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Forklift Trucks 28-52 tonnes

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

9 Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

D Error codes

E Schematics

F Technical data

G Terminology and index


A:1

A Foreword

Contents A Foreword
Foreword ............................................................................................................ A:3
About the maintenance manual ...................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
Maintenance manual's content................................................................... A:5
Function group structure ............................................................................ A:6
Product alternatives and optional equipment ............................................. A: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

Maintenance Manual DCF 280–520 UDCF07.01GB


A:2

UDCF07.01GB Maintenance Manual DCF 280–520


A Foreword – Foreword A:3

A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.

The maintenance manual contains information about how the machine


should be maintained for maximal operating reliability and service
life as well as troubleshooting information for fast correction of any
malfunctions.

Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.

Cargotec will not accept any responsibility for modifications performed


without permission from Cargotec or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.

Storage

NOTE
The maintenance manual shall be accessible to service personnel.

About the machine version


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

Cargotec reserves the right to change specifications and equipment


without prior notification. The information in the manual is valid at the
time of publication.

DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
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.

Duplication by any means such as copying, printing, etc., is prohibited.

Maintenance Manual DCF 280–520 UDCF07.01GB


A:4 A Foreword – Reading instructions

Reading instructions
Warning information
Warnings inform of potential hazards that, if warnings are not heeded,
may result in personal injury or product damage.

DANGER
Situation that may lead to severe personal injury or
fatality if the rule is not followed.

WARNING
Situation that may lead to personal injury if the rule is
not followed.

CAUTION
Situation that may lead to product damage if the rule
is not followed.

Important information
Important information is indicated by NOTE, and is provided to
facilitate the work process, handling or increase understanding of the
information.

NOTE
Information that is important without being related to safety.

Read operator's manual


The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
000262

Read the operator's manual

Read maintenance manual


The symbol to the left is used in certain cases on the machine and
001128

refers to important information in the maintenance manual.

Read the maintenance manual

UDCF07.01GB Maintenance Manual DCF 280–520


A Foreword – Reading instructions A:5

Maintenance manual's content


The information in the maintenance manual is divided into function
groups (0-12) to facilitate searching for information. The manual is
divided in 20 sections A-C, 0-12, D-G. The sections with letters contain
specific information that applies to several function groups and is not
bound to a function, e.g., section "F Technical data". This is described
in greater detail in the table below.

For more information about function groups, see Function group


structure, page A:6.

A Foreword General information about the maintenance manual's purpose, content and
reading instructions as well as survey for feedback of views and eventual
inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance General information about preventive maintenance of the machine.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/Axle
4 Brakes
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.

Maintenance Manual DCF 280–520 UDCF07.01GB


A:6 A Foreword – Reading instructions

Function group structure


The information in the manual is divided in a structure of functions
at different levels, based on the machine's design and use, called
function groups.

The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).

The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
done at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.

The idea is that the function groups are intended to work as a search
term to find different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.

The maintenance manual and workshop manual contain different


information. The maintenance manual only includes information
needed for preventive maintenance as well as simpler troubleshooting.
The workshop manual includes more in-depth information and repair
instructions.

References between sections in the same manual are indicated with


section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g., "see Sensor fuel level, description page 24".

References are not given between Maintenance manual and Workshop


manual. If more information is desired for a function group, the primary
recommendation is to search under the same function group in the
other manual.

Product alternatives and optional equipment


The information in the manual is divided in modules. For product
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.

Special equipment is not described in the manual. If you're uncertain


about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:7.
Product alternatives
Product alternatives
000264

Product alternatives are such options that exclude certain standard


Symbol indicating optional equipment equipment (e.g., engine alternative).

Equivalent information for different product alternatives is described


in separate sections following each other under the same function
group. To indicate that there are different alternatives, the supplement
"Product alternative" is used in the heading together with a simple
description of which alternative is described, e.g., "(Product alternative
Climate control unit ECC)". In addition, alternatives that are optional
are marked with the symbol for optional equipment.

UDCF07.01GB Maintenance Manual DCF 280–520


A Foreword – Reading instructions A:7

Optional equipment

Optional equipment are options that can be added to the standard


equipment to obtain additional or improved functions.

Information for optional equipment is described in separate sections


with the standard equipment as starting point. Description of the
optional equipment describes how the standard function is affected by
the option as well as which additional components are added.

Machine card

NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.

IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.

The machine card indicates of which drawings the machine consists,


in many cases these can be associated to options and product
alternatives. For more information on handling product alternatives and
optional equipment, see Product alternatives and optional equipment,
page A:6. The machine card is supplied with the spare parts catalogue
and should be in the cab.

The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the first and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.

For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.

If the information on the machine card does not help, contact Cargotec.

NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.

Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.

The function descriptions describe the function in a logical flow from


input signal to desired output signal. Most functions require that
pre-determined conditions are fulfilled for that function to be activated.
In these cases the conditions are listed above the figure.

Function descriptions use symbols to illustrate components such as


valves, sensors, etc.

Maintenance Manual DCF 280–520 UDCF07.01GB


A:8 A Foreword – Reading instructions

T 2

5 3
5 T

014280

Example of function description


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

UDCF07.01GB Maintenance Manual DCF 280–520


A Foreword – Reading instructions A:9

Symbol explanation function descriptions


Symbol explanation function descriptions
1 2
The following symbols are used in function descriptions, the symbols
3 4 are based on standard symbols used in wiring and hydraulic diagrams.
1. Electric control signal
2. Electric force
5 6
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic motor
7 8 M 6. Hydraulic oil pump with variable displacement
7. Hydraulic oil pump with fixed displacement
8. Electric motor

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

Maintenance Manual DCF 280–520 UDCF07.01GB


A:10 A Foreword – About the documentation

About the documentation


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

Ordering of documentation
The documentation is ordered from the dealer for Cargotec.

Always specify publication number when ordering.

For publication number, see the machine card.

UDCF07.01GB Maintenance Manual DCF 280–520


A Foreword – Feedback A:11

Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.

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

Copy this form, write down your views and send it to us. Thanks for
your help!

To: Cargotec Sweden AB


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

Telephone: ..........................................................................................................................................................

E-mail: .................................................................................................................................................................

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


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

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


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

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

Maintenance Manual DCF 280–520 UDCF07.01GB


A:12

UDCF07.01GB Maintenance Manual DCF 280–520


B:1

B Safety

Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic 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

Maintenance Manual DCF 280–520 UDCF07.01GB


B:2

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety B:3

B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions in this manual must
make absolutely sure that the work is performed without risks of
personal injury, without risks of machine damage, or property damage!

Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and be careful. Do not take any risks!

Cargotec has in this publication documented and warned for situations


and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.

Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.

A near accident is a warning!


An incident is an unforeseen event where neither a person, the
machine, nor property is damaged. However, incidents indicate that
there is a risk of injury and actions must be taken to avoid injury risks.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:4 B Safety – Safety instructions

Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position, page B:4
• Hydraulic 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

Service position is used for service, maintenance and other situations


when the machine needs to be secured.

Service position means:


• Machine parked, that is, applied parking brake.
007550

• Forks and trolley in completely lowered position.


• Engine off.
Machine with forks and trolley in completely lowered
position • System voltage off (with battery disconnector).

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:5

Hydraulic and brake systems, depressurising


1 Machine in service position, see Service position, page B:4.

2 Depressurise the hydraulic system.


a) For hydraulic servo:
Repeatedly activate the load handling functions.
b) For electric servo:
Switch on the system voltage, turn the start key to position I and
repeatedly activate the load handling functions.

007710

3 Turn the start key to position 0 and turn off the system voltage.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:6 B Safety – Safety instructions

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


accumulator charging valve.

NOTE
Keep the accumulator drain valve open as long as work is in
progress.

NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.

005648

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.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:7

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:8 B Safety – Safety instructions

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.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:9

Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.

Remove jewellery as it may conduct electricity and get caught in


moving parts.

Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.

Several mechanics on the same machine

WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.

Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.

Movements performed from the operator's station, e.g., all movement


of lifting equipment, may cause severe personal injuries.
Safety actions
• Make sure that the machine's lifting equipment is completely
lowered or secured in another way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you're working with.
• Do not work with drive wheels on the machine's both sides at the
same time.

Working under machine

Working under the cab

Loose objects must not be present in cabs that are to be tilted.

The cab must always be tipped to its end position and secured with
the stop device.

When the work does not allow the cab to be tilted to its end position, or
for work with cab suspension, the cab must always be secured with
the stop device.

On machines with vertically adjustable cab the cab must be secured


in the raised position with the intended lock.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:10 B Safety – Safety instructions

Working under frame

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

Lifting heavy components

WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to
move heavy components. Make sure that the device
is sturdy and intact.

Risks

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

The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.

A component lifted with lifting equipment can start to turn if the centre
of gravity changes.

A component lifted using an overhead crane may start to swing


back and forth, which can cause severe crushing injuries or material
damage.

Safety actions

Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs. See the workshop
manual for methods.

If lifting must be performed without lifting device:


• Lift near the body.
• Keep your back vertical. Raise and lower with your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.

Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:11

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.

If the body is continuously exposed to solvents, the central nervous


system may be injured. This manifests itself as trouble sleeping,
depressions, nervousness, poor memory, and general tiredness.
Continuous inhalation of gasoline and diesel vapours is suspected
of causing cancer.

Safety actions
• Avoid inhaling solvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a solvent container without tight-sealing lid.
• Use solvents with a low content of aromatic compounds. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves.
• Make sure that work clothes are solvent-resistant.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:12 B Safety – Safety instructions

Fire and explosion risks

DANGER
The operator's safety may not be jeopardised in case
of fire.
If possible, take the following actions at the slightest
sign of fire:
1. Stop the machine and turn the start key to stop
position.
2. Leave the cab.
3. Turn off the system voltage with the battery
disconnector.
4. Call the fire department.
5. Try to put out the fire.
If this is not possible, leave the machine and the
danger area.

DANGER
Smoke from a fire may be very toxic.
Smoke anesthetises, suffocates, and kills! Smoke
from fires, even small amounts, can damage lungs and
respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
fire and working with burnt materials.

Examples of flammable and explosive substances are oils, gasoline,


diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.

Risks

Examples of causes of ignition are welding, cutting with a welding


torch, smoking, sparks from grinding machines, contact between
hot machine parts and flammable materials, heat generation in rag
drenched with oil or paint (linseed oil), and oxygen. Oxygen cylinders,
lines, and valves shall be kept free from oil and grease.

Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding flames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:13

Special cases

Gas oil with added gasoline has a reduced flash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher than for gasoline.

When changing oil in the engine, hydraulic system and transmission,


keep in mind that the oil may be hot and can cause burn injuries.

Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive fires.

When a battery is being charged, the battery electrolyte's water is


divided into oxygen and hydrogen gas. This mixture is very explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge device is used since this increases the risk of sparks.

In today's machines there are a lot of electronics. When welding,


all control units must be unplugged and the electric power must be
turned off with the battery disconnector. Powerful welding currents may
otherwise short-circuit the electronics, destroy expensive equipment,
and may cause an explosion or fire.

Never weld on painted surfaces (remove paint, preferably by blasting at


least 10 cm around the welding or cutting point). Use gloves, breathing
protection, and protective safety glasses. Also, never weld near plastic
or rubber materials without first protecting them from the heat. Paint,
plastic, and rubber generate many substances when heated, and these
may be hazardous to health. Be careful with machines that have been
exposed to intense heat or fire.

Safety actions

DANGER
Remains of fuel, oils, grease, and other flammable
materials on the engine or in the engine compartment
are fire hazards.
Risk of fire!
Remove remains of flammable materials from the
engine compartment as soon as they are discovered,
be extra thorough with hot surfaces such as the
exhaust system, manifold, or turbo. If leaks of oil, fuel,
or coolant are detected, find the cause and solve the
problem before starting the engine.

• Make a habit of performing a visual check of the engine and engine


compartment before starting the engine and after operation, when
the engine has been stopped. This ensures fast detection if
anything abnormal has happened or is about to occur. Pay special
attention to oil, fuel, or coolant leaks, loose bolts, worn or poorly
tensioned drive belts, loose connections, damaged hoses, and
electrical cables. The inspection only takes a few minutes and may
prevent serious problems and expensive repairs.
• Store hazardous substance in approved and sealed container.
• Make sure that there is no ignition source near flammable or
explosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:14 B Safety – Safety instructions

Fluid or gas under pressure


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

Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).

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.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:15

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

Work on the air conditioning system must be performed by


accredited/authorised and trained personnel according to national
legislation and local regulations.

Risks

The air conditioning operates at high pressure. Escaping refrigerant


can cause frostbite injuries.

Refrigerant that is heated (e.g., when repairing leaking climate/AC


system), generates gases that are very dangerous to inhale.

Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).

Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.

The following health-hazardous air pollution is especially prominent in


workshops:
• Carbon monoxide (fumes) is found in exhaust gases. Odourless
and therefore extremely dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.

Risks

Sulphuric acid mist is corrosive and injures the respiratory tracts.


(Generated when heating certain plastics and paints.)

Isocyanates may be released in the form of vapour, dust (or may


be found in aerosol) when cutting, grinding, or welding. May cause
mucous membrane irritation with asthma-like symptoms and impaired
lung function. Even brief exposures to high concentrations may cause
problems with persistent hypersensitivity.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:16 B Safety – Safety instructions

Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.

Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs

Risks

If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.

Small springs can cause eye injuries.

Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.

Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.

Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.

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.

Rotating components and tools


Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:17

Risks

Rotating components, e.g., fans or shafts, can cause severe injuries


if touched.

Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in
the machine.

Safety actions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or pant legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.

Tyres and rims

DANGER
Tyres are to be considered as pressurised containers.
Handling incorrectly, they are a fatal hazard.
Parts can be thrown with explosive force and may
cause severe injuries.
Never repair damaged tyres, rims, or lock rings. Tyre
changes shall be performed by authorised personnel.

Risks

Dismantling wheels: Tyres, rims, and lock rings may be ejected.

Inflating tyres: Tyres, rims, or lock rings may be ejected.

Safety actions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
• 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.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:18 B Safety – Safety instructions

Risks

If the machine's lifting equipment is not lowered or secured, there is a


risk of crushing.

Risk of crushing is extra high when depressurising the hydraulic


system, see Hydraulic and brake systems, depressurising, page B:5.

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.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Safety instructions B:19

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

Maintenance Manual DCF 280–520 UDCF07.01GB


B:20 B Safety – Safety instructions

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.

UDCF07.01GB Maintenance Manual DCF 280–520


B Safety – Environment B:21

Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.

Still there are no environmentally safe chemicals, e.g., oils and


coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.

By following the simple rules below, you will contribute to protecting


our environment.

Recycling

Well-planned recycling of the machine is the starting point for finishing


the life cycle and making use of materials for re-use in new products.
According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.

Environmentally hazardous waste

Components such as batteries, oils and other chemicals, and other


materials that may constitute environmentally hazardous waste, must
be handled and taken care of in an environmentally safe and sound
manner.

Discarded batteries contain substances hazardous to personal health


and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.

Oils and fluids

Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.

Waste oils and fluids must always be taken care of by an authorised


disposal company.

Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.

Air conditioning system

The refrigerant in the air conditioning unit for the cab contributes to
the greenhouse effect if it escapes into the open air. Special training
is required for all service work on the air conditioning unit. Many
countries also require certification by an authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.

Working in a contaminated area

The machine shall be equipped for work within a contaminated area


(polluted environment or health-hazardous area) before starting the
work. Also, special local instructions apply for handling and service
work on such a machine.

Maintenance Manual DCF 280–520 UDCF07.01GB


B:22 B Safety – Environment

Declarations

The machine does not contain asbestos.

The machine contains lead in batteries and electrical wiring. Some


models have cast lead counterweights.

If the machine is equipped with air conditioning, refrigerant of the type


R134a and an amount between 1-3 kg is used.

UDCF07.01GB Maintenance Manual DCF 280–520


C:1

C Preventive maintenance

Contents C Preventive maintenance


Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:5
Service schedule............................................................................................. C:7
Washing ........................................................................................................ C:15
Lubricating 500h ........................................................................................... C:16
Lubricating 1000h ......................................................................................... C:22
Checking for cracks ..................................................................................... C:25

Maintenance Manual DCF 280–520 UDCF07.01GB


C:2

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:3

C Preventive maintenance
Preventive maintenance, general
It’s very important that preventive maintenance is performed according
to recommended intervals.

Preventive maintenance should be performed by Cargotec, or by a


service organisation authorised by Cargotec.

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

Preventive maintenance, work instructions

1 For a new machine it is very important to check-tighten the wheel


nuts during the first work week until they are seated properly.
This should be done at an interval of 4–5 operating hours (up to
approx. 40–50 operating hours).

2 For a new machine, perform check actions after 50 operating


hours, see 50h-check, page C:5.
Note completed 50h-check in the service log, see Check and
service log, page C:4.

3 Regular service shall be performed according to service schedule,


see Service schedule, page C:7. The service schedule shall be
followed to ensure high machine reliability and safety.
Note completed service in the service log, see Check and service
log, page C:4.

Maintenance Manual DCF 280–520 UDCF07.01GB


C:4 C Preventive maintenance – Preventive maintenance

Check and service log


Model:
Serial number:

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

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:5

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

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C:6 C Preventive maintenance – Preventive maintenance

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

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:7

Service schedule
Service shall be performed every 500 operating hours. Actions are
divided into 500h, 1000h and 2000h service.

Actions for 500h service are performed between 1000h and 2000h
service, which means at 500h, 1500h, 2500h, etc.

Actions for 1000h service are performed at odd thousands of operating


hours: 1000h, 3000h, 5000h, etc.

Actions for 2000h service are performed at even thousands of


operating hours: 2000h, 4000h, 6000h, etc.

After service is performed, make a note in the check and service log,
see Check and service log, page C:4.

In the column for service below, the following abbreviations are used:
R = replace
C = check or inspection
L = lubrication
h = operating hours

Object, action Service Comment Reference


500h, 1000h, 2000h,
1500h, 3000h, 4000h,
2500h, 5000h 6000h
etc. etc. etc.
0 complete machine
Checking cleanliness and C C C Check for and remove traces Section B Safety
leakage of combustible materials in the
engine compartment.
Take extra care on hot
surfaces such as exhaust
systems, manifolds or turbo.
If leaks of oil, fuel, or coolant
are detected, find the cause
and solve the problem.
Attachments (stub axles) C C Visual check in connection
with greasing.
Lubrication 500 hours L L L
Lubrication 1000 hours L L
Checking for cracks C* C* * Check every 1000h or every
year.

1 Engine (engine alternative Volvo TAD762VE)


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

Maintenance Manual DCF 280–520 UDCF07.01GB


C:8 C Preventive maintenance – Preventive maintenance

AdBlue tank C Cleaning Section 1 Engine, group


1.2.12 AdBlue tank
AdBlue filter R Section 1 Engine, group
1.2.13 AdBlue filter
Valve clearance C First check after 500 h, then
every 1500 h. NOTE
After engine replacement or Performed by service
engine overhaul check/adjust shop authorised by
after 250 h. Volvo Penta.

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.

Drive belts C/R C/R R Section 1 Engine, group


1.7.5 Cooling fan
Belt tensioner C
Coolant C C C / R* Level check. Section 1 Engine, group
1.7.7 Coolant
* Change after 5000 h or once
every two years.
For volume and quality, see
section F F Technical data.
Coolant, freezing point C C C For volume and quality, see
section F F Technical data.
Turbo C
NOTE
Injectors C* * Every 3000 h.
Performed by service
shop authorised by
Volvo Penta.

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

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:9

AdBlue tank C Cleaning Section 1 Engine, group


1.2.12 AdBlue tank

AdBlue filter R Section 1 Engine, group


1.2.13 AdBlue filter
Valve clearance C C First check after 1000 h, then
every 2000 h. NOTE
After engine replacement or Performed by service
engine overhaul check/adjust shop authorised by
after 250 h. Volvo Penta.

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.

Drive belts C C R Replace as necessary or after Section 1 Engine, group


4000 h or every two years. 1.7.5 Cooling fan
Belt tensioner C
Coolant C C C / R* Level check. Section 1 Engine, group
1.7.7 Coolant
* Replace after 8000 h or
every four years.
For volume and quality, see
section F F Technical data.
Coolant, freezing point C C C For volume and quality, see
section F F Technical data.
Turbo C
NOTE
Performed by service
shop authorised by
Volvo Penta.

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

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C:10 C Preventive maintenance – Preventive maintenance

Transmission oil filter R R The transmission oil should be Section 2 Transmission,


changed every 1,000 hours or group 2.6 Lubrication
1 time/year. system
For volume and quality, see
section F F Technical data.
Transmission oil R R For volume and quality, see
section F F Technical data.
Transmission, calibration C C Calibration of transmission is Section 2 Transmission,
recommended every 1,000 group 2.8 Control system
operating hours. transmission
3 Driveline/Axle
Propeller shaft C C C Bolted joints and universal Section 3 Driveline/Axle,
joint. group 3.2 Propeller shaft
Drive axle oil R R For volume and quality, see Section 3 Driveline/Axle,
section F F Technical data. group 3.3 Drive axle
Mounting drive axle C C Section 3 Driveline/Axle,
group 3.3 Drive axle
Differential, breather nipple C C Clean if necessary.
4 Brakes
Brake pedal C C Section 4 Brakes, group
4.1.1 Brake pedal
Oil pump brake system C C C Section 4 Brakes, group
4.3.1 Oil pump brake
system
Accumulator C C C Section 4 Brakes, group
4.3.4 Accumulator
Parking brake C/R C/R C/R Check pad thickness, change Section 4 Brakes, group
when needed. 4.5.4 Parking brake unit
C C C Clean when needed.
Oil cooler

NOTE
Do not use high pressure
wash.

R Section 4 Brakes, group


Breather filter 4.8.11 Breather filter

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:11

Oil filter, brake system R R R Section 4 brakes, group


4.8.12 Oil filter brake
system

R For volume and quality, see Section 4 Brakes, group


Oil brake system section F F Technical data. 4.8.14 Oil for brake
system
5 Steering
Link arms C/L C/L C/L Check bearings.
Sensor steering wheel C C C Section 5 Steering, group
reading mini-wheel/joystick 5.2.12 Sensor steering
control wheel reading

6 Suspension
Steering axle suspension C C Section 6 Suspension,
group 6.2.1 Steering axle
cradle
Wheel spindle, check C C Clearance in wheel Section 6 Suspension,
suspension shall be checked. group 6.2.2 Wheel spindle
Wheel hub steering axle, C Check bearing pre-load. Section 6 Suspension,
check group 6.2.3 Wheel hub
Tyres and rims C C C Damage, wear and pressure, Section 6 Suspension,
change as needed. group 6.3 Tyres and rims
Wheel nuts C C Check-tightening. Section 6 Suspension,
group 6.3 Tyres and rims
Rim C* * Checking for cracks, every Section 6 Suspension,
2000 h or in connection with group 6.3.2 Rim
tyre changes.
7 Load handling
Servo filter R R R Section 7 Load handling,
group 7.2.2 Servo filter
Lifting chains C C C Check damage, tension chain Section 7 Load handling,
when needed. group 7.2.9 Mast
Mast suspension C C
Slide plates mast C C C
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

Maintenance Manual DCF 280–520 UDCF07.01GB


C:12 C Preventive maintenance – Preventive maintenance

C C Damage. Section 7 Load handling,


Attachment group 7.10.5 Separate
Chain spreading (top lift C C Tension chain when needed. top lift attachment
attachment)
Slide plates spreader beam C C Check wear, change as
needed.

R R For volume and quality, see


Oil spreading motor unit section F F Technical data.
C C C/R Checking that the parts are Section 7 Load handling,
Twistlocks properly tightened every 500 group 7.10.5.3 Twistlocks
h.
Checking the float position
every 500 h.
Checking the vertical
movement every 2000 h.
Check for cracks every other
year or every 4000 h.
Replacement every 10000 h.
Reset the hour counter for
twistlocks after replacement.
8 Control system
C C C Section 8 Control system,
Service indicator, reset group 8.2.4 Service
indicator
9 Frame, body, cab and accessories
Instruments and controls C C C Checking function.
Turnable operator's C C Check chain tension Section 9 Frame, body,
station (clearance max. 1 cm). cab and accessories,
group 9.3.9 Turnable
operator's station
C C C Checking function. Section 9 Frame,
Air conditioning unit body, cab and
accessories, group 9.4.
Check/performance test
of air conditioning.
Fresh air filter R R R Dependent on external Section 9 Frame, body,
environment, at latest every cab and accessories,
500 h. group 9.4.1 Fresh air filter
C C C Clean when needed. Section 9 Frame, body,
Condenser cab and accessories,
group 9.4.8 Condenser
NOTE
Do not use high pressure
wash.

