt cylinders.
C
CAB . . . . . . . . . . . . . . . . . . . . . . .8:15 H
Cab interior . . . . . . . . . . . . . . . . . . . .9:42 Heating, ventilation and air conditioning . . . . . . . . 9:16
Cab structure and suspension . . . . . . . . . . . .9:38 Height limitation . . . . . . . . . . . . . . . . . . 8:7
Cab undercarriage . . . . . . . . . . . . . . . . .9:38 Height warning . . . . . . . . . . . . . . . . . . . 8:7
CAN bus . . . . . . . . . . . . . . . . . . . . 11:20 Hoses, pipes and valves . . . . . . . . . . . . . . . 10:7
CAN-bus drivetrain . . . . . . . . . . . . . . . . 11:20 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:16
CAN/POWER . . . . . . . . . . . . . . . . . . . 8:13 Hydraulic lateral cab sliding . . . . . . . . . . . . . 9:40
Central lubrication . . . . . . . . . . . . . . . . . 9:45 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:12
CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:15 Hydraulic oil cooler . . . . . . . . . . . . . . . . 10:11
Coil ram . . . . . . . . . . . . . . . . . . . . . . 7:30 Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:12
Common electrics . . . . . . . . . . . . . . . . . 11:3
Common hydraulics . . . . . . . . . . . . . . . . . 10:3
Communication. . . . . . . . . . . . . . . . . . 11:20 I
Complete machine . . . . . . . . . . . . . . . . . C:1
I/O . . . . . . . . . . . . . . . . . . . . . . . . 8:26
Condenser . . . . . . . . . . . . . . . . . . . . . 9:28
Ignition voltage (15) . . . . . . . . . . . . . . . . 11:14
Control system . . . . . . . . . . . . . . . . . . . 8:3
Ignition/heating . . . . . . . . . . . . . . . . . . . 1:46
Control system engine. . . . . . . . . . . . . . . . 1:45
Intercooler . . . . . . . . . . . . . . . . . . . . . 1:30
Control system transmission . . . . . . . . . . . . . 2:17
Control units . . . . . . . . . . . . . . . . . . . 11:18
Controls and instruments . . . . . . . . . . . . 4:4, 9:4
Coolant . . . . . . . . . . . . . . . . . . . . . . 1:35 L
Cooling fan . . . . . . . . . . . . . . . . . . . . 1:32 Lifting forks . . . . . . . . . . . . . . . . . . . . 7:28
Cooling system . . . . . . . . . . . . . . . . 1:32, 2:16 Lifting/lowering . . . . . . . . . . . . . . . . . . . 7:5
Lighting system. . . . . . . . . . . . . . . . . . . 9:32
LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:14
D Link arm . . . . . . . . . . . . . . . . . . . . . . 5:9
Load carrier . . . . . . . . . . . . . . . . . . . . 7:28
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:10
Load handling . . . . . . . . . . . . . . . . . . . 7:3
Diagrams . . . . . . . . . . . . . . . . . . . . . E:1
Lubrication system . . . . . . . . . . . . . . 1:40, 2:11
Distribution of electricity . . . . . . . . . . . . . . 11:12
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:38
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:5
Driveline/Axle . . . . . . . . . . . . . . . . . . . 3:3 M
Mast . . . . . . . . . . . . . . . . . . . . . . . 7:12
Mechanical transmission. . . . . . . . . . . . . . . 2:10
E Moisture filter . . . . . . . . . . . . . . . . . . . 9:28
Monitoring . . . . . . . . . . . . . . . . . . . . . 8:6
EL-STEERING . . . . . . . . . . . . . . . . . . . 8:23
MOVE-CAB . . . . . . . . . . . . . . . . . . . . 8:25
ELECTRIC SERVO . . . . . . . . . . . . . . . . . 8:20
Electrical distribution box . . . . . . . . . . . . . 11:17
Electrical protection . . . . . . . . . . . . . . . . . 11:4
Emergency stop switch voltage (15E) . . . . . . . . 11:15 O
Engine . . . . . . . . . . . . . . . . . . . . . . 1:3 Oil brake system . . . . . . . . . . . . . . . . . . 4:20
ENGINE . . . . . . . . . . . . . . . . . . . . . . 8:17 Oil filter, brake system . . . . . . . . . . . . . . . . 4:19
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com