C/R C/R C/R Checking, change if indication Section 9 Frame, body,


Moisture filter is grey. cab and accessories,
group 9.4.9 Moisture filter
Windshield wipers C C C Incl. washer, top up when
needed.
Lighting and audible signals C C C
Roof window C C Check damage, change when Section 9 Frame, body,
needed. cab, and accessories,
group 9.9.3 Roof window
Cab frame C C Check rust damage,
deformation or cracks.

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:13

Doors C C C Check doors' mounting points. Section 9 Frame, body,


cab and accessories,
Group 9.10.2 Doors
Cab undercarriage C C Check mountings, isolators Section 9 Frame, body,
and bolted joints. cab and accessories,
group 9.10.3 Cab
undercarriage
Frame C C Check occurrence of any
deformation and rust damage
as well as cracks in welded
joints.
Counterweights C Check that the counterweights
are positioned properly and
that the mounts and welding
seams are intact and free of
visible cracks.
Check tightening torque of
bolted joints.
C C C Section 9 Frame, body,
Central lubrication cab and accessories,
group 9.14 Central
lubrication
Paint/coatings C C Check the machine's painted
surfaces for stone chips and
scratches.
Safety decals C C C Check that safety decals are See Operator's manual
legible, securely fastened, DRF 100, section 3
and not damaged. Clean dirty Overview, group 3.2
decals and replace decals as Signs
needed.
10 Common hydraulics
Cooler hydraulic oil C C External check and cleaning. Section 10 Common
hydraulics, group 10.6.2
Cooler hydraulic oil
NOTE
Do not use high pressure
wash.

Breather filter hydraulic oil C/R R R Change at indication. Section 10 Common


tank hydraulics, group 10.6.6
Breather filter hydraulic oil
tank
Hydraulic oil filter R R Section 10 Common
hydraulics, group 10.6.7
Hydraulic oil filter
Hydraulic oil R For volume and quality, see Section 10 Common
section F F Technical data. hydraulics, group 10.6.8
Hydraulic oil
Fine filter hydraulic oil R R R Section 10 Common
hydraulics, group 10.6.9
Fine filter hydraulic oil
11 Common electrics
Fuses C C C Check that fuses are intact, Section 11 Common
change if needed. electrics, group 11.2.2
Fuses
Batteries C C C Section 11 Common
electrics, group 11.3.1
Start battery

Maintenance Manual DCF 280–520 UDCF07.01GB


C:14 C Preventive maintenance – Preventive maintenance

Battery cable C C C Section 11 Common


electrics, group 11.3.1
Start battery
Position sensors C C C Should be free from grease
and dirt, clean as needed.
• Position sensor mast
• Position sensor
attachment

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:15

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


C:16 C Preventive maintenance – Preventive maintenance

Lubricating 500h

1 Turn off the engine and turn off the system voltage.

2 Clean the area around each grease cup before greasing.

3 Lubricate the machine's grease points with lubricant in


accordance with the recommendations, see section F Technical
data. Also do a visual check of all lubricated mounts.

IMPORTANT
On machines with central lubrication, check that the
central lubrication's 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

Po- Grease points Reference


s.
1 Brake pedal inside cab (2 pcs) Brake pedal, page C:18
2 Wheel hubs (2 pc) Wheel hub and wheel spindle, page C:17
3 Wheel spindles (4 pc)
4 Link arms (4 pc) Link arms, page C:18
5 Mast, mast wheels (4-6 pc) Mast, page C:19
6 Mast, support rollers (4-6 pc)
7 Mast, chain wheels (2 pc)
8 Mast, chains (2 pc)
9 Mast, slide plates (2 pc)
10 Mast top support rollers (2 pc), if applicable.
11 Rotation cylinders (2 pc) Rotation cylinders., page C:20
12 Side shift cylinder, fork spreading cylinder (2 pcs) Side shift cylinder, page C:20
13 Tilt cylinders (2 pc) Tilt cylinder, page C:21
14 Hinges doors (2 pc)
15 Cab tilting (x 2). Applies to DCF 280-330 LB. Cab lock , page C:21
16 Fork carriage (8 pc, 4 mast wheel and 4 support Fork carriage, page C:20
rollers)
17 Fork wheel (6 pc), (not shown on diagram) Fork wheel, page C:19

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:17

Wheel hub and wheel spindle


1 Lift the right control wheel with a jack so that wheel bearing and
wheel spindle are unloaded, do not lift so high that the wheel
hangs freely.
2 Grease the wheel hub until grease comes out at the seal on the
hub's inside.
Lift the seal ring's lip with a small screwdriver to facilitate pressing
out of air. Grease until grease comes out by the seal.

NOTE
Be careful so that the seal is not damaged.

Grease point wheel hub

3 Grease the wheel spindle's upper and lower bearings.

NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.

4 Lower the wheel.


5 Repeat steps 1 - 4 on the left control wheel.

Lubrication points wheel spindle


1. Upper lubrication point
2. Lower lubrication point

Maintenance Manual DCF 280–520 UDCF07.01GB


C:18 C Preventive maintenance – Preventive maintenance

Link arms
6 Lubricate the link arm bearings (position 2 and 3) with lubricating
grease.

1. Lubrication point, upper king pin bearing


2. Lubrication point, outer link bearing
3. Lubrication point, inner link bearing
4. Lubrication point, lower king pin bearing

Brake pedal
7 Lubricate the brake pedal's hinge with grease.
8 Wipe off excess grease.

Grease points brake pedal

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:19

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

Grease points for mast.

Fork wheel
14 Lubricate rollers and wheel with lubricating grease.
007325

Maintenance Manual DCF 280–520 UDCF07.01GB


C:20 C Preventive maintenance – Preventive maintenance

Fork carriage
15 Lubricate the rollers and wheel of the fork carriage with lubricating
grease.

007292

Grease points on the fork carriage.

Rotation cylinders.
16 Lubricate the rotation cylinders' mounts with lubricating grease.
007233

Grease points on the rotation cylinders.

Side shift cylinder


17 Lubricate the side shift cylinder mounts with lubricating grease.
007293

Grease points of the side shift cylinder.

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:21

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

Grease points on tilt cylinder (diagram shows DCF


370-520).

Cab lock
19 Tilt the cab.
20 Lubricate the cab locks with lubricating grease.
007278

Grease points on cab lock (applies to DCF 280-330 LB).

Maintenance Manual DCF 280–520 UDCF07.01GB


C:22 C Preventive maintenance – Preventive maintenance

Lubricating 1000h

1 Lower carriage and engage full spreading.

2 Turn off the engine and turn off the system voltage.

3 Clean the area around each grease cup before greasing.

4 Lubricate the machine's grease points with Lubricating grease


as shown on the diagrams below, see section F Technical data.
Also do a visual check of all lubricated mounts.

6 2, 3 6

4 4

007235
5 5
Grease points, lubricating grease

Po- Grease points Reference


s.
1 Lubricating 500h Lubricating 500h, page C:16
2 Attachment, page C:23
Attachment
3 Chain wheel spreading, page C:23 and Chain spreading,
Chain and chain wheel spreading page C:23
4 Twistlocks, page C:23
Twistlocks (4 pc)
5 Universal joints (2 pc) Universal joint, page C:24
6 Turnable operator's station, gears, page C:24 and Turnable
Turnable operator's station operator's station, chain, page C:24
7 Electric connectors (not shown on diagram) Grease with contact grease

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:23

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.

Run spreading in and out several times without load.

IMPORTANT
Wipe off excess lubrication paste.

Chain wheel spreading


2 Lubricate the chain wheel bearing with lubricating grease.
Chain spreading
3 Brush chain with lubricating grease.

Twistlocks
4 Lubricate the lift pins' bearing with lubricating grease.

Maintenance Manual DCF 280–520 UDCF07.01GB


C:24 C Preventive maintenance – Preventive maintenance

Universal joint
5 Grease universal joints with lubricating grease.

Grease nipple for universal joint, example

Turnable operator's station, gears


6 Remove the cover plate and clean and lubricate the gears with
lubricating grease.

Turnable operator's station, chain


7 Remove the cover plate, clean and lubricate the chain with
lubricating grease.

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:25

Checking for cracks

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.

2 Clean every weld carefully before inspection.

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.

Magnetic particle method


1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using magnetic particle inspection and the following
equipment:
001703

• Equipment: Yoke Tiede


• Method:
Rim
a Alternating current AC
b Contrast colour
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.

Maintenance Manual DCF 280–520 UDCF07.01GB


C:26 C Preventive maintenance – Preventive maintenance

Checking cracks with penetrating fluid


1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.

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.

6 Visually inspect the area.


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

Examples of cracks
1. Linear crack
2. Pointed crack

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:27

Checkpoints
1 Check the following welds carefully:

1 8 7 6

009782
2
Checking for cracks

Po- Checkpoint Reference


s.
1 Steering axle mounts Steering axle mounts, page C:28
2 Tilt cylinder and tilt cylinder mount. Tilt cylinder and tilt cylinder mount., page C:28
3 Mounting of frame beam to back piece Mounting of frame beam to back piece, page C:29
4 Drive axle mount Drive axle mount, page C:30
5 Mast mount Mast mount, page C:30
6 Top lift attachment Top lift attachment, page C:31
7 Lifting equipment Lifting equipment, page C:31
8 Lift cylinder support Lift cylinder support, page C:33
9 Lifting forks Lifting forks, page C:34

Maintenance Manual DCF 280–520 UDCF07.01GB


C:28 C Preventive maintenance – Preventive maintenance

Steering axle mounts


1

009664

a) Steering axle mount in chassis


b) Steering axle mount in steering axle cradle

Tilt cylinder and tilt cylinder mount.


2
a) Check the tilt cylinder.
009481

Machine without tilt frame


b) Tilt mount in mast.
009783

Machine with tilt frame

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:29

c) Tilt mount in chassis.

009785
d) Tilt mount in tilt frame

009527

e) Tilt frame mount in chassis.


009784

Mounting of frame beam to back piece


3 Mounting of frame beam to back piece.
009794

Maintenance Manual DCF 280–520 UDCF07.01GB


C:30 C Preventive maintenance – Preventive maintenance

Drive axle mount


4 Drive axle mount in chassis

009668
Mast mount
5
009486 a) Mast mount in chassis.

b) Welds between mast beam and mount tab.


009487

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:31

c) Mast mount in chassis, bottom view.

009523

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


009524

Top lift attachment


6 Check the top lift attachment's welding seams.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


C:32 C Preventive maintenance – Preventive maintenance

a) Trolley side's welds against the trolley beams.

009792

b) Outer struts' welds against the trolley beams.


009791

c) Chain mounting in the trolley.


Also check the mounting pin to the chain and its split pin.
009789

UDCF07.01GB Maintenance Manual DCF 280–520


C Preventive maintenance – Preventive maintenance C:33

d) Chain mounting in the mast.


Also check the chain tightener, mounting pin to the chain and its
split pin.

009790
e) The wheel pin welds in the trolley.
Check the inner mast wheel pins as well.

009793

Lift cylinder support


8 Lift cylinders' lower support mount against mast beam.
009787

Maintenance Manual DCF 280–520 UDCF07.01GB


C:34 C Preventive maintenance – Preventive maintenance

Lifting forks
9
NOTE
There may be other variants of forks than those shown here.

a) The fork's suspension bracket against the carriage beams.


Mounting of support rollers.
When checking fork material, see section 7 Load handling, group
7.9.1 Lifting forks.

009788

UDCF07.01GB Maintenance Manual DCF 280–520


C:1

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 motor is a straight, six-cylinder, four-stroke, turbo-charged,


low-emission diesel engine with unit injectors and air-to-air intercoolers.

The transmission is hydromechanical with gears in constant mesh. It


has three or four gears in each direction depending on model. The
engine's power is transmitted using a torque converter.

The power transmission consists of propeller shaft and a rigid drive


axle with hub reduction. The machine has front-wheel drive.

The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the type
disc brake and acts on the drive axle's input shaft.

The machine is steered with the rear wheels using a double-acting


hydraulic cylinder. The steering axle is oscillation-mounted in the frame.

The wheels are fastened on the hubs using clamps. The drive axle has
twin wheels, the steering axle has single wheels.

Load handling consists of components and functions for handling loads.


Loads are lifted with forks, secured to a carriage attached to a mast.
Load handling is divided into the functions lifting/lowering, tilt, side shift,
spreading, levelling and load carrier. Lifting/lowering is the function to
raise and lower the fork carriage. Side shift is for repositioning the forks
in parallel at the same distance from each other laterally along the
carriage. Spreading is for adjusting the width between the forks on the
carriage. Tilt is for angling the load in the longitudinal direction of the
truck using the mast. Levelling is angling the load in the lateral direction
of the truck. The load carrier is for holding or gripping the load.

The control system includes functions to warn the operator of


dangerous situations and faults. The control system has diagnostic
options that facilitate troubleshooting.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


C:2

UDCF07.01GB Maintenance Manual DCF 280–520


1:1

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

Maintenance Manual DCF 280–520 UDCF07.01GB


1:2

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Engine 1:3

1 Engine
Engine, description
The engine provides power for propulsion and the working hydraulics.

The engines are low emission engines and meet 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.

The DCF 280–330 is equipped with the Volvo TAD762VE.

The DCF 370–520 is equipped with the Volvo TAD1360VE.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:4 1 Engine – Engine

Engine alternative Volvo TAD762VE,


function description
Volvo TAD762VE is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.

°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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Engine 1:5

Engine alternative Volvo TAD1360VE,


function description
Volvo TAD1360VE is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit injectors and air-to-air intercooler.

°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)

Maintenance Manual DCF 280–520 UDCF07.01GB


1:6 1 Engine – Engine

Engine alternative Volvo TAD762VE,


component location

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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Engine 1:7

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

Maintenance Manual DCF 280–520 UDCF07.01GB


1:8 1 Engine – Engine

Engine alternative Volvo TAD1360VE,


component location

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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Engine 1:9

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

Maintenance Manual DCF 280–520 UDCF07.01GB


1:10 1 Engine – Engine

Electric components machine, position


3 4 5

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)

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Fuel system 1:11

1.2 Fuel system


Fuel system, description
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the
tank is shown on an operating menu on the display in the cab. Fuel
prefilter with water trap and fuel filter are on the engine. The water trap
is equipped with electrical indication, an event menu appears on the
display when the water trap must be emptied of water.

For component locations, see Engine alternative Volvo TAD762VE,


component location, page 1:6, or Engine alternative Volvo TAD1360VE,
component location, page 1:8.

WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:12 1 Engine – Fuel system

Fuel system, bleeding

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.

4 Close the hand pump by pressing in and turning clockwise.


5 Start the engine and allow it to idle for about five minutes before
increasing speed.
014097

Volvo TAD762VE
1. Hand pump

1
014098

Volvo TAD1360VE
1. Hand pump

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Fuel tank 1:13

1.2.1 Fuel tank

Fuel tank, cleaning

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.


1 2 Empty the fuel tank of fuel. Use a pumping device.
3 Remove the drain plug from the fuel tank.
4 Rinse the fuel tank clean through the fuel filler hole.
5 Reinstall the drain plug.

2
014211

3
1. Fuel filler
2. Drain plug, under tank
3. Fuel tank

1.2.3 Fuel prefilter

Fuel prefilter, draining condensation water


(engine alternative Volvo TAD762VE)

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.

1 Machine in service position, see section B Safety.

2 Close the fuel cock.

3 Place a container under the fuel prefilter.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:14 1 Engine – Fuel prefilter

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

Fuel prefilter, draining condensation water


(engine alternative Volvo TAD1360VE)

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.

1 Machine in service position, see section B Safety.

2 Place a container under the fuel prefilter.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Fuel prefilter 1:15

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

Fuel prefilter, changing (engine alternative Volvo


TAD762VE)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.

2 Clean the fuel prefilter and water trap.

3 Drain the fuel prefilter of fuel and water.


See Fuel prefilter, draining condensation water (engine alternative
Volvo TAD762VE), page 1:13.
4 Remove the water trap (position 3) from the old filter.
5 Remove the fuel prefilter (position 2) from the filter holder, use a
filter tool. Collect any fuel in a container.

3
014214

1. Wiring
2. Fuel prefilter
3. Water trap

Maintenance Manual DCF 280–520 UDCF07.01GB


1:16 1 Engine – Fuel prefilter

6 Lubricate the gasket on the new fuel prefilter.


7 Install the new fuel prefilter on the filter holder.
Tighten in accordance with the instructions on the filter.
8 Install a new O-ring on the water trap and lubricate with diesel oil.
Install the water trap on the new fuel prefilter.
9 Bleed the fuel system, see Fuel system, bleeding, page 1:12.
10 Turn on the system voltage and start the engine. Check that the
filter seals tight.
2

3
014215

1. Wiring
2. Fuel prefilter
3. Water trap

Fuel prefilter, changing (engine alternative Volvo


TAD1360VE)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.

1 Machine in service position, see section B Safety.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Fuel filter 1:17

2 Drain the fuel prefilter of fuel and water.


See Fuel prefilter, draining condensation water (engine alternative
Volvo TAD1360VE), page 1:14.
3 Disconnect the wiring (position 1) from the sensor for water in fuel.
4 Remove the fuel prefilter from the filter holder. Collect any fuel
in a container.
5 Remove the water trap (position 3) from the old filter.
1 6 Clean the water trap using a soft cloth.
Check that the drain hole in the lower part is not blocked.

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

10 Connect the wiring to the sensor water in fuel.


11 Bleed the fuel system, see Fuel system, bleeding, page 1:12.
1. Wiring
2. Fuel prefilter 12 Turn on the system voltage and start the engine. Check that the
filter seals tight.
3. Water trap

1.2.4 Fuel filter

Fuel filter, changing (engine alternative Volvo


TAD762VE)

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.

1 Machine in service position, see section B Safety.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:18 1 Engine – Fuel filter

2 Clean around the filter.


3 Remove the filter cover (position 1).

1 4 Remove the O-ring (position 2) and filter insert (position 3).


5 Fit a new filter insert and new O-ring.
6 Fit the filter cover, tighten to a torque of 25 Nm
2 7 Bleed the fuel system, see Fuel system, bleeding, page 1:12.
8 Start the engine and check sealing.

3
014217

Fuel filter, changing (engine alternative Volvo


TAD1360VE)

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.

1 Machine in service position, see section B Safety.


The fuel filter must be replaced when the engine is cold.

2 Place a container under the fuel filter.

3 Clean around the filter.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – AdBlue tank 1:19

4 Remove the fuel filter with the filter removal tool.


5 Clean the fuel filter's mating surface on the filter holder.
6 Lubricate the O-ring on the new fuel filter with diesel oil.
7 Install the new fuel filter.
Tighten according to the instructions on the fuel filter.
8 Bleed the fuel system, see Fuel system, bleeding, page 1:12.
9 Fuel prefilters must be replaced and the water trap emptied at the
same time as replacing the fuel filter, see Fuel prefilter, changing
(engine alternative Volvo TAD1360VE), page 1:16.
10 Turn on the system voltage and start the engine. Check that the
fuel filter seals tight.

014218

1.2.12 AdBlue tank

AdBlue tank, cleaning

NOTE
Read safety recommendations for AdBlue before starting work, see
section B Safety.

1 Machine in service position, see section B Safety.

2 Remove the drain plug (position 1) on the underside of the AdBlue


tank. Drain any remaining AdBlue into a container.
3 Replace the drain plug gasket and reinstall the plug, tighten to
a tightening torque of 30 Nm.

NOTE
Only use gaskets that can withstand AdBlue.

1
014224

Maintenance Manual DCF 280–520 UDCF07.01GB


1:20 1 Engine – AdBlue tank

4 Remove the filler cap and filler pipe.

014225
5 Lower the filler cap and filler pipe in a water bath. Let them remain
for at least two minutes.
014226

6 Detach and remove the tank connections.


014227

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – AdBlue tank 1:21

7 Check the strainer on the connections. Clean when needed.

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.

9 Reinstall the tank connections.


014230

Maintenance Manual DCF 280–520 UDCF07.01GB


1:22 1 Engine – AdBlue filter

10 Reinstall the filler pipe.


11 Fill the tank with AdBlue. Refit the filler cap.

014231

1.2.13 AdBlue filter

AdBlue filter, replacement

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.

1 Machine in service position, see section B Safety.

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.

3 Remove the connection for the heating element.

NOTE
Pull the connection straight out.
014232

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – AdBlue filter 1:23

4 Drain any remaining AdBlue into a container.


Place a container under the pump unit. Connect a plastic tube to
the drain screw located on the filter holder. Open the screw and
allow the remaining AdBlue solution to run down into the container.

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.

7 Install a new O-ring (position 2) in the new filter holder.


Install a new filter insert in the filter holder.
Install the filter insert and filter holder as one unit in the pump.
Tighten the filter holder using a toque wrench.
3
NOTE
2 Check that the drain valve is closed.
014235

8 Install the hose to the filter holder. Check that the locks lock
1 securely.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:24 1 Engine – AdBlue filter

9 Reconnect the connection to the heating element. Check that


the connection locks securely.

NOTE
Ensure that the connection is connected straight.

10 Start the engine and check sealing.

014236

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Air intake and exhaust outlet 1:25

1.6 Air intake and exhaust outlet


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

Volvo Stage 3B engines are equipped with SCR technology to reduce


nitrogen oxides (NOx) in exhaust gases. SCR technology means that
AdBlue is injected into the exhaust gases before it reaches the SCR
catalyst. A sensor measures the exhaust gases' NOx levels. The SCR
is located on the left-hand side of the machine.

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.

The exhaust system consists of pipe and silencer.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:26 1 Engine – Air intake and exhaust outlet

Exhaust outlet, component location

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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Air intake and exhaust outlet 1:27

10 9 6 8

014286
1

Exhaust outlet DCF 370-520 6. Level and temperature sensor AdBlue


1. Control unit NOx 7. Exhaust pipe
2. Silencer with integrated SCR catalyst 8. AdBlue tank
3. End-pipe 9. Pump unit
4. Heat shield 10. Heating valve
5. Injector unit

Maintenance Manual DCF 280–520 UDCF07.01GB


1:28 1 Engine – Air cleaning system

1.6.1 Air cleaning system

Air filter, changing

1 Machine in service position, see section B Safety.

2 Clean the outside of the air filter housing.


3 Remove the cap from the air filter housing.

A
D

C B
010110

A Position the air filter container


B Replacement indicator
C Dust reservoir
D Cover

4 Remove the filter cartridge.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Air cleaning system 1:29

5 Clean the dust reservoir.

6 Check the safety insert, change as needed. (The safety insert


should be changed every other time the filter insert is changed).
7 Fit a new filter insert.

NOTE
The filter cartridge should be changed, not cleaned.

8 Fit the cover to the air cleaner casing.


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

Maintenance Manual DCF 280–520 UDCF07.01GB


1:30 1 Engine – Exhaust system

10 Reset the indicator.

1.6.3 Exhaust system

Exhaust system, checking

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 Machine in service position, see section B Safety.

2 Check the exhaust system's sealing and other wear.

3 Check that the exhaust system suspension is intact.

1.6.4 Intercooler

Intercooler, checking
1 Machine in service position, see section B Safety.

2 Clean the intercooler with compressed air.

NOTE
Do not use high pressure wash.

3 Check that the intercooler suspension is intact.

4 Check the sealing and check that the intercooler's hoses and
clamps are in good condition.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Intercooler 1:31

Charge-air pipe, checking

1 Machine in service position, see section B Safety.

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

Charge air pipe, Volvo TAD762VE


014249

Charge air pipe, Volvo TAD1360VE

Maintenance Manual DCF 280–520 UDCF07.01GB


1:32 1 Engine – Cooling system

1.7 Cooling system


Cooling system, description
The engine radiator is located together with the intercooler and the
transmission oil cooler in one unit, a cooling unit.
For component locations, see Engine alternative Volvo TAD762VE,
component location, page 1:6, or Engine alternative Volvo TAD1360VE,
component location, page 1:8.

1.7.4 Radiator and expansion tank

Radiator, cleaning
1 Machine in service position, see section B Safety.

2 Clean the radiator with compressed air.

NOTE
Do not use high pressure wash.

3 Check that the cooling flanges are whole.

1.7.5 Cooling fan


Drive belt, inspection
Check after operating when the belts are warm.
It should be possible to press down the drive belt approx. 3-4 cm
between the belt pulleys.
The drive belt has an automatic belt tensioner and does not need to
be adjusted. Check the condition of the belts, replace if necessary,
see Drive belt, changing (engine alternative Volvo TAD762VE), page
1:33 or Drive belt, changing (engine alternative Volvo TAD1360VE),
page 1:33.

IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.

Alternator belt, checking (engine alternative Volvo


TAD1360VE)
Check after operating when the belts are warm.
It should be possible to press down the alternator belt approx. 3-4 cm
between the belt pulleys.
The alternator belt has an automatic belt tensioner and does not need
to be adjusted. Check the condition of the belts, replace if necessary,
see Alternator belt, changing (engine alternative Volvo TAD1360VE),
page 1:34.

IMPORTANT
Always change an alternator belt that looks to be worn
or has cracks.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Cooling fan 1:33

Drive belt, changing (engine alternative Volvo


TAD762VE)
1 Machine in service position, see section B Safety.

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

Drive belt, changing (engine alternative Volvo


TAD1360VE)
1 Machine in service position, see section B Safety.

2 Remove the protective screen and the outer fan ring around the
cooling fan.

3 Remove the protective covers around the drive belts.

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

Maintenance Manual DCF 280–520 UDCF07.01GB


1:34 1 Engine – Cooling fan

Alternator belt, changing (engine alternative Volvo


TAD1360VE)
1 Machine in service position, see section B Safety.

2 Remove the protective screen and the outer fan ring around the
cooling fan.

3 Remove the protective covers around the drive belts.

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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Coolant 1:35

1.7.7 Coolant

Coolant level, check

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

Coolant should be filled in the system's expansion tank (position A).


The coolant should be visible in the sight glass (position C) on the
expansion tank.

DCF 370–520

Coolant should be filled in the system's expansion tank (position A).


The fluid level should be between MIN and MAX markings (position
014061

D) on the expansion tank.

DCF 280-330 NOTE


A Position for coolant reservoir (expansion tank) Open very carefully as hot coolant may jet up.
B Filling point
C Sight glass If the coolant level becomes too low, the warning light for low coolant
level (position 40) lights up on the instrument panel.

NOTE
A low coolant level may cause engine damage or may cause the
engine to stop.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:36 1 Engine – Coolant

1 Machine in service position, see section B Safety.


2 If needed, top up with ready-mixed recommended coolant. For
volume and quality, see section F F Technical data.

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.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Coolant 1:37

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:38 1 Engine – Coolant

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.

Check whether the installation has additional cocks or plugs on


007394

the coolant line's lowest points. Allow the drain cocks or plugs to
remain open and ensure that the heating knob is set to full heat
during cleaning.
Drain point engine.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If there still are impurities after flushing for some time, cleaning
with coolant can be performed. Otherwise continue with Cleaning
with coolant, page 1:39.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Coolant 1:39

Cleaning with coolant


1 Fill the cooling system with 15-20 % concentrated coolant mixture.
Only use recommended concentrated coolant mixed with clean
water.

2 Drain the cooling system after 1-2 days of operation.

NOTE
In order to avoid dissolved materials getting into the cooling
system, drain quickly, within 10 minutes, without the engine
having been stationary for a long time.
Remove the filler cap from the expansion tank and any lower
radiator hose to increase the drain speed.

3 Immediately flush the system thoroughly with clean hot water to


prevent dirt getting on the internal surfaces. Flush until clean water
runs out. Make sure the heat control is at full heat during cleaning.

4 If impurities should remain after a long time of flushing, cleaning


can be performed with radiator cleaning agent and after-treatment
with neutraliser.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:40 1 Engine – Lubrication system

1.8 Lubrication system


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

For component locations, see Engine alternative Volvo TAD762VE,


component location, page 1:6, or Engine alternative Volvo TAD1360VE,
component location, page 1:8.

Oil and oil filter, changing (engine alternative


Volvo TAD762VE)

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Run the engine until warm.

2 Machine in service position, 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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Lubrication system 1:41

6 Carefully remove the filter cover (position 1).


1
7 Remove the O-ring (position 2) and filter insert (position 3).

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

Oil and oil filter, changing (engine alternative


Volvo TAD1360VE)

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Run the engine until warm.

2 Machine in service position, see section B Safety.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:42 1 Engine – Lubrication system

3 Remove the drain plug from the engine and drain the engine of oil.

007317

4 Clean the filter holder (position1).


1
5 Remove all oil filters (position 2–4) using a filter extractor.
6 Clean the mating surface of the filter holder and check that no
gasket from the old filter remains in place.
7 Install new oil filters.
Lubricate the O-rings on the filters with engine oil.
Full flow filter: tighten to contact and then an additional one-half
to three-quarter turn.
Bypass filter: tighten to contact and then another three-quarter
turn.
8 Fit the drain plug when the oil has drained. Tighten to a maximum
torque of 60±10 Nm.
2
NOTE
4
Do not tighten the oil plug with higher tightening torque, the
3 threads will be damaged.

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

Oil level, checking (engine alternative Volvo


TAD762VE)

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.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Lubrication system 1:43

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

Oil level, checking (engine alternative Volvo


TAD1360VE)

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:44 1 Engine – Lubrication system

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

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Control system engine 1:45

1.9 Control system engine


Control system engine, description
The engine is controlled by a control and monitoring system, for which
the central unit is a control unit.

The control unit controls the amount of fuel to the unit injectors by
opening and closing a fuel valve 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)).

If serious malfunctions are detected by the control and monitoring


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

Maintenance Manual DCF 280–520 UDCF07.01GB


1:46 1 Engine – Ignition/heating

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).

For component locations, see Engine alternative Volvo TAD762VE,


component location, page 1:6, or Engine alternative Volvo TAD1360VE,
component location, page 1:8.

UDCF07.01GB Maintenance Manual DCF 280–520


1 Engine – Start/stop 1:47

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).

Start lock-out is available as an option, where a code has to be


entered via the display before the engine can be started.

Automatic engine shutdown is available as optional equipment.


This means that the engine switches off automatically after 3-30
minutes (depending on customer setup) irrespective of whether the
operator is sitting in the seat or not. The conditions are that the
machine is stationary and idling.

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.

For component locations, see Engine alternative Volvo TAD762VE,


component location, page 1:6, or Engine alternative Volvo TAD1360VE,
component location, page 1:8.

Maintenance Manual DCF 280–520 UDCF07.01GB


1:48

UDCF07.01GB Maintenance Manual DCF 280–520


2:1

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

Maintenance Manual DCF 280–520 UDCF07.01GB


2:2

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Transmission 2:3

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 transmission is fully automatic with torque converter. The TE17


has three forward gears and three reverse gears, and the TE32 has
four forward gears and four reverse gears.

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.

The gear position is selected by modulating pressure via electrical


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

Maintenance Manual DCF 280–520 UDCF07.01GB


2:4 2 Transmission – Transmission

Transmission TE17, function description


Condition Reference value
Sensor operator in seat Operator in seat

F
R

<˚ 1
18 5

17 6 2
D794 D790-1 D790-2

D793 D795 D797-1


9 16 20

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)

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Transmission 2:5

Transmission alternative TE17, component


location
Left side Right side

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


2:6 2 Transmission – Transmission

Transmission alternative TE32, function


description

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. Multi-function lever (S162) 16. Pressure sensor gear 1/3 (B6067)


2. Control unit KIT (D790-2) 17. Pressure sensor gear 2/4 (B6069)
3. Accelerator pedal (B690) 18. Sensor engine rpm (B7530)
4. Declutch pedal (S220-1) 19. Sensor rpm turbine (B7510)
5. Control unit cab (D790-1) 20. Sensor rpm drum (B7520)
6. Control unit, transmission (D793) 21. Sensor rpm output shaft (B7580)
7. Oil pump transmission 22. Temperature monitor torque converter (S2210)
8. Oil filter transmission 23. Sensor oil temperature (B7660) (from cooler to sump)
9. Solenoid valve drive forward (Y6066F) 24. Oil cooler
10. Solenoid valve drive reverse (Y6066R) 25. Control unit KID (D795)
11. Servo valve gear forward/reverse (Y6300) 26. Sensor gear position
12. Servo valve gear 1/3 (Y6067) 27. Control unit engine (D794)
13. Solenoid valve gear selection 1/3 (Y6075) 28. Make-contact declutch (S220-2)
14. Servo valve gear 2/4 (Y6069) 29. Control unit frame (D797-1)
15. Solenoid valve gear selection 2/4 (Y6074)

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Transmission 2:7

Transmission alternative TE32, component


location

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


2:8 2 Transmission – Transmission

Transmission electrical components,


component location

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)

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Torque converter/Clutch system 2:9

2.2 Torque converter/Clutch system


Torque converter/clutch, description
The torque converter transmits the engine's power to the transmission.

For component locations see:


Transmission alternative TE17, component location, page 2:5.
Transmission alternative TE32, component location, page 2:7.

Breather filter, cleaning

1 Machine in service position, see section B Safety.

2 Disconnect the breather filter from the transmission.


3 Clean the breather filter from dirt.
4 Reinstall the breather filter.

Transmission alternative TE17


1. Breather filter, on top of torque converter.

Transmission alternative TE32


1. Breather filter, on top of torque converter.

Maintenance Manual DCF 280–520 UDCF07.01GB


2:10 2 Transmission – Mechanical transmission

2.3 Mechanical transmission


Mechanical transmission, description
The transmission is built with all gears in constant mesh. It is shifted
by hydraulic pressurising of clutch discs for each of the gears. The
discs connect the input shaft with the main shaft or tubular shaft,
depending on which gear has been selected. Shifting takes place
without disengaging the transmission from the engine.

Transmission alternative TE17 has three gears in each direction and


transmission alternative TE32 has four gears in each direction. Shifting
is automatically controlled by Control unit, transmission (D793) which
selects gear electrically by activating solenoid valves that control oil
pressure to the different clutches.

The FORWARD and REVERSE clutches are electro-hydraulically


modulated, which means that the clutch pressure is built up gradually.
This allows for switching between FORWARD and REVERSE and vice
versa whilst travelling at a speed that is lower than the set limit.

Modulation also allows for smooth shifts between FORWARD and


REVERSE.

Declutch is controlled with a separate declutch pedal that is activated


at a certain brake pressure.

High modulation (i.e. smooth driving/intensive slippage between gears)


gives high wear on the transmission and high oil temperature. Sensor
for oil temperature gives a warning when the oil is hotter than 100 °C.
If the oil temperature sensor indicates 125 °C the transmission stops
working.

For component locations see:


Transmission alternative TE17, component location, page 2:5.
Transmission alternative TE32, component location, page 2:7.

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Lubrication system 2:11

2.6 Lubrication system


Lubrication system, description
The transmission has its own lubrication system that is used for
lubrication, control, and cooling of the transmission. The transmission
oil cooler is located at the bottom in the cooling unit behind the
engine, a thermostat in the cooler enables the oil to reach operating
temperature faster.

At high oil temperature (100 ºC) a warning is activated in Control unit


KID (D795) and performance is reduced, if the oil temperature goes
above 125 ºC the transmission declutches.

For component locations see:


Transmission alternative TE17, component location, page 2:5.
Transmission alternative TE32, component location, page 2:7.

Oil and oil filter transmission, changing

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

NOTE
Do not over-fill the transmission!

1 Operate and warm up the transmission oil.

2 Machine in service position, see section B Safety.

3 Place a container under the transmission.

4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.

NOTE
Make sure that the drain plug's washer seal is also removed.

Draining transmission oil

Maintenance Manual DCF 280–520 UDCF07.01GB


2:12 2 Transmission – Lubrication system

5 Clean the area around the oil filter.


6 Change oil filter.
Lubricate the O-ring on the new oil filters with transmission oil.
Tighten to contact and then another two-thirds turn.
7 When the transmission oil has drained, fit the drain plug.

NOTE
Make sure that the drain plug's washer seal is also removed.

Oil filter transmission TE17

Oil filter transmission TE32

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Lubrication system 2:13

8 Remove the transmission dipstick and fill new transmission oil


through the dipstick's hole to the low level marking on the dipstick.
For volume and quality, see section F F Technical data.
9 Start the engine and let the engine run at idle for at least two
minutes.
10 Check that the drain plug for transmission oil seals tightly.
11 Check the transmission oil level with the engine running at idle and
top up to the marking for low level.

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

Maintenance Manual DCF 280–520 UDCF07.01GB


2:14 2 Transmission – Lubrication system

12 Warm up the transmission so that the oil temperature is approx.


60-65 ºC on the display. Use operating menu oil temperature to
check the transmission oil temperature.
a
13 Check the oil level and top up to the MAX marking for oil level.

000356
b 14 Calibrate the transmission, see Transmission, calibration, page
2:18.
Operating menu oil temperature
a Transmission oil temperature
b Hydraulic oil temperature

Oil level, check

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.

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Lubrication system 2:15

1 Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 82-93°C on the
display). The oil dipstick has two markings, MAX and MIN, the oil
level should be at MAX.
Wipe off the dipstick before checking.

NOTE
The oil dipstick is long. Wear gloves.

2 Fill transmission oil (position B) if needed (for volume and grade,


A see section F Technical data).
B Fill – wait awhile – check on the oil dipstick.

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

Maintenance Manual DCF 280–520 UDCF07.01GB


2:16 2 Transmission – Cooling system

2.7 Cooling system


Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:11.

For component locations see:


Transmission alternative TE17, component location, page 2:5.
Transmission alternative TE32, component location, page 2:7.

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Control system transmission 2:17

2.8 Control system transmission


Control system transmission, description
Control unit transmission controls shifting based on signals from
pressure, temperature, and speed (rpm) sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure in
the transmission, so that the selected gear gives the right speed.

For component locations see:


Transmission alternative TE17, component location, page 2:5.
Transmission alternative TE32, component location, page 2:7.

In case of serious transmission malfunctions the control unit uses


two modes with reduced functionality to protect the transmission,
Limp-home and Shut-down.

Mode Limp-Home

The display on transmission control unit shows LH.

In case of:
• a malfunction of a control output from the transmission is detected.
• a malfunction connected to a sensor for “engine speed” is detected.
• two of three “vehicle speed” sensors are defective.

In 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.

The control unit uses standard values for modulation.

Mode Shutdown

The display on transmission control unit shows "Sd".

The transmission has an integrated secondary solenoid and pressure


sensor that monitor the transmission's internal oil pressure. This
secondary solenoid is handled by the control unit.

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.

In this mode the transmission is in permanent neutral position as there


is no oil pressure to enable selection of a gear.

Maintenance Manual DCF 280–520 UDCF07.01GB


2:18 2 Transmission – Control system transmission

Transmission, calibration

DANGER
Do not leave the machine during calibration. The
machine may start to move.

1 Stop the machine on level ground, select neutral, and apply the
parking brake. Let the engine idle.

2 To select the function to calibrate, first navigate to the service


000056 menu. Then press Enter.

3 Enter the code for calibration.


The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060

The code determines which service menu shall be activated


(Service, Diagnostics, Initiation or Calibration).

4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION DRIVETRAIN with Enter.

SCALE STEERING
DRIVE-TRAIN RETURN
000062

5 Scroll with the arrow keys (1 and 2) and select DRIVETRAIN,


CALIBR DRIVE-TRN 4(6) menu 4.
GEARBOX WARM UP
6 Check that the oil temperature is at least 61 °C.
MODE X
ACTUAL TEMP XXX If the oil temperature is too low go to DRIVETRAIN, menu 4.
003887

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.

UDCF07.01GB Maintenance Manual DCF 280–520


2 Transmission – Control system transmission 2:19

7 Select DRIVE-TRAIN, menu 3.


CALIBR DRIVE-TRN 3(6) GEARBOX TUNING
START AUTO CALIBR
PHASE X SUB-PH X Description: Calibration of transmission clutches.
CLUTCH X STATUS X

005148
ACTION X XXXXrpm

PHASE: Indicates current phase in the calibration.


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

8 Check that the gear lever is in neutral position.

9 Start calibration by pressing Enter.

Maintenance Manual DCF 280–520 UDCF07.01GB


2:20 2 Transmission – Control system transmission

10 Calibration starts (takes approx. 15 minutes) and engine speed


is raised to approx. 770 rpm.
The transmission will activate different gears during calibration.

NOTE
If the machine starts to move during calibration then use the
footbrake to keep the machine stationary.

IMPORTANT
Calibration can be aborted at any time by selecting
travel direction reverse.

11 When the engine speed decreases to idling and PHASE = 4 then


calibration is complete.

12 Turn off the ignition to store the values.

UDCF07.01GB Maintenance Manual DCF 280–520


3:1

3 Driveline/Axle

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

Maintenance Manual DCF 280–520 UDCF07.01GB


3:2

UDCF07.01GB Maintenance Manual DCF 280–520


3 Driveline/Axle – Driveline/Axle 3:3

3 Driveline/Axle
Driveline/Axle, description
The machine's power transmission consists of propeller shaft and drive
axle with differential and hub reduction.

Maintenance Manual DCF 280–520 UDCF07.01GB


3:4 3 Driveline/Axle – Propeller shaft

3.2 Propeller shaft


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

005193

Propeller shaft, checking


• After 50h:
Check-tighten drive axle and transmission mounting bolts to 98
Nm (oiled bolt) for DCF 280-330 and to 156 Nm (oiled bolt) for
DCF 370-520.
• After 500h:
Clean.
Check clearance in universal joints.
• After 1000h:
Grease universal joints with universal grease EP2.
Check-tighten drive axle and transmission mounting bolts to 98
Nm (oiled bolt) for DCF 280-330 and to 156 Nm (oiled bolt) for
DCF 370-520.

Grease nipple for universal joint, example

UDCF07.01GB Maintenance Manual DCF 280–520


3 Driveline/Axle – Drive axle 3:5

3.3 Drive axle


Drive axle, description
The drive axle transmits the engine power to the wheels. After the
drive axle's input shaft there is a differential that changes the gear ratio,
distributes the power between the right and left drive wheel, and makes
it possible for the drive wheels to have different speeds when cornering.
The half shaft transmits the power from the differential to the wheel
hubs. At the wheel hubs there are hub reductions that change the gear
ratio between wheels and engine to reduce the stress on the half shaft.

1 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

Drive axle DCF 280-330, checking

1 Check the drive axle's attachment to the frame so that there is no


corrosion on structural elements (e.g., attaching bolts).

2 Check-tighten the drive axle's attaching bolts to 1275 Nm (oiled


bolt).
3 Check-tighten the wheel nuts to 400 Nm (oiled bolt).
4 Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
5 Check that drive axle seals tight.
6 Check the oil level in drive axle and the hub reductions.

Attaching bolts drive axle

Maintenance Manual DCF 280–520 UDCF07.01GB


3:6 3 Driveline/Axle – Drive axle

Drive axle DCF 370-520, checking

1 Check the drive axle's attachment to the frame so that there is no


corrosion on structural elements (e.g., attaching bolts).

2 Check-tighten the drive axle's attaching bolts to 2350 Nm (oiled


bolt).
3 Check-tighten the wheel nuts to 400 Nm (oiled bolt).
4 Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
5 Check that drive axle seals tight.
6 Check the oil level in drive axle and the hub reductions.
Attaching bolts drive axle

UDCF07.01GB Maintenance Manual DCF 280–520


3 Driveline/Axle – Drive axle 3:7

Drive axle oil, changing

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

Wheel hub, drive axle


1. Drain plug hub
2. Level and filling plug hub

3 Position a receptacle at each hub. Position a piece of sheet metal


or similar in the wheel rim to lead the oil into the receptacle.
4 Remove the drain plugs for the hubs (position 1) on both sides.
Also remove the level and filling plugs for the hubs (position 2) to
facilitate draining.
Both sides shall be drained separately.

Maintenance Manual DCF 280–520 UDCF07.01GB


3:8 3 Driveline/Axle – Drive axle

5 Position a receptacle under the differential carrier and remove


the drain plug.
6 Install the drain plugs on the hubs and the differential.

NOTE
Check that the seals are intact, clean and in the correct position.

Differential drive axle

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.

8 Install the hubs' level and filler plugs.

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.

11 Turn on the system voltage.


12 Check the oil level in the drive axle after a short test-drive.

UDCF07.01GB Maintenance Manual DCF 280–520


4:1

4 Brakes

Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1 Controls and instruments .................................................................................4:4
4.1.1 Brake pedal .................................................................................................4:4
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Oil pump brake system................................................................................4:8
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

Maintenance Manual DCF 280–520 UDCF07.01GB


4:2

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Brakes 4:3

4 Brakes
Brakes, general
There are brakes to stop the machine. The brakes act on the drive axle
(steering axle does not have brakes).

The brake system is divided into three functions:


• Power-assisted brake system, function description, page 4:5
• Parking brake system, function description, page 4:12
• Temperature control, cleaning and oil brake system, function
description, page 4:17

Maintenance Manual DCF 280–520 UDCF07.01GB


4:4 4 Brakes – Controls and instruments

4.1 Controls and instruments


4.1.1 Brake pedal

Brake pedal, checking and adjusting

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.

Stop bolt screw for adjusting clearance between brake


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

4 Grease the pedal hinges with EP2 universal grease.


5 Check that the rubber on the pedal is intact and that the tread
pattern isn't worn out. Change when needed.

Brake pedal grease points. (Figure shows unattached


brake pedal)

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Power-assisted brake system 4:5

4.3 Power-assisted brake system


Power-assisted brake system, function
description
The service brake system consists of a hydraulic oil tank, oil pump
brake system, oil filter brake system, accumulator charging valve,
accumulators, brake valve, pressure sensors, brake cylinder and
wheel brake units.

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.

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.

On machines with a separate braking system the servo brake system


consists of oil tank brake system, oil pump brake system, oil filter brake
system, accumulator charging valve, accumulators, brake valve,
pressure sensor, brake cylinder, wheel brake units and cooler brake
system.

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.

On machines with turnable operator's stations there is an extra brake


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

Maintenance Manual DCF 280–520 UDCF07.01GB


4:6 4 Brakes – Power-assisted brake system

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

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Power-assisted brake system 4:7

Power-assisted brake system, component


location

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


4:8 4 Brakes – Oil pump brake system

4.3.1 Oil pump brake system


Oil pump brake system, checking

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

Checking pump pressure


1 Operate and warm up the machine so that the oil in the brake
system reaches operating temperature, at least 50 ºC.

2 Machine in service position, see section B Safety.

3 Depressurise the brake and hydraulic systems, 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

Pressure check connection pump pressure

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Oil pump brake system 4:9

6 Close the drain valve on the accumulator charging valve and


check the pump pressure during charging.
During charging the pressure should increase to 20.5±1.0 MPa
before the accumulator charging valve switches to cooling. The
pressure drops when the accumulator charging valve switches
to cooling.
7 Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8 Turn off the engine.
9 Depressurise the brake and hydraulic systems, see section B
Safety.

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.

Checking accumulator charging


12 Depressurise the brake and hydraulic systems, see section B
Safety.

13 Connect a pressure gauge (0–25 MPa) to the pressure check


connection for accumulator pressure on the accumulator charging
valve.
14 Start the engine and let it idle.
004810

Pressure check connection accumulator pressure

Maintenance Manual DCF 280–520 UDCF07.01GB


4:10 4 Brakes – Accumulator

15 Close the drain valve on the accumulator charging valve.

NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.

16 Check that the pressure rises slowly to 20.5±1.0 MPa.


17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve shall switch to cooling at 15.5±0.5 MPa.
18 Depressurise the brake and hydraulic systems, see section B
Safety.

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.

4.3.9 Wheel brake

Wheel brake, bleeding

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

Brake cylinder
1 Machine in service position, see section B Safety.

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Wheel brake 4:11

2 Place a box wrench on the breather nipple and connect a


transparent hose to the breather nipple.
Direct the other end of the hose down into a collection container.
3 Start the machine and push down the brake pedal, hold the pedal
down.
4 Open the breather nipple and let the oil run out of the nipple until it
is free from air bubbles.

NOTE
The hydraulic hose between the brake pedal and brake is long.
For this reason allow at least two litres of oil pass through the
breather nipple during bleeding to ensure that no air pockets
remain in the system.

5 Close the breather nipple.

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.

1 Machine in service position, see section B Safety.

2 Position a receptacle under the drive axle at the inside of the


wheel. Position a piece of sheet metal or similar at the air nipple to
lead the oil down into the receptacle.

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.

Breather nipple cooling circuit, top side of drive axle at


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

Maintenance Manual DCF 280–520 UDCF07.01GB


4:12 4 Brakes – Parking brake system

4.5 Parking brake system


Parking brake system, function description
The parking brake consists of hydraulic oil tank, oil pump brake system,
oil filter brake system, accumulator charging valve, pressure sensor
and parking brake unit.

Oil pump brake system pumps oil (from the tank) which is cleaned
in the oil filter. The accumulator charging valve directs pressure to
the accumulators that store the pressure. The parking brake unit is
released with pressure from the accumulators by 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.

On machines with a separate parking brake system it consists of oil


tank brake system, oil pump brake system, oil filter brake system,
accumulator charging valve, accumulators, pressure sensor and
parking brake unit.

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. Oil pump brake system 7. Control unit frame (D797-1)


2. Oil filter, brake system 8. Solenoid valve, parking brake (Y642)
3. Accumulator charging valve 9. Parking brake unit
4. Accumulators 10. Make-contact (closing switch) parking brake (S200)
5. Switch parking brake (S107) 11. Control unit KIT (D790-2)
6. Control unit cab (D790-1)

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Parking brake system 4:13

Parking brake system, component location

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

Maintenance Manual DCF 280–520 UDCF07.01GB


4:14 4 Brakes – Parking brake unit

4.5.4 Parking brake unit

Parking brake unit, checking and adjusting

DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.

1 Start the engine and run up hydraulic pressure until the


accumulators are fully charged and the accumulator charging
valve switches to cooling.

2 Turn off the engine and turn the start key to position I.

3 Release the parking brake.

4 Check that the parking brake caliper can move on the bracket.

5 Check that the brake disc is clean from oil and dirt.

6 Remove the cover from the brake caliper.


Check that there is no oil inside the cover.

7 Loosen the lock nut.


8 Adjust the adjustment screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc becomes 0.5±0.1 mm.
10 Tighten the lock nut.

NOTE
To avoid turning the adjustment screw as well, it must be held
still when tightening the lock nut.

11 Refit the cover on the caliper.


12 Check the function of the parking brake.

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Parking brake unit 4:15

4.5.4.2 Parking brake pads

Brake pads, changing

DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.

1 Machine in service position and blocked wheels, see section B


Safety.

2 Remove the cover from the brake caliper.

3 Loosen the lock nut.


4 Loosen the adjusting screw so that the brake pads become loose.
5 Remove the split pin and loosen the nut on the attaching bolt
holding the parking brake caliper.

Maintenance Manual DCF 280–520 UDCF07.01GB


4:16 4 Brakes – Parking brake unit

6 Pull out the attaching bolt so that the brake pads can be twisted
out and removed.

NOTE
The bolt does not have to be removed.

7 Remove the parking brake pads.


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

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Temperature control, cleaning and oil brake system 4:17

4.8 Temperature control, cleaning


and oil brake system
Temperature control, cleaning and oil brake
system, function description
Brake system
The wheel brakes are cooled when the hydraulic oil is pumped through
the brake unit.

The temperature control system consists of hydraulic oil tank, oil pump
brake system, oil filter brake system, accumulator charging valve and
wheel brake units.

Oil pump brake system pumps oil (from the tank) which is cleaned in
the oil filter. When the accumulators are charged, the accumulator
charging valve 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.

Maintenance Manual DCF 280–520 UDCF07.01GB


4:18 4 Brakes – Temperature control, cleaning and oil brake system

11
D795

D797-1
D 9 D

C
C
3 4
P T

2 5

6 10
1 M
7

010570
8 ˚C ˚C

1. Oil pump brake system 7. Thermal bypass valve


2. Oil filter, brake system 8. Temperature sensor (B762)
3. Accumulator charging valve 9. Control unit frame (D797-1)
4. Wheel brake
10. Cooling fan (M674)
5. Distribution block
11. Control unit KID (D795)
6. Cooler brake system

Temperature control, cleaning and oil brake


system, control system

2 3

5
7
4
007200

1. Sensor oil temperature brake system (B762) 5. Oil cooler


2. Oil tank brake system 6. Thermal bypass valve
3. Breather filter 7. Tank heater
4. Cooling fan (M674) 8. Oil filter, brake system

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Breather filter 4:19

Oil pump brake system, Accumulator charging valve, Drive


axle block, Wheel brake
See Power-assisted brake system, component location, page 4:7.

4.8.11 Breather filter

Breather filter, changing

1 Clean the area around the brake tank's breather filter.

2 Remove the cover from the filter holder.


Remove the bolt in the centre and lift away the cover.
2 3 Remove the old filter insert.
4 Clean the filter holder.

NOTE
1 Work carefully so that contaminants do not enter the tank.

5 Fit a new filter insert.


005255

6 Refit the cover onto the filter holder.

1. Filling oil brake system


2. Breather filter oil tank

4.8.12 Oil filter, brake system

Oil filter brake system, changing

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.

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic and brake systems, see section B


Safety.

NOTE
Leave the valves open when changing.

3 Remove the cover plates over the area next to the transmission.

Maintenance Manual DCF 280–520 UDCF07.01GB


4:20 4 Brakes – Oil brake system

4 Remove the drain plug on the underside of the filter.


Let the oil drain. Wait a while since the oil drains slowly.
5 Remove the filter holder.

NOTE
The filter holder is heavy, loosen it carefully.

6 Remove the filter cartridge.

NOTE
Note the position of the O-rings.

7 Clean the filter holder.


8 Install the O-rings on the filter insert and filter holder. Lubricate
the O-rings with hydraulic oil.
9 Fit the new filter insert to the filter bracket.
10 Fit the filter holder and the drain plug.
11 Close the valves that were opened to drain the pressure in the
hydraulic system.

NOTE
007201

Check that the accumulator drain valve is completely closed


and tighten the lock ring.

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.

4.8.14 Oil brake system

Brake system oil, changing

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic and brake systems, see section B


Safety.

UDCF07.01GB Maintenance Manual DCF 280–520


4 Brakes – Oil brake system 4:21

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

Maintenance Manual DCF 280–520 UDCF07.01GB


4:22

UDCF07.01GB Maintenance Manual DCF 280–520


5:1

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

Maintenance Manual DCF 280–520 UDCF07.01GB


5:2

UDCF07.01GB Maintenance Manual DCF 280–520


5 Steering – Steering 5:3

5 Steering
Steering, general
The function steering means to steer the machine while operating. The
machine is steered with the rear wheels by a power-assisted steering
system.

Joystick or mini-wheel steering is available as an option and means


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

On machines with turnable operator's stations, the steering reading is


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

Maintenance Manual DCF 280–520 UDCF07.01GB


5:4 5 Steering – Power assisted system

5.2 Power assisted system


Power assisted system, function description
The function power assisted system refers to steering the machine.
The machine's steering is power-assisted with pressure from the
hydraulic oil pumps.

Steering consists of steering wheel, steering wheel shaft, steering


valve, hydraulic oil pump, priority valve, steering cylinder, link arms
and wheel spindles.

The steering wheel 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

UDCF07.01GB Maintenance Manual DCF 280–520


5 Steering – Power assisted system 5:5

Power-assisted system turnable operator's


station, function description

On machines with turnable operator's station, a directional control


valve is located between the steering valve and the steering cylinder,
which shifts direction on steering cylinder deflection when driving with
the operator's station turned backward. The directional control valve is
controlled by Control unit frame option (D797-2), which uses sensors
to detect which direction the operator's station is turned.

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


5:6 5 Steering – Power assisted system

Joystick steering/mini-wheel, function


description

Joystick control or mini-wheel steering means that the machine is


controlled by an electrical control in the left-hand armrest of the driver's
seat. The electrical control sends signals to the control system. The
steering cylinder is pressurised by a control valve that is also controlled
by the control system.

Joystick control and mini-wheel function in the same way, the difference
is in the design of the 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.

UDCF07.01GB Maintenance Manual DCF 280–520


5 Steering – Power assisted system 5:7

Condition Reference value


Joystick control activated Voltage signal from switch mini-wheel/joystick steering
Steering wheel No signal from sensor steering wheel reading
stationary
Speed Under 2 km/h (when activated)
Control switch Not activated

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

Maintenance Manual DCF 280–520 UDCF07.01GB


5:8 5 Steering – Power assisted system

Power assisted system, component location

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)

UDCF07.01GB Maintenance Manual DCF 280–520


5 Steering – Link arm 5:9

5.2.6 Link arm

Link arm, checking


Check the link arms' guide bearings, axles and the bolts that lock
the link arms' axles.

007918
5.2.12 Sensor steering wheel reading
Sensor steering wheel reading, checking

1 (product option mini-wheel or joystick steering)


2
Check that the joystick control and mini-wheel disconnect when the
steering wheel is turned.

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


5:10

UDCF07.01GB Maintenance Manual DCF 280–520


6:1

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

Maintenance Manual DCF 280–520 UDCF07.01GB


6:2

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Suspension 6:3

6 Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the driveline/axle, see section 3 Driveline/Axle, group3.3 Drive axle.

Maintenance Manual DCF 280–520 UDCF07.01GB


6:4 6 Suspension – Suspension

6.2 Suspension
Suspension, description
The steering axle cradle is mounted to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journaled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journaled wheel hubs where
the wheels are mounted.

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Suspension 6:5

Suspension, component location


1 2 3 4 5 6 Suspension refers to:
• Steering axle cradle
• Steering spindle
• Wheel hub

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

Maintenance Manual DCF 280–520 UDCF07.01GB


6:6 6 Suspension – Steering axle cradle

6.2.1 Steering axle cradle

Steering axle cradle, checking

1 Machine in service position, see section B Safety, with transverse


wheels.

2 Check that the bushings in the suspension are intact.

3 Measure the distance between the frame and the steering axle
cradle. Note the measurement.
4 Lift the machine under the rear counterweight.

NOTE
Do not lift under the steering axle.

5 Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
6 Calculate the difference between the two measurements. The
difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.
007842

The figure shows front mounting

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Wheel spindle 6:7

6.2.2 Wheel spindle


Wheel spindle bearing DCF 280-330, checking
1 Machine in service position, see section B Safety.

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.

Wheel spindle bearing DCF370-520, checking


1 Machine in service position, see section B Safety.

2 Push the O-ring up carefully.


3 Measure with feeler gauge between axial bearing and axial
washer. Max. clearance: 1.5 mm.

6.2.3 Wheel hub

Wheel hub, checking

1 Clean the hub covers on the control wheels.


2 Remove the hub cover.
3 Wipe off grease from hub cap and hub nut. Handle it as
environmentally hazardous waste.

4 Bend up the lock washer's tabs, remove the lock nut and the lock
washer.

Maintenance Manual DCF 280–520 UDCF07.01GB


6:8 6 Suspension – Wheel hub

5 Torque the bearing nut as follows.


A. Lube the thread on the spindle and the side of the nut that
faces the bearing with oil SAE 80W/140 or equivalent.
B. Tighten the nut to 250 Nm.
C. Rotate the hub at least 2 revolutions and then tighten the nut
45 degrees.
D. Rotate the hub again at least 2 revolutions and then tighten
the nut another 45 degrees.
6 Fit the lock washer and outer lock nut.
7 Tighten to at least 250 Nm or as tight as required to fold the
locking washer into the closest groove.
8 Fill the bearing cap with grease and fit it.
9 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate pressing
out of air. Grease until grease comes out by the seal.

NOTE
Be careful so that the seal is not damaged.

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Tyres and rims 6:9

6.3 Tyres and rims


Tyres and rims, safety

DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
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.

Maintenance Manual DCF 280–520 UDCF07.01GB


6:10 6 Suspension – Tyres and rims

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.

Tyre and rim system, description


The tyres are the points of contact between the machine and the
ground, and the tyres absorb unevennesses and provide suspension.

The drive axle is exposed to high forces during operation, if the drive
wheels' rolling circumference is different the stresses increase on
the drive axle. It is important that the tyres on the drive axle are the
same model, type and make, and have equal wear and proper inflation
pressure.

Tyres and rims, check


Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:9.

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Tyres and rims 6:11

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 Check the rims.


1 2 3
• Check that the lock ring and lugs are installed correctly.
• Check that there are no cracks in the rims' parts.
In case of damage, the tyre and rim must be removed and
checked.
002202

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

Examples: The figure shows inflation of drive wheel.

Maintenance Manual DCF 280–520 UDCF07.01GB


6:12 6 Suspension – Tyres and rims

Tyre and rim system, removing and fitting (drive


axle)
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:9.
Removing
1 Machine in service position, see section B Safety.

2 Lift the machine under the drive axle by the relevant wheel.
Support under the drive axle in a secure way.

DANGER
With double wheel fitting both tyres must be deflated
otherwise the inner may explode when the outer is
removed.
Risk of tyre explosion! Fatal danger!
Empty both tyres of air.

3 Release the air from the tyres by:


a) Unscrewing the valve and releasing the air.
014571

b) If this does not work, undo the valve in the rim and release the air.
014573

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Tyres and rims 6:13

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

5 Remove the nuts, washers and clamps.

Maintenance Manual DCF 280–520 UDCF07.01GB


6:14 6 Suspension – Tyres and rims

6 Remove the spacer ring.


Pull the wheel out a bit so that the spacer ring comes loose.

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.

12 Fit the inner spacer ring.

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.

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Tyres and rims 6:15

14 Fit the outer spacer ring.

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.

Tyre and rim system, removing and fitting


(steering axle)
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:9.
Removing
1 Machine in service position, see section B Safety.

2 Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.

3 Release the air from the tyres by:

Maintenance Manual DCF 280–520 UDCF07.01GB


6:16 6 Suspension – Tyres and rims

a) Unscrewing the valve and releasing the air.

014571
b) If this does not work, undo the valve in the rim and release the air.

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

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Tyres and rims 6:17

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

Maintenance Manual DCF 280–520 UDCF07.01GB


6:18 6 Suspension – Tyres

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

changing tyre or rim version, another air pressure


may apply, contact Cargotec. Plate for air pressure
in tyres must be replaced with a plate that shows
Examples: The figure shows inflation of drive wheel. applicable pressure.
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.
Check that all parts are in place when the tyre
pressure is 30 kPa.

NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.

1 Make sure that the lock ring and lock lugs are in the correct
position before inflating.

2 Connect the compressor with a locking air-chuck to the nipple


on the tyre.

3 Stand at an angle behind the tyre and remain there until inflating
has been completed in order to prevent being hit by rim parts in
the event of an explosion.

4 Inflate the tyre to prescribed pressure, see specifications.


When changing tyre or rim version, another air pressure may
apply, contact Cargotec.

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Rim 6:19

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.

1 Dismantle the rim, see Tyre, change, page 6:19.

2 Carefully clean the outside of the rim edge with a steel brush.
001703

3 Measure wear after the lock ring.


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

Max 0,5 mm
001715

Maintenance Manual DCF 280–520 UDCF07.01GB


6:20 6 Suspension – Rim

4 Check the rim's diameter.


Measure the rim edge's circumference (O) with a measuring tape
and calculate the diameter (D). [D = Circumference (O) / 3.14]
Compare the value of the diameter with specified min.
measurement. If diameter is smaller, then the wheel rim, lock
ring, and the tapered rim must be discarded and replaced with
new parts.
D Information about min. diameter can be obtained from Cargotec.
O

O. Circumference 001701

D. Diameter

5 Check for damage in the areas with high stress concentration.


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

Magnetic particle method


1 Blast the applicable area clean so that it is completely free of
paint residue.
2 Test using particle powder and the following equipment:
001703

• Equipment: Yoke Tiede


• Method:
Rim a Alternating current AC
b Contrast colour
• Checking medium:
a Wet
b Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic particle method,
checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.

Checking cracks with penetrating fluid


1 Clean the area with cleaning fluid part no. 923626.0668.
2 Spray penetrating fluid part no. 923626.0669 on the cleaned area
and let dry 10 min.
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.

UDCF07.01GB Maintenance Manual DCF 280–520


6 Suspension – Rim 6:21

6 Visually inspect the area.


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

001705
Examples of cracks
1. Linear crack
2. Pointed crack

Maintenance Manual DCF 280–520 UDCF07.01GB


6:22

UDCF07.01GB Maintenance Manual DCF 280–520


7:1

7 Load handling

Contents 7 Load handling


7 Load handling .....................................................................................................7:3
7.2 Lifting/lowering .................................................................................................7:5
7.2.3 Pressure reducer.......................................................................................7:10
7.2.4 Servo filter ................................................................................................. 7:11
7.2.9 Mast ..........................................................................................................7:12
7.2.10 Position sensor mast .................................................................................7:16
7.4 Side shift ........................................................................................................7:17
7.5 Spreading.......................................................................................................7:21
7.7 Tilt ..................................................................................................................7:25
7.7.7 Tilt cylinder ................................................................................................7:27
7.9 Load carrier....................................................................................................7:28
7.9.1 Lifting forks ................................................................................................7:28
7.9.3 Coil ram .....................................................................................................7:30
7.10 Other functions...............................................................................................7:31
7.10.5 Separate top lift attachment ......................................................................7:31

Maintenance Manual DCF 280–520 UDCF07.01GB


7:2

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Load handling 7:3

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

The components used for each respective function are described


under each subfunction. Consequently, common components are
described in several locations, but in general under the first function to
use the component.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:4 7 Load handling – Load handling

Together with the general description is a detailed description of what


is unique about the specific subfunction. The next subfunction to use
the same component only has a description of what is unique for the
new function.

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Lifting/lowering 7:5

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.

The free-lift cylinders are pressurised by the free-lift slide in


control valve load handling and the lift cylinders are pressurised by
control valve load handling.

There are two versions of the lifting/lowering function, depending


on how the function is controlled.
• Hydraulic servo means that the control levers are supplied with
hydraulic pressure, which controls the lifting/lowering function.
• Electric servo means that the control levers are electric and
send voltage signals to the control system in order to control the
lifting/lowering function. (Electric servo is included if the machine
is equipped with a turnable operator's station).

Free-lift mast is only present in combination with electric servo.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:6 7 Load handling – Lifting/lowering

Lifting/lowering, hydraulic servo

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Lifting/lowering 7:7

Lifting/lowering, electric servo

Condition Reference value


Control switch Disengaged

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


7:8 7 Load handling – Lifting/lowering

Lifting/lowering with free-lift, electric servo

Condition Reference value


Control switch Disengaged

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

1. Position sensor mast down (B261) b. Control lever (S815-P1)


2. Position sensor fork carriage up (B260) 10. Control unit cab (D790-1)
3. Control unit frame (D797-1) 11. Solenoid valve lift fork carriage (Y6005-2) or solenoid
valve lower fork carriage (Y6004-2)
4. Control unit frame option (D797-2)
12. Load control valves
5. Hydraulic oil pumps
13. Free-lift cylinder
6. Pressure reducer
14. Solenoid valve lift mast free-lift (Y6005-1) or solenoid
7. Accumulator servo circuit valve lower mast free-lift (Y6004-1)
8. Servo filter 15. Load control valve
9. a. Control lever lifting/lowering (R8071) 16. Lift cylinders

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Lifting/lowering 7:9

Lifting/lowering, component location

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

Maintenance Manual DCF 280–520 UDCF07.01GB


7:10 7 Load handling – Pressure reducer

7.2.3 Pressure reducer


Pressure reducer, checking servo pressure

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Operate and warm up the machine so that the hydraulic oil


reaches operating temperature, at least 50 ºC.

2 Machine in service position, see section B Safety.

3 Turn the start key to position 0.

4 Connect a pressure gauge (0–25 MPa) to the test outlet on the


pressure reducer.
007698

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

MPa MPa MPa MPa


007699

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Servo filter 7:11

7.2.4 Servo filter

Servo filter, change

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Machine in service position, see section B Safety.

2 Depressurise the hydraulic and brake systems, see section B


Safety.

3 Turn the start key to position 0 and turn off the system voltage.

4 Clean the outside of the filter housing and filter holder.


5 Remove the filter holder and remove the cartridge downward.
6 Clean the inside of the filter holder.
7 Place the new cartridge in the filter holder.
007370

8 Check that the O-ring on the filter holder is intact and in place.
9 Fit the filter and filter holder.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:12 7 Load handling – Mast

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

Mast suspension, checking

1 Machine in service position, see section B Safety.

2 Visually check that the frame's mounting points and welding


seams are intact.
3 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
007276

Mast suspension, checking bearings

1 Raise and secure the trolley

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

2 Machine in service position, see section B Safety.

3 Visually check that the frame's mounting points and welding


seams are intact.

4 Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Mast 7:13

5 Make a marking on the mast.


6 Remove the load from the mast mountings in an appropriate
manner.
7 Make a new marking on the mast. Measure the distance between
the markings. The measurement should be max. 1 mm.
8 If the difference is greater, the bearings in the mast mountings
must be replaced, see Workshop manual.

009673

Maintenance Manual DCF 280–520 UDCF07.01GB


7:14 7 Load handling – Mast

Slide plates mast, checking

1 Machine in service position, see section B Safety.

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

Support rollers mast, checking

1 Machine in service position, see section B Safety.

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Mast 7:15

Lifting chains, checking and adjusting


With the aim of increasing safety, the lifting chains should be checked
regularly according to the following:

The chains must be thoroughly cleaned over their 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.

2 P-measurement = the distance between 2 pins

Measurement over 25 links


P-mea- P-mea- [mm]
005670 surement surement
[in] [mm] Max.
New chain
measurement
3/4 19.05 476.25 490
1 25.4 635 654
1.1/4 31.75 793.75 817
1.1/2 38.1 952.5 981
2 50.8 1270 1308

On chains with up to 1 inch pitch, it is possible to use a special


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

Adjusting
3 Check that the pins for the outer washers are securely fastened.

4 Check that the washers are free of visible cracks.

5 Check that the chain is free from mechanical damage.

6 Check that the chain is free of rust.

7 Check that the chain bends easily over the pulley (does not jam
when bending).

8 Place the machine on level surface with the mast vertical (0° tilt).

9 Lower the carriage to the bottom position.

10 Check that there is 10-20 mm of space between the carriage and


the mast. Adjust the position by tensioning or loosening the chains
equally on the adjustment nuts in the carriage.

NOTE
If the chain is slack when the carriage is in its lowest position,
the chain must be tightened.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:16 7 Load handling – Position sensor mast

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

7.2.10 Position sensor mast

Position sensor, checking

1 Machine in service position, see section B Safety.

2 Wipe the sensors clean with a rag or similar item.


3 Check that they are secured properly.
4 Check that the distance between the sensor and the indicator pin
is 5±1 mm.
007568

The diagram shows an example of a position sensor


on a mast.

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Side shift 7:17

7.4 Side shift


Side shift, function description
Side shift means moving the lifting forks laterally. Control valve, load
handling, pressurises the side shift cylinders that push the forks on
the fork carriage laterally to the right or left depending on which
direction the control lever is moved.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:18 7 Load handling – Side shift

Side shift, hydraulic servo

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Side shift 7:19

Side shift, electric servo

Condition Reference value


Control switch Disengaged

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


7:20 7 Load handling – Side shift

Side shift, component location


2

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Spreading 7:21

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:22 7 Load handling – Spreading

Spreading, hydraulic servo

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Spreading 7:23

Spreading, electric servo

Condition Reference value


Control switch Disengaged

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


7:24 7 Load handling – Spreading

Spreading, component location


2

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Tilt 7:25

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.

There are two versions of tilt, depending on how the function is


controlled.

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.

Tilt, hydraulic servo

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

1. Hydraulic oil pumps 5. Control lever tilt


2. Pressure reducer 6. Tilt slide in control valve load handling
3. Accumulator servo circuit 7. Load holding valve
4. Servo filter 8. Tilt cylinders

Maintenance Manual DCF 280–520 UDCF07.01GB


7:26 7 Load handling – Tilt

Tilt, electric servo

Condition Reference value


Control switch Disengaged

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)

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Tilt cylinder 7:27

Tilt, component location


2
9

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

7.7.7 Tilt cylinder

Tilt cylinder, checking


Check:
• visually that the frame's mounting points and welding seams are
intact.
• that the tilt fork is securely fastened to the tilt cylinder (333 Nm
tightening torque).
• that the tilt cylinders are correctly adjusted.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:28 7 Load handling – Load carrier

7.9 Load carrier


Load carrier, general
The load carrier is designed to lift a load when required. There are
several ways to lift the load, such as:
• Lifting forks.

Fork shank system, which allows use of:
– Lifting forks
– Inverted lifting forks
– Coil ram

The machine is additionally prepared for attaching separate top lift
attachments that are connected to lifting forks or inverted lifting
forks, see Separate top lift attachment, description, page 7:31.

7.9.1 Lifting forks


Lifting forks, component location

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Lifting forks 7:29

Lifting forks, checking

DANGER
Damaged lifting forks must be changed.
Repairs to lifting forks change their strength, which
may lead to dropped loads and fatalities.

1 Machine in service position, see section B Safety.

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.

5 Forks which have been hot-straightened must be heat treated


again (carried out by an approved firm).

Maintenance Manual DCF 280–520 UDCF07.01GB


7:30 7 Load handling – Coil ram

7.9.3 Coil ram


Coil ram, component location

007488
5

1. Coil ram for fork shank system 4. Mobile lock hook


2. Upper mounting hook 5. Lower mounting hook
3. Lock pin

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Other functions 7:31

7.10 Other functions


7.10.5 Separate top lift attachment
Separate top lift attachment, description

The machine has provision for connecting a separate top lift


attachment. This is lifted with lifting forks and is attached electrically
to a contact on the fork carriage. It is connected hydraulically to the
spreading function via quick-couplings located on the fork carriage.
The side shift and spreading cylinders remain connected to side shift.

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.

For further description, see:


Spreading 20"-40", description, page 7:31
Rotation, description, page 7:38
Twistlocks, description, page 7:41

7.10.5.1 Spreading

Spreading 20"-40", description


Electric servo

Spreading 20"-40" is only available if a separate top lift attachment


is attached. The spreading motor for the attachment is connected to
the spreading section of the load handling control valve instead of the
side shift and spreading cylinders.
Electric servo
007503

Spreading 20"-40" is activated with the switch for Spreading 20"-40",


and the solenoid valves for spreading on the control valve for load
handling, when the switch is activated. The attachment's changeover
valve for spreading, rotation or twistlocks directs the control pressure
on to the attachment's spreading motor.

See Spreading, electric servo, page 7:23.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:32 7 Load handling – Separate top lift attachment

Spreading 20"-40", function description (electric


servo)

Condition Reference value


Control switch Disengaged
Top lift attachment Connected

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)

3. Accumulator servo circuit 10. Relay spreading 20-40 (K6)


4. Servo filter 11. Solenoid valve spreading (Y6046)
5. Switch, spreading 20"-40" 12. Spreading motor
6. Control unit cab (D790-1) 13. Sensor damping
7. Relay, activate spreading 20"-40" (K3006) 14. Relay damping (K5)
8. Control unit frame (D797-2) 15. Solenoid valve damping (Y6046-2)

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:33

Spreading 20"-40", component location

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

Maintenance Manual DCF 280–520 UDCF07.01GB


7:34 7 Load handling – Separate top lift attachment

Oil spreading motor unit, changing

NOTE
Read safety instructions for oil before starting work, see section B
Safety.

1 Remove the drain plug.


2 Remove and clean the sight glass.
3 Fit the drain plug when all the oil has drained.

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

Spreading chains, checking

1 Before adjusting, the clearance between the slide plates and


extension beams must be checked, as otherwise the chain's
mounts may be damaged, see .

20-foot position
2 Start the engine, move in the spreading to the 20-foot position
and turn off the engine.

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:35

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.

4 Check the C-C measurement between the twistlocks.


C-C 20 foot: 5853±3 mm.
If the 20-foot setting is correct, go to step 8.

5 If necessary, adjust the distance by moving the washers between


high and left 20-foot stop. The number of washers must not be
changed.

NOTE
Note the distance that the stop is adjusted to.

Move out the spreading a bit in order to move the washers.

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.

6 Remove the cover plates on the attachment's main beam.

7 If the 20-foot stop is adjusted, the spreader chains must be


adjusted by an equal amount, see step 14.

NOTE
Check the vertical position of the chain tensioner to ensure that
the chain runs straight against the chain wheel.
005105

Maintenance Manual DCF 280–520 UDCF07.01GB


7:36 7 Load handling – Separate top lift attachment

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

100 N Chain tension


815 m m 11 Start the engine and move the spreading out to the 40-foot
position.
12 Wait 2 minutes and then check the tension of the chains.
13 Use a pull scale and measure how far the chain moves when
pulled out with a force of 100 N at 815 mm in from the main
beam's inner reinforcement collar, as shown in the figure.
Standard attachment: X = 8-13 mm.
Overheight attachment: X = 5-6 mm.
815m m
100 N

0 N
010486

100 N
X

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:37

14 If needed, adjust the tension of the chains.


Start the engine and run out the spreading until the chain
tensioners are visible in the inspection holes (approx. 250 mm).
Adjust the chains, hold the chain tensioner with a box-end wrench
so that the chain is not twisted while adjusting.

NOTE
Adjust the chain on the chain tightener max 2 mm at a time.

15 Repeat steps 11–14 until the tension of the chains is correct.


16
If the machine is equipped with 30- or 35-foot stop.
Start the engine and run out spreading to the 30- or 35-foot
position. Turn off the engine and check the C-C measurement
between the twistlocks.
C-C 30 foot: 8918±3 mm
C-C 35 foot: 10488±3 mm

IMPORTANT
Check the distance of the stop from both 20\q and 40\q.

17 Apply lubricating grease to the spreading chains.


18 Fit the cover plates onto the attachment's main beam.

Slide plates main beam attachment, checking

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.

3 Unload applicable slide plate.


Take the strain off the lower slide plates by lifting the spreader
beam at the outside edge or by using wedges to change the
spreader beam's position on the attachment's main beam.
4 Remove the attaching bolts from the slide plate console.
5 Remove the slide plate's guide bolts.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:38 7 Load handling – Separate top lift attachment

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.

8 Place the slide plate in the correct position.


Check the clearance between spreader beam and slide plate.
Clearance should be max. 1 mm with all slide plates installed.
Fit or remove spacer plates until the distance is correct.

NOTE
Excessive clearance may result in damage to the spreader
beam during load handling.

9 Install the slide plate console.


10 Install the slide plate guide bolt.
11 Repeat steps 3–10 on the other slide plates.
12 Start the machine and check the spreader's function. Try to lift a
container and check that there is no clearance in the spreader
beams.

7.10.5.2 Rotation

Rotation, description

Rotation is only available when a separate top lift attachment is


attached. The rotation cylinders for the attachment are connected to
the spreading section of the load handling control valve instead of the
side shift and spreading cylinders.
012515

When a top lift attachment is attached, spreading in becomes rotation


clockwise, and spreading out becomes rotation anticlockwise. For
function description, see Rotation, function description (electric
servo), page 7:39.

For more information, see Spreading, function description, page 7:21.

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:39

Rotation, function description (electric servo)

Condition Reference value


Control switch Disengaged
Top lift attachment Connected
Spreading Not activated
Twistlocks Not activated

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

Maintenance Manual DCF 280–520 UDCF07.01GB


7:40 7 Load handling – Separate top lift attachment

Rotation, component location

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:41

7.10.5.3 Twistlocks

Twistlocks, description
Electric servo

Twistlocks are only available if a separate top lift attachment is


attached. The lock cylinders for the attachment are connected to the
spreading section of the load handling control valve instead of the
side shift and spreading cylinders.

007502
Twistlocks secure the container to the attachment. Twistlocks are
operated with hydraulic cylinders that are controlled by the control
valve for load handling.

The twistlock function is present in version:


Electric servo
Twistlocks are activated with the switch for twistlocks, and the
solenoid valves for spreading on the control valve for load handling,
when the switch is activated. The attachment's changeover valve for
spreading, rotation or twistlocks directs the control pressure on to
the attachment's lock cylinders. See Twistlocks, function description
(electric servo), page 7:42.

Maintenance Manual DCF 280–520 UDCF07.01GB


7:42 7 Load handling – Separate top lift attachment

Twistlocks, function description (electric servo)

Condition Reference value


Control switch Disengaged
Top lift attachment Connected
Spreading Not activated

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

1. Hydraulic oil pumps 12. Control unit frame (D797-2)


2. Pressure reducer 13. Solenoid valve spreading out (Y6018) or solenoid
3. Accumulator servo circuit valve spreading in (Y6019)

4. Servo filter 14. Relay twistlocks (K7)


5. Switch, lock twistlocks (S1003) 15. Solenoid valve twistlock (Y6044)
6. Control unit cab (D790-1) 16. Lock cylinders
7. Relay twistlock activated (K3005) 17. Sensor locked twistlocks (B7205L/R) or sensor
unlocked twistlocks (B7204L/R)
8. Sensor contact (B7202L/R and B7203L/R)
18. Relay twistlocks locked (K4) or relay twistlock
9. Relay contact (K1) unlocked (K3)
10. Indicator light contact (H564) 19. Indicator light locked twistlocks (H563) or indicator
11. Control unit KIT (D790-2) light unlocked twistlocks (H562)

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:43

Twistlocks, component location

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

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7:44 7 Load handling – Separate top lift attachment

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.

1 Check that the twistlocks function correctly.


1 Lock and open the twistlocks, check that the indicator lights work,
both in the cab and on the attachment.
2 Clean the twistlocks from any dirt.
3 Under the rubber cover for twistlocks: check pin, link arm and
lock nut.
2
4 Clean the area around sensor contact.

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

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:45

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.

9 Clean the area around the lubrication body.


10 Grease the lift pin's bearing with universal grease "EP2".
11 Repeat steps 1-10 on all twistlocks.

Twistlocks, checking for cracks

DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.

1 Remove the lift pins from the attachment.

NOTE
Twistlocks are heavy, be careful when removing.

2 Check for cracks within the marked area on the lift pins without
causing damage.
3 If the lift pins show signs of cracking, they must be replaced with
new ones.
002313

4 Install approved twistlocks.


Area for checking for cracks on lift pin.
NOTE
Use the new attaching nut and spherical bearing.

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7:46 7 Load handling – Separate top lift attachment

Twistlocks, checking vertical movement

WARNING
Dropped component.
Risk of crushing, product damage.
Twistlock weighs approx. 30 kg.

1 Check the vertical movement for twistlocks.


1
Press up the lift pin and check that the clearance is 1.5–2 mm.
2 Adjust twistlocks when needed. Step 3-6.
3 Remove the nut (position 1) from the lift pin and dismantle
twistlocks (position 2).
4 Replace the adjusting shim (position 3) with the most suitable from
the adjusting shim kit to obtain correct clearance for the vertical
movement. See spare parts catalogue for part number of the kit.
See spare parts catalogue for part number of the kit.
3
5 Assemble twistlocks. Tighten the nut to 700 Nm.
6 Check again the vertical movement for twistlocks.

1,5-2 mm
012582

2
1. Nut
2. Twistlocks
3. Adjusting shims

Twistlocks, checking float position

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.

UDCF07.01GB Maintenance Manual DCF 280–520


7 Load handling – Separate top lift attachment 7:47

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

Sensor contact, checking and adjusting


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

Maintenance Manual DCF 280–520 UDCF07.01GB


7:48 7 Load handling – Separate top lift attachment

Sensor twistlocks, checking and adjusting


1 Check that the sensors are free of damage and dirt.
1 2 1 3
2 Turn the start key to position I and check that the light indicator
on the sensor is lit on those sensors that have indicator plates
positioned in front of the sensor. On the other two, the light
indicator should not be lit.
If necessary, loosen the lock nut and screw in/out the sensor until
the distance between the sensor and the indicator plate is 5±1 mm.
3 Check that indicator light twistlocks open is lit.

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.

UDCF07.01GB Maintenance Manual DCF 280–520


8:1

8 Control system

Contents 8 Control system


8 Control system ...................................................................................................8:3
8.2 Monitoring ........................................................................................................8:6
8.2.2 Bypass ........................................................................................................8:6
8.2.3 Speed limitation...........................................................................................8:6
8.2.4 Service indicator..........................................................................................8:7
8.2.6 Height limitation...........................................................................................8:7
8.2.7 Height warning ............................................................................................8:7
8.3 Error codes ......................................................................................................8:8
8.4 Diagnostics ....................................................................................................8:10
8.4.1 CAN/POWER ............................................................................................8:13
8.4.2 LIGHTS .....................................................................................................8:14
8.4.3 CAB ...........................................................................................................8:15
8.4.4 CLIMATE ...................................................................................................8:15
8.4.5 HYD...........................................................................................................8:16
8.4.6 ENGINE ....................................................................................................8:17
8.4.7 TRANSM ...................................................................................................8:18
8.4.8 ELECTRIC SERVO ...................................................................................8:20
8.4.9 ATTACH ....................................................................................................8:21
8.4.10 OLS ...........................................................................................................8:21
8.4.11 EXTRA ......................................................................................................8:22
8.5 Settings ..........................................................................................................8:27

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8:2

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – Control system 8:3

8 Control system
Control system, general
In many cases the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator or
limit the machine's functions in case of certain dangerous situations or
if there are malfunctions in the machine.

The function control system is divided into the following functions:


• Monitoring functions
• Error codes
• Diagnostics
• Settings
• Software

Monitoring functions describe the machine's monitoring functions that


warn the operator or limit the machine's functions in the event of a
dangerous situation.

Error codes notify operators and mechanics when malfunctions have


been detected.

Diagnostic test is tool for performing service and troubleshooting with


menus in the machine’s display.

Settings is the tool for setting and adapting the machine’s functions.

The software creates the functions in the control system.

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8:4 8 Control system – Control system

Control system, description


The machine is equipped with an electronic system used for
B C D
controlling and monitoring the machine’s different functions.

The system provides information to the operator in the form of alarm


information, operating information, and event-controlled information.
The information is shown on the steering wheel panel's display (C)
and on a panel for warning and indicator lights (B).

The function keys are used to navigate in the display menus for
service and troubleshooting, for example.

000053

A
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

• Function key 1: Scroll anticlockwise in menu system as well as


enter value 1.
• Function key 2: Scroll clockwise in menu system as well as enter
value 2.
• Function key 3 (Reset): Abort selection of menu/session in
progress as well as enter value 3. Confirm alarm.
• Function key 4: Enter value 4, gradually adjust settings (for
example, contrast in guide lights for function keys) and gradually
change values in operating menus.
• Function key 5: Enter value 5, gradually adjust settings (for
example, contrast in guide lights for function keys) and gradually
change values in operating menus.
• Function key 6 (Return): Confirm selection of menu and
sub-menu, as well as confirm entered value.

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8 Control system – Control system 8:5

Operating menus
Operating menus

Operating menu Engine and transmission are shown in the display


1 2
when the machine is started. This menu is shown until another
U
menu is selected or an event-controlled menu is shown (e.g., in case
of error code of the type "WARNING" and "STOP"). Other menus
(see list below) are scrolled with the function keys 1 (arrow left) and
2 (arrow right).

The following operating menus are available to aid the operator:


• Operating menu engine and transmission
• Operating menu engine
• Operating menu transmission and hydraulics
• Operating menu electrical system
• Operating menu service

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

Under certain conditions, the control system calls the operator's


attention to important information with figures on the display. Examples
of warnings are warning for overloading when the overload system
is activated.

Warnings are described in connection with each function. The following


event menus are available:
• Event menu start interlock
• Open door
• Automatic spreading 20"-40"
Service menu
Service menu

The service menu is the gateway to the machine's diagnostic system.


Different parts of the Service menus are made available by pressing
"Enter" and entering different codes. The different service menus are:
000056

• Error codes, description, page 8:8


• Diagnostics, general, page 8:10
• Setup, general, page 8:27

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8:6 8 Control system – Monitoring

8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:
• Bypass
• Speed limitation
• Service indicator

8.2.2 Bypass
Bypass, description
Bypass is activated with the bypass switch.

Bypassing the safety system makes it possible to:


• lock and open twistlocks without full contact
• Spread 20'-40' with locked twistlocks
• lower load with contact on top lift attachment
• manual control of recirculation damper by ECC or EHC
• release of parking brake in case of malfunction of switch parking
brake
• output signal to solenoid valves with active error codes
• machine engages neutral when no one is sitting in the driver's seat

WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!

8.2.3 Speed limitation


Speed limitation, description

Speed limitation prevents the machine's speed from exceeding pre-set


value by limiting gear position and engine rpm.

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8 Control system – Service indicator 8:7

8.2.4 Service indicator


Service indicator, resetting

1 Machine in service position, see section B Safety.

2 Navigate first to the service menu and press Enter.

000056
3 Enter code for resetting service indicator.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060

The code determines which service menu shall be activated


(Service, Diagnostics, Initiation or Calibration).

4 Reset the service indication by pressing Enter. NEXT SERVICE is


SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh To change duration of the service interval, set the desired interval
SERVICE INTERVALL with the plus and minus key.
STORED XXXXh
004908

PRESENT XXXXh

8.2.6 Height limitation


Height limitation, description

Height limitation is a part of the control and monitoring system and


prevents the machine from lifting higher than a pre-set height without
the operator being informed. Height limitation is adjustable according
to customer requirements

8.2.7 Height warning


Height warning, description

Height warning alerts when the set maximum lifting height is reached.
Height warning is adjustable according to customer requirements.

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8:8 8 Control system – Error codes

8.3 Error codes


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

Explanation of error codes is found in Operator's manual and Workshop


manual.
Error code indication

53 54 Error code indication

Error code is indicated with activate Indicator for active error codes
(position 36). Error codes are divided into three error code levels,
depending on how serious they are.

Error code levels are indicated as follows:


B • STOP is indicated with a STOP-sign on the display together
with a flashing red light from indicator for control and monitoring
system (position 54) and activated Indicator for active error codes
(position 36).
Error code with level STOP shown automatically on display.
36 • WARNING is indicated on the display, together with a flashing red
light for control and monitoring system (position 54) and activated
Indicator for active error codes (position 36).
Error code with level WARNING shown automatically on display.
• INFORMATION is indicated with activate Indicator for active error
codes (position 36).
Error code with level INFORMATION shown in error code list
under operating menu for service.
000348

B. Symbol error code level


36. Indicator active error codes
53. Display control system
54. Indicator for the control system
Error code display
Error code display

Error code information is shown with display figures in two ways:


• Automatically on display.
The error code is acknowledged with function key Reset (R).
003817

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.

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – Error codes 8:9

• In the error code list under operating menu for service.


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

001998
Example of display in error code list
NOTE
If error code isn’t included in the error code list, it may be due
to the following:
– condition for error detection no longer exists, e.g.,
control lever is released or engine is off.
– loose connection/poor contact.

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8:10 8 Control system – Diagnostics

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.

The following pages show compilations of the diagnostic menus. The


workshop manual has a more detailed description of each diagnostic
menu.

The diagnostic test is divided into the following groups:


• CAN/POWER, menu overview, page 8:13
• LIGHTS, menu overview, page 8:14
• CAB, menu overview, page 8:15
• CLIMATE, menu overview, page 8:15
• HYD, menu overview, page 8:16
• ENGINE, menu overview, page 8:17
• TRANSM, menu overview , page 8:18
• ELECTRIC SERVO, menu overview, page 8:20
• EXTRA
– VBFS, menu overview, page 8:22
– EL-STEERING, menu overview, page 8:23
– EXT-ATTACH, menu overview, page 8:24
– FREELIFT, menu overview, page 8:24
– MOVE-CAB, menu overview, page 8:25
– OPT, menu overview, page 8:26
– RMI, menu overview, page 8:26

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8 Control system – Diagnostics 8:11

Diagnostic menu, description


1 The diagnostic tests are built up of menus. The menus are grouped
2 3 4 according to logical areas. With the diagnostic menus it is possible to
read off how the control unit interprets input signals as well as what
7 DIAG CAB 2(X) output signals are sent by the control unit.
FRONT WIPER
SWITCH (1-3) 2 Signal values (position 6) in the menu indicate measured values by
5 the relevant control unit. The control units have internal voltmeters
OUTPUT 11 6

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

Pos. Designation Description


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

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8:12 8 Control system – Diagnostics

Diagnostics, operating instructions


To choose diagnostics, do the following:
1 Navigate to the service menu.
2 Push Enter.

000056
3 Enter the code for diagnostics.
The code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060

The code determines which service menu shall be activated


(Service, Diagnostics, Initiation or Calibration).

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

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8 Control system – CAN/POWER 8:13

8.4.1 CAN/POWER
CAN/POWER, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG CAN/POWER 1(X) DIAG CAN/POWER 2(X) DIAG CAN/POWER 3(X)


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

DIAG CAN/POWER 4(X) DIAG CAN/POWER 5(X) DIAG CAN/POWER 6(X)


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

DIAG CAN/POWER 7(X) DIAG CAN/POWER 8(X) DIAG CAN/POWER 9(X)


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

DIAG CAN/POWER 10(X) DIAG CAN/POWER 11(X) DIAG CAN/POWER 12(X)


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

DIAG CAN/POWER 13(X) DIAG CAN/POWER 14(X) DIAG CAN/POWER 15(X)


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

DIAG CAN/POWER 16(X) DIAG CAN/POWER 17(X)


791-1 ATTACHMENT (OPT) REDCAN STATUS CHECK
24V SENSOR SUPPLY XY PRESS ENTER
5V REF X.XXV
007294

SEGMENT ERROR X

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8:14 8 Control system – LIGHTS

8.4.2 LIGHTS
LIGHTS, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG LIGHTS 1(X) DIAG LIGHTS 2(X) DIAG LIGHTS 3(X)


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

DIAG LIGHTS 4(X) DIAG LIGHTS 5(X) DIAG LIGHTS 6(X)


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

DIAG LIGHTS 7(X) DIAG LIGHTS 8(X) DIAG LIGHTS 9(X)


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

DIAG LIGHTS 10(X) DIAG LIGHTS 11(X) DIAG LIGHTS 12(X)


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

DIAG LIGHTS 13(X) DIAG LIGHTS 14(X) DIAG LIGHTS 15(X)


WORKING LIGHT ATTACH SWITCH LIGHTS STEP LIGHT
SWITCH X SWITCH X
OUTPUT LE XY RI XY OUTPUT XXX OUTPUT XXX
007491

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – CAB 8:15

8.4.3 CAB
CAB, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG CAB 1(X) DIAG CAB 2(X) DIAG CAB 3(X)


WASHER FRONT WIPER REAR WIPER
SWITCH X SWITCH (1-3) X SWITCH X
OUTPUT FRONT XY OUTPUT XY OUTPUT XY
OUTPUT REAR ROOF XY FEEDBACK X FEEDBACK X

DIAG CAB 4(X) DIAG CAB 5(X) DIAG CAB 6(X)


ROOF WIPER HORN BUZZER X
SWITCH X SWITCH X SWITCH SEAT X
OUTPUT XY SWITCH 2 X ALARM X
FEEDBACK X OUTPUT XY OP X

DIAG CAB 7(X) DIAG CAB 8(X)


FUEL SEAT HEATER
SENSOR VALUE XXXohm SWITCH X
PROC XXX OUTPUT XY

007489
8.4.4 CLIMATE
CLIMATE, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG CLIMATE 1(X) DIAG CLIMATE 2(X) DIAG CLIMATE 3(X)


PRESENT INPUT SIGNAL TEMP COIL XXX PRESENT INPUT SIGNAL
REQUIRED TEMP XXX TEMP COOLANT XXX PRESSURE SWITCH X
PRESENT TEMP XXX TEMP AMBIENT XXX
WATER VALVE FEEDB. XXX TEMP DE-ICE XXX

DIAG CLIMATE 4(X) DIAG CLIMATE 5(X) DIAG CLIMATE 6(X)


PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL
WATER VALVE XX.XXV REQUIRED TEMP XX.XXV FAN SPEED XXX
DRAUGHT VALVE XX.XXV REQ. DRAUGHT XX.XXV RECIRKULATION XY
REQ. FAN SPEED XX.XXV COMPRESSOR XY

DIAG CLIMATE 7(X) DIAG CLIMATE 8(X)


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

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8:16 8 Control system – HYD

8.4.5 HYD
HYD, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG HYDRAULIC 1(X) DIAG HYDRAULIC 2(X) DIAG HYDRAULIC 3(X)


HYDRAULIC OIL BRAKE COOLANT OIL HYDRAULIC PRESSURE
TEMP XXX TEMP XXX
FAN XY FAN XY LIFT CYLINDER XXX
SET OUTPUT +/- X SET OUTPUT +/- X TILT CYLINDER XXX

DIAG HYDRAULIC 4(X) DIAG HYDRAULIC 5(X) DIAG HYDRAULIC 6(X)


PRESSURE SWITCHES P-BRAKE CUT OFF HYDRAULIC
BRAKE PRESSURE X SWITCH X/Y PUMPS
BRAKE LIGHT PRESS. X FEEDBACK SWITCH X PUMP 2 XY

010284
DECLUTCH PRESSURE X VALVE XY PUMP ATTACHMENT XY

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8 Control system – ENGINE 8:17

8.4.6 ENGINE
ENGINE, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG ENGINE 1(X) DIAG ENGINE 2(X) DIAG ENGINE 3(X)


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

DIAG ENGINE 4(X) DIAG ENGINE 5(X) DIAG ENGINE 6(X)


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

DIAG ENGINE 7(X) DIAG ENGINE 8(X) DIAG ENGINE 9(X)


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

DIAG ENGINE 10(X)


EATS STATUS
TANK LEVEL XX
TANK TEMP XX

014712
IND. SEVERITY XX

Maintenance Manual DCF 280–520 UDCF07.01GB


8:18 8 Control system – TRANSM

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

DIAG TRANSM. 1(X) DIAG TRANSM. 2(X) DIAG TRANSM. 3(X)


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

DIAG TRANSM. 4(X) DIAG TRANSM. 5(X) DIAG TRANSM. 6(X)


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

DIAG TRANSM. 7(X) DIAG TRANSM. 8(X) DIAG TRANSM. 9(X)


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

DIAG TRANSM. 10(X) DIAG TRANSM. 11(X) DIAG TRANSM. 12(X)


PRESENT SENSOR INPUT PRESENT VALUE SPEED LIMIT
PRESS FEEDB XXXXohm AXLE RATIO XXXXX SPD GEAR LOG
TRANSM.TEMP XXXXmV RADIUS XXXX CAB XX X XX
CONV OUT TEMP XXXXmV FRAME XX X XX

DIAG TRANSM. 13(X) DIAG TRANSM. 14(X)


ACT ERROR AREA XXX CONVERTER STATUS (Nm)
TYPE XXX TORQUE IMPELLER XXXX
NUMBER OF OCCU. XXXXX TORQUE TURBINE XXXX
009944

TIME AGO XXXXX

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – TRANSM 8:19

Applies for transmission alternative TE32.

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG TRANSM. 1(15) DIAG TRANSM. 2(15) DIAG TRANSM. 3(15)


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

DIAG TRANSM. 4(15) DIAG TRANSM. 5(15) DIAG TRANSM. 6(15)


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

DIAG TRANSM. 7(15) DIAG TRANSM. 8(15) DIAG TRANSM. 9(15)


FWD SELECTION X SUPPLY ANALOG OUTPUTS
REV SELECTION X FWD/REV SUPPLY X FWD/REV F.B XXXXmA
2/4 SELECTION X 2/4 SUPPLY X 2/4 FEEDBACK XXXXmA
1/3 SELECTION X 1/3 SUPPLY X 1/3 FEEDBACK XXXXmA

DIAG TRANSM. 10(15) DIAG TRANSM. 11(15) DIAG TRANSM. 12(15)


2/4 PRESSx10 XXXXBar PRESENT VALUE SPEED LIMIT
1/3 PRESSx10 XXXXBar AXLE RATIOx1024 XXXXX SPD GEAR LOG
TRANSM.TEMP XXXXmV RADIUS XXXX CVB XX X XX
CONV OUT TEMP XXXXmV SPEED LIMIT XXXX FRAME XX X XX

DIAG TRANSM. 13(15) DIAG TRANSM. 14(15) DIAG TRANSM. 15(15)


ACT ERROR AREA XXX CONVERTER STATUS (Nm)
TYPE XXX TORQUE IMPELLER XXXX NOT USED
NUMBER OF OCCU. XXXXX TORQUE TURBINE XXXX

013398
TIME AGO XXXXX

Maintenance Manual DCF 280–520 UDCF07.01GB


8:20 8 Control system – ELECTRIC SERVO

8.4.8 ELECTRIC SERVO


ELECTRIC SERVO, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA

DIAG ELSERVO 1(X) DIAG ELSERVO 2(X) DIAG ELSERVO 3(X)


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

DIAG ELSERVO 4(X) DIAG ELSERVO 5(X) DIAG ELSERVO 6(X)


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

DIAG ELSERVO 7(X) DIAG ELSERVO 8(X) DIAG ELSERVO 9(X)


OUTPUT SIDESHIFT LE OUTPUT SIDESHIFT RI OUTPUT SPREADING IN
REFERENCE XY REFERENCE XY REFERENCE XY
REQUIRED VALUE XXXmA REQUIRED VALUE XXXmA REQUIRED VALUE XXXmA
FEEDBACK XXXmA FEEDBACK XXXmA FEEDBACK XXXmA

DIAG ELSERVO 10(X) DIAG ELSERVO 11(X) DIAG ELSERVO 12(X)


OUTPUT SPREADING OUT OUTPUT LIFT 2 OUTPUT LOWER 2
REFERENCE XY REFERENCE XY REFERENCE XY
REQUIRED VALUE XXXmA REQUIRED VALUE XXXmA REQUIRED VALUE XXXmA
FEEDBACK XXXmA FEEDBACK XXXmA FEEDBACK XXXmA

DIAG ELSERVO 13(X) DIAG ELSERVO 14(X) DIAG ELSERVO 15(X)


PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS REGENERATION STATUS
SPREADER IN X OUT X OPTION LOCKING X INPUT DAMPING X
PISTOL X LEVELLING LOCKING X OUTPUT LEFT XY
007297

UNLOCK TW X OUTPUT RIGHT XY

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – ATTACH 8:21

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

DIAG OLS 1(X) DIAG OLS 2(X) DIAG OLS 3(X)


PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL VD VALUE XXXXXkg
PRESENT LOAD XXXXXkg
LIFT CYLINDER X.XXV BY-PASS X
TILT CYLINDER X.XXV MAST POS SENSOR X

DIAG OLS 4(X)


PRESENT INPUT SIGNAL
TILT ANGLE LIM X
HEIGHT LIM X

010620

Maintenance Manual DCF 280–520 UDCF07.01GB


8:22 8 Control system – EXTRA

8.4.11 EXTRA
8.4.11.1 VBFS

VBFS, menu overview

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

DIAG VBFS 1(X) DIAG VBFS 2(X) DIAG VBFS 3(X)


PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT INPUT SIGNAL
REVERSIBLE SEAT REVERSIBLE SEAT SEAT SENSORS
SWITCH CW X SEAT CW XY SEAT POS FRONT X
SWITCH CCW X SEAT CCW XY SEAT POS REAR X

DIAG VBFS 4(X) DIAG VBFS 5(X) DIAG VBFS 6(X)


PRESENT INPUT SIGNAL PRESENT OUTPUT SIGNAL HEAD LIGHTS REAR
ACCELERATOR 2 X.XXV STEERING VALVE SWITCH X
REQUIRED SPD PROC XXX VALVE CAB FRONT XY HEAD LE/RI XY
REQUIRED SPD RPM XXXX VALVE CAB REAR XY DIMMED LE/RI XY

DIAG VBFS 7(X) DIAG VBFS 8(X) DIAG VBFS 9(X)


PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
TAILLIGHT FRONT BRAKE LIGHT FRONT REVERSIBLE SEAT
RELEASE BRAKE XY

009945
FRONT LE/RI XY FRONT LE XY RI XY DAMP SPEED XY

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – EXTRA 8:23

8.4.11.2 EL-STEERING

EL-STEERING, menu overview

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

DIAG STEERING 1(X) DIAG STEERING 2(X) DIAG STEERING 3(X)


PRESENT INPUT SIGNAL SWITCHES PRESENT INPUT SIGNAL
SIGNAL 1 P6 X.XXV ON/OFF X HORN X
SIGNAL 2 P7 X.XXV FORWARD X STEER.WHEEL CUT OFF X
LOGIC X.XXV REVERSE X

DIAG STEERING 4(X) DIAG STEERING 5(X)


OUTPUT STEERING LEFT OUTPUT STEERING RIGHT
REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX

007652
FEEDBACK XXX FEEDBACK XXX

Maintenance Manual DCF 280–520 UDCF07.01GB


8:24 8 Control system – EXTRA

8.4.11.3 EXT-ATTACH

EXT-ATTACH, menu overview

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

DIAG EXT-ATTACH 1(X) DIAG EXT-ATTACH 2(X) DIAG EXT-ATTACH 3(X)


PRESENT INPUT SIGNAL PRESENT INPUT SIGNALS PRESENT INPUT SIGNALS
LOCK TW X SPREADING OUT X
EXT-ATTACH ACTIVE X UNLOCK TW X SPREADING IN X

DIAG EXT-ATTACH 4(X) DIAG EXT-ATTACH 5(X) DIAG EXT-ATTACH 6(X)


PRESENT INPUT SIGNALS NOT USED PRESENT OUTPUT SIGNAL
ALIGNMENT X 4:E FUNCTION
LOCKED TW X TW ACTIVE XY
UNLOCKED TW X SPREADING ACTIVE XY

DIAG EXT-ATTACH 7(X) DIAG EXT-ATTACH 8(X)


OUTPUT SPREADING IN OUTPUT SPREADING OUT
REFERENCE XY REFERENCE XY
REQUIRED VALUE XXX REQUIRED VALUE XXX

010286
FEEDBACK XXX FEEDBACK XXX

8.4.11.4 FREELIFT

FREELIFT, menu overview

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

DIAG FREELIFT 1(X)


PRESENT INPUT SIGNAL
MAST CARRIAGE
MAST POS DOWN X
010285

LIFT CARRIAGE TOP X

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – EXTRA 8:25

8.4.11.5 MOVE-CAB

MOVE-CAB, menu overview

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

DIAG MOVE-CAB 1(X) DIAG MOVE-CAB 2(X) DIAG MOVE-CAB 3(X)


INPUT SWITCHES PRESENT INPUT SIGNAL PRESENT INPUT SIGNAL
UP/RIGHT X AUTO CABTILT X CAB UPPER POS X
DOWN/LEFT X LIFT HEIGHT POS X CAB LOWER POS X
OPEN DOORS X

DIAG MOVE-CAB 4(X) DIAG MOVE-CAB 5(X) DIAG MOVE-CAB 6(X)


PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL OUTPUT RIGHT
VALVE CAB UP XY ACTIVATE SLID-CAB XY REFERENCE XY
VALVE CAB DOWN XY REQUIRED VALUE XXX
FEEDBACK XXX

DIAG MOVE-CAB 7(X)


OUTPUT LEFT
REFERENCE XY
REQUIRED VALUE XXX

007653
FEEDBACK XXX

Maintenance Manual DCF 280–520 UDCF07.01GB


8:26 8 Control system – EXTRA

8.4.11.6 OPT

OPT, menu overview

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

DIAG OPTION 1(X) DIAG OPTION 2(X) DIAG OPTION 3(X)


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

DIAG OPTION 4(X) DIAG OPTION 5(X)


PRESENT OUTPUT SIGNAL PRESENT OUTPUT SIGNAL
D797-2 C1 P28 XY D791-1 C1 P14 XY
D797-2 C1 P42 XY D791-1 C1 P28 XY

007654
8.4.11.7 I/O

I/O, menu overview


Not used.

8.4.11.8 RMI

RMI, menu overview

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

DIAG RMI 1(X) DIAG RMI 2(X) DIAG RMI 3(X)


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

SMS XXX: UNS.DATA XXX

UDCF07.01GB Maintenance Manual DCF 280–520


8 Control system – Settings 8:27

8.5 Settings
Setup, general
Settings offer the option of adapting the properties of the functions
for each unique machine. Settings are entered via the menus in the
display. Settings options are divided into sections such as Initiations
and Calibrations

Initiation is performed before the machine is put into operation. This


is done to compensate for mechanical and electrical tolerance values
(variations between different machines).

Calibration should be performed to optimise the use of important


functions. Certain functions require calibration in order to operate.

Maintenance Manual DCF 280–520 UDCF07.01GB


8:28

UDCF07.01GB Maintenance Manual DCF 280–520


9:1

9 Frame, body, cab and accessories

Contents 9 Frame, body, cab and accessories


9 Frame, body, cab and accessories ...................................................................9:3
9.1 Controls and instruments .................................................................................9:4
9.2 Safety and emergency equipment ...................................................................9:9
9.3 Seats.............................................................................................................. 9:11
9.3.9 Turnable driver's seat ................................................................................9:14
9.4 Heating, ventilation and air conditioning ........................................................9:16
9.4.1 Fresh air filter ............................................................................................9:28
9.4.8 Condenser.................................................................................................9:28
9.4.9 Moisture filter.............................................................................................9:28
9.4.19 Supplemental heater .................................................................................9:30
9.5 Wiper/washer system.....................................................................................9:31
9.6 Lighting system ..............................................................................................9:32
9.7 Signalling system ...........................................................................................9:34
9.8 Entertainment and communication ................................................................9:36
9.9 Glass/windows/mirrors...................................................................................9:37
9.9.3 Roof window..............................................................................................9:37
9.9.5 Rearview mirror .........................................................................................9:37
9.10 Cab structure and suspension .......................................................................9:38
9.10.2 Doors.........................................................................................................9:38
9.10.3 Cab undercarriage ....................................................................................9:38
9.10.4 Hydraulic lateral cab sliding.......................................................................9:40
9.11 Cab interior ....................................................................................................9:42
9.12 Frame.............................................................................................................9:43
9.13 Body structure................................................................................................9:44
9.14 Central lubrication ..........................................................................................9:45
9.15 Paint/coatings ................................................................................................9:47

Maintenance Manual DCF 280–520 UDCF07.01GB


9:2

UDCF07.01GB Maintenance Manual DCF 280–520


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

9 Frame, body, cab and


accessories
Frame, body, cab and accessories,
description
The machine consists of frame, body and cab.

The frame (chassis) is the machine's structural part and is made of


high-strength steel.

The body consists of fenders, 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.

Maintenance Manual DCF 280–520 UDCF07.01GB


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

9.1 Controls and instruments


Overview

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

UDCF07.01GB Maintenance Manual DCF 280–520


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

Left Instrument panel


Left Instrument panel
16. Switch for fan (S118)
17. Switch for heat (S117)
24..28 29 30 31 18. Switch for air distribution (S139)
19. Switch for work lights cab roof (S105-1)
19..23
20. Spare
18 21. Switch for work lights mast (S105-3)

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:6 9 Frame, body, cab and accessories – Controls and instruments

Steering wheel panel


Steering wheel panel
36
35
34 32. Warning lamp for low battery charge
33
32 33. Warning lamp for low brake pressure
34. Indicator light for active error codes
35. Warning lamp for bypass of hydraulic functions
36. Indicator light for activated lever or mini-wheel steering
37..41 49 37. Warning lamp for high coolant temperature
38. Warning lamp for low oil pressure in engine
42..46 39. Indicator light for preheating
47 48 40. Warning lamp for low coolant level engine
41. Warning light for high oil temperature in transmission
42. Warning lamp for low fuel level
43. Warning lamp for high temperature hydraulic oil
50 51 52 53 44. Indicator light for high beam
45. Indicator light for direction indicators
46. Indicator light for parking brake
47. Indicator light for locked twistlocks (secured load)
48. Indicator light for contact (attachment / load)
49. Indicator light for unlocked twistlocks (load released)
50. Panel for warning and indicator lights
51. Display for control and monitoring system
64
54 52. Indicator for control and monitoring system
63 53. Ignition (S150)
55
62 54. Switch for defroster
56
55. Switch for windshield wiper roof, interval
005073

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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Controls and instruments 9:7

Panel for hydraulic functions

65 Panel for hydraulic functions


66
67 65. Lifting/lowering
68
66. Tilt
67. Side shift
68. Fork spreading
69. Opening the twistlock (attachment)
70. Switch for horn (S149)
71. Switch for twistlocks, automatic/manual locking (S1003)
70
72. Switch for spreading 20'-40' (S1012) (attachment)
73. Switch for spreading stop at 30' or 35' (attachment)
74. Switch for turnable operator's station (S169)
Switch for hydraulic lateral cab sliding (S1010)
75. Switch for by-pass of hydraulic functions (S1005)
Key for bypass of hydraulic functions
013923

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:8 9 Frame, body, cab and accessories – Controls and instruments

Operating menus, overview

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

Event menus overview


Side lift attachment with twistlock locking

1 2
009703

1. Event menu start interlock


2. Event menu open door

UDCF07.01GB Maintenance Manual DCF 280–520


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

9.2 Safety and emergency equipment


General
A good working environment has safety and emergency equipment to
make the operator's work safe. The machine may be equipped with
the following equipment.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:10 9 Frame, body, cab and accessories – Safety and emergency equipment

9. External rear view mirrors


9a Used to provide increased visibility for operating and load
handling.

9a 9a shows blocked area in front of machine.


9b
9b shows blocked area at side of machine.
9c shows blocked area behind machine.

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.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Seats 9:11

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:12 9 Frame, body, cab and accessories – Seats

Seats, description (product alternative BE- GE


9120)

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.

The seat has the following equipment:


• mechanical adjustment
• air suspension (with external compressor)
5 • armrest right
• seat belt (3-point)

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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Seats 9:13

Seat, description (product alternative


Isringhausen 6800)

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.

Isringhausen 6800 seat has the following equipment:


• head restraint
• armrest
• air suspension (with external compressor)
• air-adjusted lower back (lumbar) support
• seat belt
• seat heating

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:14 9 Frame, body, cab and accessories – Turnable driver's seat

9.3.9 Turnable driver's seat


Turnable driver's seat, function description

Operator's station, with driver's seat, electrically turnable. The electric


motor's gear changes the position of the operator's station via a pinion.

The seat console has an integrated steering column and steering


wheel with panel. This follows with the console when the seat is
reversed. The driver's seat itself does not differ from the other seat
options.

The turnable operator's station has doubled pedals. Because the


steering wheel and the hand control follow when turning, the direction
of the control valve and headlights are turned with special reverse
valves (directional control valves).

Steering wheel deflection is transmitted to the steering valve via a


chain. The chain has a tensioner that is tightened so that the chain is
backlash-free without becoming heavy.
007499

Condition Reference value


Speed Under 2 km/h (when activated)
Control switch Not activated

1 8 8
<° <°

2
D790-1

D797-2
3

4 5
A798 7 7
009759

M 6

1. Switch turnable operator's station (S169) 6. Motor seat turning (M675)


2. Control unit cab (D790-1) 7. Accelerator pedal front (B690-1) and accelerator
pedal back (B690-2)
3. Control unit frame (D797-2)
8. Sensor turnable operator's station forward (S720-F)
4. Solenoid valve brake seat turning (Y676)
or sensor turnable operator's station backward
5. Control unit turnable operator's station (A798) (S720-F)

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Turnable driver's seat 9:15

Turnable driver's seat, checking

1 Rotate the operator's station 90° to the right.


2 Machine in service position, see section B Safety.
3 Remove the cover plate and lubricate the gears with grease.

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:16 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

9.4 Heating, ventilation and air


conditioning
Heating and ventilation unit, function description
(product alternative EHC)
The heating and ventilation unit (EHC) handles heating and
ventilation. (The heating and ventilation unit cannot add cooling.)

The temperature in the cab is thermostat-controlled by Control unit


cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 ºC. The
system is operated with controls on the instrument panel.

The heating and ventilation system used heat from the engine's
cooling system via a heater to warm the outdoor air. Outdoor air is
forced by the fan through the heater and on through channels in the
cab's interior, and is then directed at, e.g., the windshield (defroster)
or the feet.

At the air inlet before the cab fan there is a filter that cleans the air
before it is forced into the machine.
001839

The heating and ventilation unit can:


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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:17

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:18 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

Air conditioning, function description (product


alternative ECC)

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


combination is called (ECC) and handles heating, ventilation, cooling,
and dehumidification.

The temperature in the cab is thermostat-controlled by Control unit


cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 ºC. The
system is operated with controls on the instrument panel.

For cooling, the compressor that compresses the refrigerant is


activated. Refrigerant is evaporated in the evaporator in the cab.
When the refrigerant is evaporated, cold is then generated in the
evaporator. The outdoor air is cooled when it is forced through the
evaporator by the cab fan. Then the air can be directed in the same
way as for the heating system.
001839

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

As an option for the air conditioning there is automatic shut-off


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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:19

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


9:20 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

Heating, ventilation and air conditioning,


component location

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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:21

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)

General recommendations for work on the air


conditioning unit

CAUTION
Authorisation is required to perform repairs on the
climate control unit.

WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:22 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

WARNING
Electric fans can injure hands.
Risk of personal injury.
Avoid placing hands near the cooling fans when the
engine is running.

Air conditioning, checking/performance test

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.

Should be performed during continuous operation every week from


early spring to late autumn as well as in winter during long periods
of high humidity.

In winter, during cold and dry periods of low operation, the compressor
should be run for a few minutes every week so that the rubber hoses,
couplings, gaskets and axle seals are lubricated.
1 Check that the condenser is not clogged – clean condenser fins
with compressed air as needed.

2 Check that the compressor turns on and off without error.

3 Check that the drain for the cooling element's condensation water
is not clogged.

4 Check that there is no refrigerant leakage. In case of leakage, oil


and gas often form a dusty, dirty spot.

5 Start the engine and engage the cooling function with setting on
maximum cooling.
Let the engine run at min. 1,500 rpm. (At temperatures below
approx. 0 ºC, the cooling function will not start due to low pressure
in the system.)

6 Set the fan to intermediate speed.

UDCF07.01GB Maintenance Manual DCF 280–520


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

7 After running for 10 minutes, check that there are no bubbles


visible in the receiver dryer's sight glass. (Bubbles should occur
only when the compressor starts and stops).
8 Place a thermometer by the air vent closest to the evaporator. After
5-10 minutes, the temperature should be under 10 ºC. (Deviations
in the measurement result can occur if the performance test is
conducted when the ambient temperature is below approx. 18 ºC).
If bubbles occur, subsequent filling should be done by an expert.

013669

Check the temperatures on the hoses and similar items


as follows:
1 Check that the hoses and components on the pressure side have
roughly the same temperature by feeling them with your hand.

NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) can be very hot. Risk of burn injuries.

2 All hoses and components on the pressure side (from the


compressor to the expansion valve) should be warm.

3 All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.

4 Check the expansion valve. Frost or cold temperatures on


the intake side indicate that it is defective or clogged and that
circulation is limited or stopped on the pressure side.

5 Check that the compressor cuts in and out normally. Run the
cab fan at low speed and let the compressor work at high rpm.
When the temperature in the air vents nozzles is close to 0 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.)

Maintenance Manual DCF 280–520 UDCF07.01GB


9:24 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.

Refrigerant amount, checking


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

It is easiest to confirm bubbles if you observe the sight glass at the


same time as the compressor starts. Then bubbles are usually seen
from a few seconds after the compressor has started, until the system
starts to work normally.

NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 ºC.

Sight glass inspection


1 Machine in service position, see section B Safety.

2 Start the engine and let it idle.

3 Switch on the air conditioning with max. cooling and fan.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:25

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:26 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

Action in the event of leakage in the system


1 Turn off the air conditioning.

2 Check the cooling plant and pinpoint leaks. For this purpose, use
special leak detection equipment. If there still is refrigerant left,
the remaining refrigerant amount shall be evacuated and then
measured.

3 Rectify faults, seal leaks by replacing gaskets, hoses, etc.

4 Fill with the correct quantity of R134a refrigerant according to the


following points when all defects have been repaired.

5 The following work requires special filling equipment.

6 Connect the suction pressure gauge's blue hose to the service


valve on the compressor's suction side marked with S, SUC or
SUCTION.

7 Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.

8 Connect the hoses to the fluid reservoir.

9 Connect the yellow filler and vacuum hose to the nitrogen 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.

11 Conduct leakage detection of all hose nipples and other


connections by applying leakage indicator around all sealing
surfaces and check whether gas bubbles arise.

12 Loosen the yellow hose from the nitrogen tube and connect it to
the vacuum pump.

13 Start the vacuum pump and open the cock on the suction side
very carefully, otherwise the oil 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.

16 Bleed the yellow hose by unloading the service connection at the


manometer set until pure gas flows out.

17 Open the cock on the suction side and allow the gas to flow
around until the pressure gauges indicate the same pressure as
in the tube.

18 Start the compressor and set the cooling thermostat and fan to
max.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:27

19 Open the cock on the pressure side and let the compressor suck
from the cylinder. Observe the sight glass. At the beginning the
fluid is mixed with a lot of bubbles. The longer the compressor
sucks, there will be less bubbles and the fluid will be clearer.
If the bubbles suddenly disappear the cooling thermostat has
probably cut out. Bypass the thermostat using a cable directly
from the connection 24 V or wait until the thermostat cuts in again.
Continue until the correct refrigerant amount has been reached.

NOTE
Directly bypassing the compressor's coupling magnet can lead
to compressor damage caused by incorrect refrigerant quantity.

Close the cock on the suction side and then the cock on the
cylinder. Disconnect the service hoses from the compressor and
install the protective caps. Check for leaks according to step 11
or with a special leak detector.
20 In case of overfilling, the pressure and temperature increase
slowly until the high-pressure monitor cuts off the current to the
013669

compressor's electromagnet. This is due to the refrigerant rushing


around in the system without being evaporated or condensed in
the condenser. The result is that the cold in the cooling coil is
lost and high heat is generated in the condenser. Also, a steady
stream of bubbles can be seen in the sight glass. Return to step 2.
21 In case of underfilling or a lack of refrigerant, bubbles appear in
the sight glass - return to step 2.

Compressor cooling oil


22 At delivery, the compressor is filled with cooling oil. Under normal
conditions the oil should not be changed or refilled. In the event
of suspected incorrect oil quantity, see the instruction: "When
replacing the compressor."
In case of refrigerant loss there may also be oil loss, since
approx. 25% of the oil volume is absorbed by the refrigerant.
Recommended oil types that may be used are shown in the
section F Technical data.

When replacing the compressor


23 The compressor is filled with cooling oil when delivered. When
changing cooling compressor, change the oil as follows:
• Drain the defective compressor of oil and measure the
quantity.
• Then drain the new compressor of oil and refill with the same
amount that was drained from the defective compressor. For
oil volume in the system, see section F Technical data.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:28 9 Frame, body, cab and accessories – Fresh air filter

9.4.1 Fresh air filter

Fresh air filter, changing


The fresh air filter is located at the front of the cab.
1 Machine in service position, see section B Safety.
2 Remove the cover and change the fresh air filter.

9.4.8 Condenser

Condenser, cleaning

1 Machine in service position, see section B Safety.

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

1. Radiator
2. Condenser

9.4.9 Moisture filter

Moisture filter, checking

1 Machine in service position, see section B Safety.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Moisture filter 9:29

2 Start the engine and let it idle.


3 Check the colour of the indicator on the moisture filter.
Blue indication = moisture filter ok.
Grey or pink indication = change moisture filter (see Moisture filter,
changing, page 9:29).

Indicator moisture filter

Moisture filter, changing

WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.

1 Machine in service position, see section B Safety.

2 Drain the air conditioning of refrigerant R134a, with the intended


draining equipment.

IMPORTANT
Working on the air conditioning requires special
authorisation.

3 Disconnect hoses and cabling from the moisture filter.


4 Disconnect the moisture filter pressure switch from the moisture
filter.
5 Change the moisture filter.
6 Fit the pressure switch and connect the hoses to the moisture filter.
7 Leak test and refill the machine with refrigerant R134a, using the
intended equipment.
For volume, see section F Technical data.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:30 9 Frame, body, cab and accessories – Supplemental heater

9.4.19 Supplemental heater


Supplemental heater, description

1
Supplemental heater, an option for the heating unit, uses excess heat
in the engine's cooling system to keep the cab warm.

An additional electric water pump pumps the cooling water through


the heating system when the engine is off. The cab fan pumps air
into the cab. The supplemental heater switches off automatically
when the temperature in the cab is 6 °C below the set value on the
air conditioning. The supplemental heater is activated with Switch
supplemental heater when the ignition is on.

3 2
004909

1. Switch supplemental heater (S199-1)


2. Control unit, cab KCU (D790-1)
3. Circulation pump supplemental heater (M667)

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Wiper/washer system 9:31

9.5 Wiper/washer system


Wiper/washer system, description
On the cab there are wipers for the front windshield, rear window,
and roof window. The function is to clean the windows and maintain
B good visibility from the cab.

The wiper arm is attached to the wiper motor's shaft over a splined
taper. The shaft is made of hardened steel and the wiper arm's
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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:32 9 Frame, body, cab and accessories – Lighting system

9.6 Lighting system


Lighting system, function description
The function of the lighting is to increase safety during operation and
load handling.
The lights are turned off automatically after 5 minutes of idling so that
the lights do not drain the batteries. Extra work lights are turned off after
2 minutes. The lighting is activated automatically when the operator
sits in the set, selects a gear, or if the accelerator pedal is depressed.

NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.

1 2 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)

8. Lever direction indicator (S161) 26. Control unit frame (D797-2)


9. Switch interior lighting on Control unit KIT (D790-2) 27. Extra work lights mast (E404L-2 & E404R-2)
10. Control unit KIT (D790-2) Extra work lights front fender (E404L-2 & E404R-2)

11. Relay work lights cab roof (K3017-1 and K3017-2)


28. For turned driver's seat:
12. Work lights cab roof (E406L-1 E406R-1, E406L-2 &
Driving lights low beams rear (E401L & E401R)
E406R-2)
29. For turned driver's seat:
13. Back-up lights (E405L & E405R), white
Driving lights high beams rear (E402L-2 & E402R-2)
14. Rotating beacon (H428)
15. Interior lights (E434-1) 30. For turned driver's seat:
16. Make-contact brake lights (S216) Tail lights front (H413L & H413R) red
17. Control unit frame (D797-1) 31. For turned driver's seat:
18. Direction indicator (H422, H423, H426 & H427) Brake lights front (H410L & H410R)

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Lighting system 9:33

Lighting system, component location


The function of the lighting is to increase safety during operation and
load handling.

NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.

The following lighting is available:

1 2 3 4 5
6, 7

20, 21, 22, 23, 24

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


9:34 9 Frame, body, cab and accessories – Signalling system

9.7 Signalling system


Signal system, function description
The function of the signals is to increase safety during operation and
load handling. This can take place with light and sound. The machine
has the following signal systems:

NOTE
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.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Signalling system 9:35

Signalling system, component location


The following communication systems are available.

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:36 9 Frame, body, cab and accessories – Entertainment and communication

9.8 Entertainment and


communication
Entertainment and communication, general

For information and description of equipment, see supplier's


documentation for each product.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Glass/windows/mirrors 9:37

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.

The rear-view mirrors are of the type convex mirror. There is an


interior rear view mirror on all machines.

Tinted tempered glass windows are available as an option.

The following panes may be of laminated glass:


• Side windows front, position E

001512
A E B • Windshield (front window), position B

A Side windows As an option the machine can be equipped with a back-up


(reversing) camera and a screen in the cab to improve visibility to
B Windscreen (front window)
the rear. The back-up camera is located on the counterweight. The
C Roof window monitor is installed on an adjustable stand on the left door pillar.
D Rear window
E Side windows, front

9.9.3 Roof window


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

Roof window, checking


Check that the roof window is not damaged or cracked. If the roof
window is defective, change it immediately.

WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!

9.9.5 Rearview mirror


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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:38 9 Frame, body, cab and accessories – Cab structure and suspension

9.10 Cab structure and suspension


Design and suspension, description
The cab has a flat floor with a bracket for the driver's seat. It is
suspended in the cab substructure via heavy-duty rubber insulators
located on the cab's underside. This is to minimise vibrations from
the frame to the cab. There is an insulator at four points, one in each
corner. Each insulator bracket has a rubber bushing and a bolt.

The cab can be slid laterally by means of hydraulics . See Hydraulic


lateral cab sliding, function description, page 9:40.

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 Visually inspect the door's mounting points.


Lubricate the hinges of the doors if necessary.
3 Check the door's locking mechanism with regard to function and
wear.
006914

9.10.3 Cab undercarriage


Cab undercarriage, checking
1 Machine in service position, see section B Safety.

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Cab undercarriage 9:39

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

The cab's mounting points with dampers, machines with


or without hydraulic lateral cab sliding.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:40 9 Frame, body, cab and accessories – Hydraulic lateral cab sliding

9.10.4 Hydraulic lateral cab sliding


Hydraulic lateral cab sliding, function description

The cab is shifted laterally by a hydraulic cylinder pushing or pulling


it sideways. The function is used to improve visibility during load
handling.

Condition Reference value


Control switch Not activated
Parking brake Released
Doors Closed
Speed < 5 km/ h

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)

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Hydraulic lateral cab sliding 9:41

Hydraulic lateral cab sliding, component location

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:42 9 Frame, body, cab and accessories – Cab interior

9.11 Cab interior


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

Recycled material is used for all parts.


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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Frame 9:43

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

Maintenance Manual DCF 280–520 UDCF07.01GB


9:44 9 Frame, body, cab and accessories – Body structure

9.13 Body structure


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

007107
1. Counterweight
2. Hood with safety catch over engine compartment
3. Fenders

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Central lubrication 9:45

9.14 Central lubrication


Central lubrication, description

Central lubrication lubricates the machine's lubrication points


automatically during operation according to preset intervals and
replaces the lubrication in preventive maintenance. The machine
has two separate central lubrication systems, one for the machine
and one for the attachment.

The central lubrication is built up of the following components:


• Pump unit, with lubricant reservoir.
• Distribution block, that distributes and portions the grease
between the different grease points.
The distribution block lubricates one point at a time. If a point
cannot be lubricated properly, e.g. in the event of a line blockage,
the following points will not be lubricated. The grease is forced
out through the safety valve on the pump unit.
• Lines, between main unit and distribution block as well as
distribution block and grease nipples.
• Grease nipples, at grease points.

On the pump unit it is possible to adjust the lubrication interval's


frequency and duration.
Example illustration, components, central lubrication
The central lubrication is supplied with voltage when the parking
1. Pump unit
brake is released.
2. Safety valve
3. Distribution block NOTE
The central lubrication does not grease the propeller shaft's
universal joint or the brake pedal, these must still be greased
during preventive maintenance.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:46 9 Frame, body, cab and accessories – Central lubrication

Central lubrication, checking

1 Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling the
connections at the distribution block. A blocked hose remains
pressurised and the connection becomes firm.

NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.

2 Turn the start key to position I.


3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in switch manual
operation (position 5).
If the indicator pins do not move even when the pump is running,
troubleshoot the pump unit.

NOTE
The system can be lubricated manually through the grease
nipple on the distribution block.
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

UDCF07.01GB Maintenance Manual DCF 280–520


9 Frame, body, cab and accessories – Paint/coatings 9:47

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.

For information on other surface and material colours, contact


Cargotec.

Maintenance Manual DCF 280–520 UDCF07.01GB


9:48

UDCF07.01GB Maintenance Manual DCF 280–520


10:1

10 Common hydraulics

Contents 10 Common hydraulics


10 Common hydraulics .........................................................................................10:3
10.2 Safety valves..................................................................................................10:4
10.3 Tanks and accumulators ................................................................................10:5
10.4 Pumps............................................................................................................10:6
10.5 Hoses, pipes and valves ................................................................................10:7
10.6 Temperature control, cleaning and hydraulic oil.............................................10:8
10.6.2 Hydraulic oil cooler .................................................................................. 10:11
10.6.6 Breather filter hydraulic oil tank ............................................................... 10:11
10.6.7 Hydraulic oil filter .....................................................................................10:12
10.6.8 Hydraulic oil.............................................................................................10:12
10.6.9 Fine filter hydraulic oil..............................................................................10:14

Maintenance Manual DCF 280–520 UDCF07.01GB


10:2

UDCF07.01GB Maintenance Manual DCF 280–520


10 Common hydraulics – Common hydraulics 10:3

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.

The brake system can be found under section 4 Brakes.

On the machine there is a pressure plate with the most important


pressure information (stamped in). The pressure plate is on the
left-hand side of the machine.

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

7 MPa MPa MPa MPa

6 5 4
010618

1. Adjusting control pressure 5. Max pressure hydraulic oil pumps


2. Gas pressure brake accumulators 6. Servo pressure control levers
3. Hydraulic oil pressure accumulator brake system 7. Max. brake pressure
4. Max pressure hydraulic oil pumps

Maintenance Manual DCF 280–520 UDCF07.01GB


10:4 10 Common hydraulics – Safety valves

10.2 Safety valves


Safety valves, component location

NOTE
The valve shall be closed during operation and is opened to
depressurise the machine.

1. Accumulator drain valve with opening knob and lock ring.

007210

UDCF07.01GB Maintenance Manual DCF 280–520


10 Common hydraulics – Tanks and accumulators 10:5

10.3 Tanks and accumulators


Tanks and accumulators, component location
Tank

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

Maintenance Manual DCF 280–520 UDCF07.01GB


10:6 10 Common hydraulics – Pumps

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

1. Hydraulic oil pump for brake system, cooling


and filtering.
2. Hydraulic oil pump for load handling.
3. Hydraulic oil pump for steering and load
handling.

UDCF07.01GB Maintenance Manual DCF 280–520


10 Common hydraulics – Hoses, pipes and valves 10:7

10.5 Hoses, pipes and valves


Hoses, pipes and valves, component location

2
3

007538
1. Priority valve 3. Shuttle valve brake for turnable driver's seat
2. Accumulator charging valve

Maintenance Manual DCF 280–520 UDCF07.01GB


10:8 10 Common hydraulics – Temperature control, cleaning and hydraulic oil

10.6 Temperature control, cleaning


and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
The hydraulic system's oil is cooled and cleaned by means
of it circulating through a cooler and filters. The cooler has a
temperature-controlled electric fan that counteracts overheating.

Temperature control consists of hydraulic oil tank, hydraulic oil pump,


hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, sensor
hydraulic oil temperature and thermal bypass valve.

The hydraulic oil pump for the brake system pumps oil (from the
tank) through the brake system's cooling circuit to be cooled in the
hydraulic oil cooler. 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.

UDCF07.01GB Maintenance Manual DCF 280–520


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

°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

1. Hydraulic oil pumps 8. Control unit frame (D797-1)


2. Brake oil filter 9. Control unit KID (D795)
3. Accumulator charging valve 10. Cooling fan (M668)
4. Drive axle block 11. Thermal bypass valve
5. Fine filter 12. Control unit KIT (D790-2)
6. Cooler hydraulic system 13. Hydraulic oil filter
7. Sensor hydraulic oil temperature (B776)

Maintenance Manual DCF 280–520 UDCF07.01GB


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

Temperature control, cleaning and hydraulic oil,


component location

2
4
3

007213
8 7

1. Cooling fan and cooler hydraulic oil 5. Drive axle block


2. Fine filter hydraulic oil 6. Breather filter hydraulic oil tank
3. Hydraulic oil pump 7. Tank heater
4. Hydraulic oil filter 8. Sensor hydraulic oil temperature (B776)

UDCF07.01GB Maintenance Manual DCF 280–520


10 Common hydraulics – Hydraulic oil cooler 10:11

10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, cleaning

1 Machine in service position, see section B Safety.

2 Clean the hydraulic oil cooler with compressed air.


Blow away dust and other loose dirt.

010654

Hydraulic oil cooler.

10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, changing

1 Turn off the engine and turn off the main electric power.

2 Clean the area around the filter housing.


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

Maintenance Manual DCF 280–520 UDCF07.01GB


10:12 10 Common hydraulics – Hydraulic oil filter

10.6.7 Hydraulic oil filter

Hydraulic oil filter, changing

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.

1. Cover plate for oil filter


2. Filling point hydraulic oil
3. Sight glass hydraulic oil
4. Filling point hydraulic oil
5. Breather filter hydraulic oil tank

5 Clean the filter holder's parts. Be especially thorough with the


magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and cover plates. Tighten the bolts crosswise.
8 Check the oil level, see Hydraulic oil, level check, page 10:12.

Magnetic rod

10.6.8 Hydraulic oil


Hydraulic oil, level check

NOTE
Check the hydraulic oil level with the trolley completely lowered and
the mast tilted completely inward.

1 Machine in service position, section B Safety.

2 Check the oil level in the hydraulic tank. The oil level should be
visible in the sight glass. Top up with oil as required. For oil grade,
see section F Technical data.

UDCF07.01GB Maintenance Manual DCF 280–520


10 Common hydraulics – Hydraulic oil 10:13

Hydraulic oil, changing

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 Machine in service position, see section B Safety.

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.

4. Filling point hydraulic oil


5. Breather filter hydraulic oil tank

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.

7 On machines without separate brake oil tanks:


Bleed the brake cylinders and cooling circuit, see section 4
Brakes, group 4.3.9 Wheel brake.

Maintenance Manual DCF 280–520 UDCF07.01GB


10:14 10 Common hydraulics – Fine filter hydraulic oil

10.6.9 Fine filter hydraulic oil

Fine filter hydraulic oil, changing

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 Machine in service position, see section B Safety.

2 Remove the cover.


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

UDCF07.01GB Maintenance Manual DCF 280–520


11:1

11 Common electrics

Contents 11 Common electrics


11 Common electrics ............................................................................................11:3
11.2 Electrical protection........................................................................................ 11:4
11.2.2 Fuses ........................................................................................................ 11:4
11.3 Batteries......................................................................................................... 11:9
11.3.1 Start battery............................................................................................... 11:9
11.4 Alternator ..................................................................................................... 11:11
11.5 Distribution of electricity ............................................................................... 11:12
11.5.1 Voltage feed ............................................................................................ 11:12
11.5.2 Electrical distribution box......................................................................... 11:17
11.5.3 Control units ............................................................................................ 11:18
11.6 Communication ............................................................................................ 11:20
11.6.1 CAN bus .................................................................................................. 11:20
11.6.2 Redundant CAN-bus ............................................................................... 11:20
11.6.3 CAN-bus drivetrain .................................................................................. 11:20
11.6.5 RMI (Remote Machine Interface) ............................................................ 11:21

Maintenance Manual DCF 280–520 UDCF07.01GB


11:2

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Common electrics 11:3

11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN-bus.

Maintenance Manual DCF 280–520 UDCF07.01GB


11:4 11 Common electrics – Electrical protection

11.2 Electrical protection


Electrical protection, component location
1. Control switch
1 2
2. Circuit fuses, electrical distribution box cab

3. Main fuses, electrical distribution box frame

4. Circuit fuses, electrical distribution box frame

5. Battery disconnector

3
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.

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Fuses 11:5

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

Main fuses 007281

1. Electric power feed relay K315-1, electric power to


ignition voltage (30), (50 A)
2. Battery voltage (30) to cab, engine and transmission,
(50 A)
3. Electric power feed relay K3009-1, power to
emergency stop switch voltage(30), (50 A)
4. Ignition voltage (15) to control units on frame, engine,
cab and transmission, (50 A)

Maintenance Manual DCF 280–520 UDCF07.01GB


11:6 11 Common electrics – Fuses

Circuit fuses
Circuit fuses

Circuit fuses are grouped in fuse holders that are located in the
electrical distribution box on the frame and the electrical distribution
box in the cab.

By the fuse holders there are fuse plates with information about fused
function and fuse rating.

A
B
012543

Fuses on frame
A. 30-fuses (battery voltage), F58-1
B. 15-fuses (ignition voltage), F58-2

C. 15E-fuses (emergency stop switch voltage), F58-3


Fuses in cab
D. 15-fuses (ignition voltage) and 30-fuses (battery
voltage), F58-4
E. 15-fuses (ignition voltage), F58-5

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Fuses 11:7

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

E5 10A OPT RADIO

MAIN POWER
F6 25A OPT SEAT HEATER, TURNABLE SEAT

F58-4 30
G7 15A OPT WORK LIGHT

CAB
H8 15A OPT AIRCUSHIONED SEAT

A1 25A KCU (KALMAR CAB UNIT)

F58-5 15 SUPPLY POWER CAB


B2 10A KIT (KALMAR INFORMATION TERMINAL)

C3 15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)

D4 5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)

E5 10A SERVICE

F6 5A OPT MAP READING LIGHT

G7 10A OPT CONVERTER 12V

014092
H8 10A OPT COMPRESSOR HORN

Circuit fuses electrical distribution box cab

014278

Circuit fuses electrical distribution box frame

Maintenance Manual DCF 280–520 UDCF07.01GB


11:8 11 Common electrics – Fuses

Fuses, changing

IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.

1 Turn off the system voltage (battery disconnector).

2 Remove the cover from the fuse holder.

3 Check that the fuses are intact. Change when needed.

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Batteries 11:9

11.3 Batteries
11.3.1 Start battery

Start battery, checking

WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed in
the eyes, rinse immediately with plenty of water and
contact a doctor immediately.

1 Check the battery voltage from the operating menu for electrical
system.
With the engine off, the battery voltage should be 23–25 V.
With engine at max. engine speed (2,000 rpm), the battery voltage
should be 27–29 V.
000354

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


11:10 11 Common electrics – Start battery

Battery cables, checking

DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no
machine parts wear or chafe against the battery cables.
Change damaged battery cables.

The following battery cables should be checked for clamping, risk of


rubbing and damage to the battery cables. Rectify incorrect clamping
and risks of rubbing. Change battery cables that show signs of damage.
Diesel-powered machines
• Plus-cable between battery and battery disconnector.
• Plus-cable between battery disconnector and starter motor.
• Plus-cable between starter motor and alternator.
• Plus-cable between battery disconnector and main fuses.
• Plus-cable between starter motor and preheating relay.
• Plus-cable between preheating relay and preheating coil.
• Ground cable between battery and frame.
• Ground cable between engine and frame.

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Alternator 11:11

11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. See section 1 Engine.

Maintenance Manual DCF 280–520 UDCF07.01GB


11:12 11 Common electrics – Distribution of electricity

11.5 Distribution of electricity


Distribution of electricity, description
This section describes distribution of electric power and communication
between control units. Electric power distribution describes the
foundation of the electrical system and the network of control units.

11.5.1 Voltage feed


Start-up of electrical system, description
When the machine is not used, the machine's electrical system is in
a powerless mode, that is, neither power electronics nor control units
are supplied with voltage. At machine start, voltage feed is activated
and the redundant CAN-bus is initiated. Start is handled by control
unit cab (D790-1).

The first pre-requisite for the machine to be able to perform any action
is to first establish the redundant voltage feed for control units and
then establish CAN-bus communication to administer control signals
for functions.

Control units establish communication when:


• Operator’s door is opened
• Interior lighting is lit
• Flashing hazard lights are activated
• Step lighting is activated
• Start key in position I
Start-up

Startup signal Start-up

The following takes place at start-up:


D790-1 D790-2 D795 1. Start-up signal to Control unit cab (D790-1).
007284

D797-2 D797-1
(+)

Start-up signal is sent


2. Control unit cab (D790-1) initiates connection of redundant
D790-1 D790-2 D795 voltage feed. See Redundant voltage feed of control units,
description, page 11:14.
3. Control unit cab (D790-1) activates ignition voltage (15).
See Ignition voltage (15), description, page 11:14.
007285

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.

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Voltage feed 11:13

System down in powerless mode


The system goes down in powerless mode when:
• Start key in position 0 and no activity signal has been sent.
• Start key in position 0 and the hold circuit's run time for
supplemental heating has run out.
• Start key in position 1 and automatic engine shut-down has been
activated.

The following takes place when the system goes down in powerless
mode.
1. Cab control unit (D790-1) cuts off emergency stop switch voltage
(15E).
See Emergency stop switch voltage (15E), description, page 11:15.
2. Control unit cab (D790-1) cuts off ignition voltage (15).
See Ignition voltage (15), description, page 11:14.
3. Redundant voltage feed to control units is cut off.
4. Cab control unit (D790-1) disconnects the redundant CAN bus.
See Redundant CAN-bus, description, page 11:20.
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.

11.5.1.1 Battery voltage (30)

Battery voltage (30), description


The battery voltage feeds voltage:
• Control system at start. See Start-up of electrical system,
description, page 11:12.
• Starter motor
• Main relays (15-voltage)
• Control switch relays (15E-voltage)
• Engine
• Transmission

Maintenance Manual DCF 280–520 UDCF07.01GB


11:14 11 Common electrics – Voltage feed

11.5.1.2 Redundant voltage feed of control units

Redundant voltage feed of control units, description


A Startup signal The redundant voltage feed only feeds the control units' control logic
and buses, and is controlled completely by Control unit cab (D790-1).
The control units' outputs remain without power and are supplied with
D790-1 D790-2 D795 voltage first when ignition voltage is activated.

The redundant voltage feed for each control unit is independent of


other control units. If a control unit is not working the voltage feed to
other control units is not affected.
D797-2 D797-1
(+) When all control units have redundant voltage feed and bus
communication, the system is ready to receive, process signals.
B
When redundant voltage feed is activated the following takes place.
D790-1 D790-2 D795
1. Start-up signal is sent to Control unit cab (D790-1), see A in
illustration.
2. A hold circuit is activated in Control unit cab (D790-1) which
activates the control unit's control logic.
007286

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.

11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description


The ignition voltage feeds the power electronics.
Startup
2 The ignition voltage is activated by:
• Start key in position I
D790-1 • Flashing hazard lights (Hazard) activated
1
D1 D2
When ignition voltage is activated the following takes place.
D795 1. Battery disconnector in position 1. Voltage feed to Control unit
3 cab (D790-1), ignition, switch flashing hazard lights, door switch
K315-1 and interior lighting.
D790-2 2. Switch for start-up signal gives pulse to Control unit cab (D790-1).
- + 4 CAN bus communication is established (not drivetrain).
D797-1 3. Start key in position I or flashing hazard lights activated.
D3
4. Control unit cab (D790-1) feeds voltage to power relay ignition
D4 (K315-1) and relay ignition key lock (K315-2) in electronic box
D797-2 frame.
(+)
5. Ignition voltage supplies control units, relays, solenoid valves and
D5 other electronics.
D793
K315-2 Drivetrain’s CAN bus establishes communication.
007287

D794

Power feed ignition circuit


D1. Diagnostic menu CAN/POWER 5
D2. Diagnostic menu CAN/POWER 7
D3. Diagnostic menu CAN/POWER 10
D4. Diagnostic menu CAN/POWER 13
D5. Diagnostic menu CAN/POWER 12

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Voltage feed 11:15

11.5.1.4 Emergency stop switch voltage (15E)

Emergency stop switch voltage (15E), description


S250 The emergency stop switch voltage supplies functions which require
a control switch, e.g. working hydraulics.
D1
1 The control switch is activated with Switch control switch.
D790-1
D5 Condition for activating emergency stop switch voltage is that Switch,
2 4 control switch, is not pressed in.
D4 D2 • Start key in position I
• Ignition voltage (15)
K3009-1 K3009-2
D3 • Switch, control switch not activated.
D797-2
- + 5
(+) When emergency stop switch voltage is activated the following takes
place.
3
D4 Y6010 1. Ignition voltage is connected to Control unit cab (D790-1).
K3002 2. Control unit cab (D790-1) activates Power relay K3009-1 in
electrical distribution box frame and emergency stop switch
voltage (15E) feeds the circuit until relay K3009-2 in electrical
5 distribution box frame.
D797-1 Y6011
3. 15E-feed sends a voltage signal to Control unit cab (D790-1) and
verifies that Power relay control breaker (K3009-1) is active but
that Power relay control breaker (K3009-2) is inactive.
D4
Y6004 This verifies that the control breaker is working.
K3007 4. Control unit cab (D790-1) activates power relay control breaker
(K3009-2) in the electrical distribution box and the emergency
stop switch voltage supplies voltage to the control units (not
5 drivetrain).
Y6005
5. When Switch control switch (S250) is pushed down, the
007288

emergency stop switch voltage (15E) is cut off to Control unit


cab (D790-1) and power is guided to relay K3002 and K3007, as
well as Power relay control switch K3009-1 and K3009-2. Power
Power feed, control breaker circuit supply to the control units is cut off and the functions cease.
D1. Diagnostic menu CAN/POWER 6 As extra safety the cab control unit (D790-1) also sends status
D2. Diagnostic menu CAN/POWER 6 for Switch, control breaker (S250) on the CAN bus. In this way
functions are also cut off at signal level.
D3. Diagnostic menu CAN/POWER 13
D4. Diagnostic menu CAN/POWER 15
D5. Diagnostic menu CAN/POWER 6
D6. Diagnostic menu CAN/POWER 6

Maintenance Manual DCF 280–520 UDCF07.01GB


11:16 11 Common electrics – Voltage feed

11.5.1.5 Voltage converter

Voltage converter, description

The voltage converter is located under a protective casing to the left


behind the driver's seat.

The voltage converter converts 24 Volt to 12 Volt. 12 V voltage


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

12 V voltage is also available in sockets on the instrument panel,


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

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Electrical distribution box 11:17

11.5.2 Electrical distribution box


Electrical distribution box, component location

5 6
4 7
3
15
2
1 8
16

9 17

10 18

11 19
12

13

14

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

Maintenance Manual DCF 280–520 UDCF07.01GB


11:18 11 Common electrics – Control units

11.5.3 Control units


Control units, general
Control units are appointed responsibility for parts of functions.
Therefore a certain function cannot be associated to a special control
unit, instead the function occurs in cooperation between control units,
sensors, valves, etc.

Control unit cab and control units on the frame and attachment have
indicator lamps that can be used to check basic information on the
status of other control units.

Indicator lamps have the following significations:


Indicator lamps control unit cab
Table Indicator lamps control unit cab

Light 1 Green light when there is battery voltage to unit. The


light is physically controlled by voltage feed to the
4 control unit.
Light 2 Flashes green when redundant voltage feed control
3 unit and redundant CAN-bus communication is active.
2 No power in system.
006767

1 Green light when power electronics and 15-voltage


are supplied with voltage.
Indicator lamps control unit cab
Light 3 Long yellow single flashing light at communication with
Control unit KID (D795), which is a prerequisite for
trouble-shooting.
Short yellow single flashing light at communication
with Control unit engine (D794) and Control unit
transmission (D793).
Double flashing yellow light (short and long flashes)
at communication with display and engine or
transmission.
Light 4 Red light at active error.
Indicator lamps control units on frame and attachment
Table Indicator lamps control units on frame and attachment
1
2 Light 1 Green light when there is battery voltage to unit. The
light is physically controlled by voltage feed to the
3 control unit.

4 Light 2 Flashes green when any redundant voltage feed left,


redundant voltage feed right or 15-voltage is not found.
006766

Green light when redundant voltage feed, left,


redundant voltage feed, right and 15-voltage are
Indicator lamps control units on frame and attachment. supplied with voltage.
Light 3 Yellow single flashing light at communication with
Control unit KID (D795) or Control unit cab (D790-1).
Yellow double flashing light during communication with
Control unit KID (D795) and Control unit KIT (D790-2).
Light 4 Red light at active error.

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – Control units 11:19

Control units, position

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)

Maintenance Manual DCF 280–520 UDCF07.01GB


11:20 11 Common electrics – Communication

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.

2 The network consists of control units and segments. Segment is the

007290
D794 D793 CAN-bus between control units.

1. Segment
2. CAN-bus drivetrain

11.6.1 CAN bus


CAN-bus, description
The CAN-bus consists of two twisted cables (twisted pair).

11.6.2 Redundant CAN-bus


Redundant CAN-bus, description
Redundant CAN-bus means that each control unit has two
D790-1 D790-2 D795 connections for communication. The CAN-bus is connected in series
CAN R CAN L CAN R CAN L
between the control units. This means that the CAN-bus can handle
loss of a segment. If several segments fail, then one or some control
units lose contact with the network and work independently, often with
CAN L CAN R CAN L CAN R
limited capacity to perform their task.
007291

D797-2 D797-1
(+)
Signals can be checked with diagnostic menu.
Principle illustration redundant CAN-bus

11.6.3 CAN-bus drivetrain


CAN-bus drivetrain, description
Communication with Control unit engine (D794) and Control unit
D790-1 transmission (D793) are separate from the redundant CAN-bus.

Signals can be checked with diagnostic menu.


003171

D794 D793
Principle illustration CAN-bus drivetrain

UDCF07.01GB Maintenance Manual DCF 280–520


11 Common electrics – RMI (Remote Machine Interface) 11:21

11.6.5 RMI (Remote Machine Interface)


RMI (Remote Machine Interface), description

Remote Machine Interface is a tool for listening to the machine at a


distance. RMI consists of a control unit which is connected to the
machine, antenna for communication and GPS-antenna ( ) for
positioning.

007443
RMI interface (A911) records communication on the CAN bus and
sends the information to a central RMI server. In the event of a fault
RMI-interface (A911) the control unit in the machine can send information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.

From the RMI server, data from the machine can be analysed and
processed for reading off different values. For example, when it is
time for a service or if there are error codes stored in the machine.

There is a GPS-antenna available as an option, making it


possible to read off the machine's position.

NOTE
RMI only sends data from the machine, but no data can be sent to
the machine. RMI cannot be used to control the machine.

Maintenance Manual DCF 280–520 UDCF07.01GB


11:22

UDCF07.01GB Maintenance Manual DCF 280–520


D:1

D Error codes

D Error codes
Error codes
See Workshop manual DCF 280–520, section D Error codes.

Maintenance Manual DCF 280–520 UDCF07.01GB


D:2

UDCF07.01GB Maintenance Manual DCF 280–520


E:1

E Diagrams

E Diagrams
Diagrams
See Workshop manual DCF 280–520, section E Diagrams.

Maintenance Manual DCF 280–520 UDCF07.01GB


E:2

UDCF07.01GB Maintenance Manual DCF 280–520


F:1

F Technical data

Contents F Technical data


Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:5
Specifications for lift capacity and dimensions.................................................F:7
Oils and lubricants, recommendation...............................................................F:9
Tightening torques, recommendations...........................................................F:11
Tightening torque, ORFS connections ...........................................................F:12
Tightening torque, connections for air conditioning unit.................................F:13
Unit explanations ...........................................................................................F:14
Conversion SI-units........................................................................................F:15
Conversion table, length ................................................................................F:16
Conversion table, area...................................................................................F:16
Conversion table, volume ..............................................................................F:16
Conversion table, weight................................................................................F:16
Conversion table, pressure ............................................................................F:17

Maintenance Manual DCF 280–520 UDCF07.01GB


F:2

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:3

F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.

0. complete machine Volvo TAD762VE Volvo TAD1360VE


Guaranteed sound power level in LWA 110 dB(A) LWA 111 dB(A)
accordance with 2000/14/EC and
2005/88/EC including measurement
uncertainty 1.5 dB.

1. Motor Volvo TAD762VE Volvo TAD1360VE


Power acc. to ISO 3046 (net power) 185 kW between 1600-2200 rpm 256 kW between 1500-1900 rpm
Torque ISO 3046 1178 Nm at 1200 rpm 1745 Nm at 1200 rpm
Max. rpm 2200 rpm 1900 rpm
Number of cylinders 6 cylinders
Alternator, power 2400 W 2640 W
System voltage, voltage capacity 24 V (2x12 V / 140 Ah)

2. Transmission DANA TE17 DANA TE32


No. of gears, forward - reverse 3 – 3 4 – 4

3. Driveline/Axle DCF 280-330 DCF 370-420 DCF 450-520


Drive axle, type AxleTech PRC3806W4H AxleTech PRC7534W4H Kessler D102

4. Brakes
Footbrake system - wheels affected Wet Disc Brake - drive wheel
Parking brake system - wheels affected Spring brake - drive wheel

5. Steering
Steering system Hydraulic servo

6. Wheels DCF 280-330 DCF 370-420 DCF 450-520


Dimension, front and rear 16.00x25 18.00x25 18.00x33
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air filled. Spare and replacement tyres must be of a brand approved by Cargotec.

9. Cab Volvo TAD762VE Volvo TAD1360VE


Equivalent sound pressure level LpAZ 71 dB(A) LpAZ 70 dB(A)
in cab according to EN12053 with
measurement uncertainty σR = 2.5 dB.
Measuring value with standard engine.
Whole-body vibration in accordance 0.4 - 0.7 m/s2
with EN13059 with measurement
uncertainty k = 0.3 x measured value.

9.6 Lighting system


Control lights 1.2 W2x4.6d
Interior lighting 10 S8.5

Maintenance Manual DCF 280–520 UDCF07.01GB


F:4 F Technical data – Technical data

9.6 Lighting system


Rear lights 5 BA15s
Brake lights 21 BA15s
Direction indicators 21 BA15s
Rear lights, brake lights & direction indicators - Replace complete
LED
Running lights 5 W2.1x9.5d
- Replace complete
Running lights LED
Headlights (during high, low beam) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work light bulb 70 PK22s (H3)
35 D1S Xenon tube. Cartridge and
Work light, Xenon ballast are replaced complete.
- Replace complete
Work lighting LED
Rotating beacon 70 PK22s (H1)

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:5

Volumes
Any deviation from this table must be supported with written approval
from Cargotec.

DCF 280-330 DCF 370-520


1.2 Engine, fuel system Volvo TAD762VE Volvo TAD1360VE
Fuel tank, volume 300 l 400 l
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1–D,
ASTM D 975 No 2–D.
AdBlue tank, volume 20 l
Quality AdBlue, according to ISO standard 22241.
1.7 Engine, cooling system Volvo TAD762VE Volvo TAD1360VE
Coolant volume 35 l 48 l
Coolant filling Volvo Penta Coolant VCS, ready-mixed

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.

1.8 Engine, lubrication system Volvo TAD762VE Volvo TAD1360VE


Oil type, quality See Oils and lubricants, recommendation, page F:9.
Oil volume incl. filter 27 l 36 l

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

4.8 Brake system


Oil grade See Oils and lubricants, recommendation, page F:9.
Oil tank brake system, volume 170 l

Maintenance Manual DCF 280–520 UDCF07.01GB


F:6 F Technical data – Technical data

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

9 Frame, body, cab and accessories


Refrigerant air conditioning R134a
Volume refrigerant 2000 g
Lubricant air conditioning ZEXEL PAG-oil ZXL100 (1.7 dl)
Windshield wiper fluid, volume 5 l

10 Common hydraulics DCF 280-330 DCF 370-520


Oil grade See Oils and lubricants, recommendation, page F:9.
Hydraulic oil tank, volume 300 l 600 l
Hydraulic oil system, volume 400 l (total, including tank) 800 l (total, including tank)

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:7

Specifications for lift capacity and


dimensions

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

Listed measurements explained in table below.

DCF280-12 DCF300-12 DCF330-12 DCF DCF DCF DCF


Capacity and
dimensions • LB • LB • LB 370-12 420-12 450-12 500-12

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

Maintenance Manual DCF 280–520 UDCF07.01GB


F:8 F Technical data – Technical data

DCF280-12 DCF300-12 DCF330-12 DCF DCF DCF DCF


Capacity and
dimensions • LB • LB • LB 370-12 420-12 450-12 500-12

Groove (c-c), front - rear


2540 - 2440 3030 - 2625 3030 - 2815
(S [mm])
Minimum turning radius,
6600 6900 7400 8150 8650
outer (R1 [mm])
Slewing radius, inner (R2
950 1000 1100 1200
[mm])
Ground clearance, min 300
[mm]
Max height at cab tilting, - - - -
3800 3800 3800
(T1 [mm])
Max width at cab tilting, - - - -
3850 3850 3850
(T2 [mm])
Min. travel width at 90°
stacking with forks (A1 10325 10795 11295 12100 12600
[mm])
Dimensions, Standard duplex mast
Lift height (H4 [mm]) 5000
Mast height, min. (H3 4520 5050
[mm])
Mast height, max. (H5
6770 7550
[mm])
Mast tilting, forward - back
5 - 10
(α - β [])
Ground clearance, min. -
under mast (mm)
Dimensions, Forks
Width (b [mm]) 300
Thickness (a [mm]) 110 135 145
Length of fork arms (l
2400
[mm])
Width straight over fork
2750 - 1550 2750 - 1950
arms, max-min (V [mm])
Side shift at width straight
200 -
over fork arms (V1 - V 300 - 2150 200 - 2350
2300
[mm])
Weight
Service weight [kg] 40600 49300 51900 54800 61000
Axle load pressure front,
19600 25500 27400 27600 33000
(without load) [kg]
Axle load pressure front,
69300 69100 68800 81000 88600 93900 105000
(with classified load) [kg]
Axle load pressure rear,
21000 23800 24500 27200 28000
(without load) [kg]
Axle load pressure rear,
4300 4500 4800 5300 5500 5900 6000
(with classified load) [kg]

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:9

Oils and lubricants, recommendation


Cargotec's stated service intervals in the maintenance manual are
conditional on oil selection according to the following table. The
table states recommended viscosity for different oil types and grades
depending on outdoor temperature.

Any deviation from this table must be approved in writing by Cargotec,


and may mean changed service intervals.

°C -40 -30 -20 -10 0 +10 +20 +30 +40


Oil type, quality F -40 -22 -4 +14 +32 +50 +68 +86 104
1.8 Engine, lubrication system
VDS-3 SAE 15W40
SAE 5W30 (engine oil)

2.6 Transmission, lubrication system


ATF Dexron III DEXRON III (trademark)

3.3 Driveline/Axle, drive axle


API GL-5 SAE 80W140
SAE 75W90

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.

API = American Petroleum Institute

VDS = Volvo Drain Specification

Maintenance Manual DCF 280–520 UDCF07.01GB


F:10 F Technical data – Technical data

Grease

Use a universal grease type EP according to NLGI Grade 2 (EP2) for


all grease points except for lifting equipment and slide plates.

For lifting equipment, use a universal grease type EP according to


NLGI Grade 2 (EP2) with 3-5% Molybdenum disulfide intermix.

For slide plates, use lubricants approved by Cargotec. Order from


Cargotec Parts department. 0.65 kg cartridge for grease gun, part no.
923110.0360, and 5 kg can, part no. 923595.0003.

NOTE
Select grease grade according to relevant climate.

Electrical connector grease

Use electrical contact grease part no. 923836.0552.

Sealant silicone

Use silicone part no. 923107.0308.

Silicone adhesive

Use silicone adhesive part no. 923854.0100.

Coolant

Only use ready-mixed recommended coolant. Select mixture of the


coolant that is adapted for correct temperature.

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.

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:11

Tightening torques, recommendations


The tightening torques in the following table are recommendations
when tightening bolts and nuts.

When torquing using a machine, for example, bolt runner, the tightening
torque should be reduced by approx. 5%.

For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.

Tighten to the prescribed torque without stopping.

Recommended tightening torque varies depending on surface


treatment. Certain combinations of bolts and nuts require lubrication
according to the following table.

State Screw Nut Lubrication


1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil

Quality 8.8 10.9 12.9


State 1 2 3 1 1

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

Maintenance Manual DCF 280–520 UDCF07.01GB


F:12 F Technical data – Technical data

Quality 8.8 10.9 12.9


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

Tightening torque, ORFS connections


Pipe and hose coupling

Pipe diameter Tightening torque


mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -

15 - 80-90
16 5/8
18 3/4
120-130
20 -

22 7/8
150-170
25 1"
28 -

30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2

Wrench size Tightening torque


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

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:13

Goods coupling

UNF-UN Metric-ISO BSSP


Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400

Tightening torque, connections for air


conditioning unit
O-ring coupling cooling coils

Hose diameter Thread Tightening torque


mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"

The above values should be considered guidelines and may vary


depending on installation.

Maintenance Manual DCF 280–520 UDCF07.01GB


F:14 F Technical data – Technical data

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

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:15

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

Maintenance Manual DCF 280–520 UDCF07.01GB


F:16 F Technical data – Technical data

Conversion table, length


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

Conversion table, area


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

ft2 - 0.092903 - 0.000929 1 0.1111 144.000


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

Conversion table, volume


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

Conversion table, weight


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

UDCF07.01GB Maintenance Manual DCF 280–520


F Technical data – Technical data F:17

Conversion table, pressure


Unit kp/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735,56 Dry (mmHg) = 0.96784 atm

Maintenance Manual DCF 280–520 UDCF07.01GB


F:18

UDCF07.01GB Maintenance Manual DCF 280–520


G:1

G Terminology and index

Contents G Terminology and index


Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:7

Maintenance Manual DCF 280–520 UDCF07.01GB


G:2

UDCF07.01GB Maintenance Manual DCF 280–520


G Terminology and index – Terminology and index G:3

G Terminology and index


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

Maintenance Manual DCF 280–520 UDCF07.01GB


G:4 G Terminology and index – Terminology

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.

UDCF07.01GB Maintenance Manual DCF 280–520


G Terminology and index – Terminology G:5

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.

Maintenance Manual DCF 280–520 UDCF07.01GB


G:6

UDCF07.01GB Maintenance Manual DCF 280–520


G Terminology and index – Index G:7

Index Entertainment and communication


Environment . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . 9:36
. B:21
Error codes . . . . . . . . . . . . . . . . . . 8:8, D:1
Exhaust system . . . . . . . . . . . . . . . . . . 1:30
A EXT-ATTACH . . . . . . . . . . . . . . . . . . . 8:24
About the documentation . . . . . . . . . . . . . A:10 EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:22
About the maintenance manual . . . . . . . . . . . . A:3
Accumulator . . . . . . . . . . . . . . . . . . . . 4:10
AdBlue filter . . . . . . . . . . . . . . . . . . . . 1:22 F
AdBlue tank . . . . . . . . . . . . . . . . . . . . 1:19 Feedback . . . . . . . . . . . . . . . . . . . . . A:11
Air cleaning system . . . . . . . . . . . . . . . . . 1:28 Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:14
Air intake and exhaust outlet . . . . . . . . . . . . . 1:25 Foreword . . . . . . . . . . . . . . . . . . . . . A:3
Alternator . . . . . . . . . . . . . . . . . . . . 11:11 Frame . . . . . . . . . . . . . . . . . . . . . . . 9:43
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:21 Frame, body, cab and accessories . . . . . . . . . . 9:3
FREELIFT . . . . . . . . . . . . . . . . . . . . . 8:24
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:28
B Fuel filter . . . . . . . . . . . . . . . . . . . . . 1:17
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:9 Fuel prefilter . . . . . . . . . . . . . . . . . . . . 1:13
Battery voltage (30) . . . . . . . . . . . . . . . . 11:13 Fuel system . . . . . . . . . . . . . . . . . . . . 1:11
Body structure . . . . . . . . . . . . . . . . . . . 9:44 Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:13
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:4 Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:4
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3
Breather filter . . . . . . . . . . . . . . . . . . . 4:19
Breather filter hydraulic oil tank . . . . . . . . . . . 10:11 G
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:6 General safety information . . . . . . . . . . . . . . B:3
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:37

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

Maintenance Manual DCF 280–520 UDCF07.01GB


G:8 G Terminology and index – Terminology

Oil pump brake system . . . . . . . . . . . . . . . 4:8 Settings . . . . . . . . . . . . . . . . . . . . . . 8:27


OLS . . . . . . . . . . . . . . . . . . . . . . . 8:21 Side shift . . . . . . . . . . . . . . . . . . . . . 7:17
OPT . . . . . . . . . . . . . . . . . . . . . . . 8:26 Signalling system . . . . . . . . . . . . . . . . . . 9:34
Other functions . . . . . . . . . . . . . . . . . . . 7:31 Speed limitation . . . . . . . . . . . . . . . . . . 8:6
Spreading . . . . . . . . . . . . . . . . . . 7:21, 7:31
Start battery . . . . . . . . . . . . . . . . . . . . 11:9
P Start/stop . . . . . . . . . . . . . . . . . . . . . 1:47
Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:47 Steering axle cradle . . . . . . . . . . . . . . . . . 6:6
Parking brake pads . . . . . . . . . . . . . . . . . 4:15 Supplemental heater . . . . . . . . . . . . . . . . 9:30
Parking brake system . . . . . . . . . . . . . . . . 4:12 Suspension . . . . . . . . . . . . . . . . . . 6:3–6:4
Parking brake unit . . . . . . . . . . . . . . . . . 4:14
Position sensor mast . . . . . . . . . . . . . . . . 7:16
Power assisted system . . . . . . . . . . . . . . . 5:4
Power-assisted brake system . . . . . . . . . . . . 4:5 T
Pressure reducer . . . . . . . . . . . . . . . . . . 7:10 Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Preventive maintenance . . . . . . . . . . . . . . . C:3 Technical data . . . . . . . . . . . . . . . . . . . F:3
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:4 Temperature control, cleaning and hydraulic oil . . . . . 10:8
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6 Temperature control, cleaning and oil brake system . . . 4:17
Terminology . . . . . . . . . . . . . . . . . . . . G:3
Terminology and index . . . . . . . . . . . . . . . G:3
R Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:25
Radiator and expansion tank . . . . . . . . . . . . . 1:32 Tilt cylinder . . . . . . . . . . . . . . . . . . . . 7:27
Reading instructions . . . . . . . . . . . . . . . . A:4 Torque converter/Clutch system . . . . . . . . . . . 2:9
Rearview mirror . . . . . . . . . . . . . . . . . . 9:37 TRANSM . . . . . . . . . . . . . . . . . . . . . 8:18
Redundant CAN-bus . . . . . . . . . . . . . . . 11:20 Transmission. . . . . . . . . . . . . . . . . . . . 2:3
Redundant voltage feed of control units . . . . . . . 11:14 Turnable driver's seat . . . . . . . . . . . . . . . . 9:14
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:19 Twistlocks . . . . . . . . . . . . . . . . . . . . . 7:41
RMI . . . . . . . . . . . . . . . . . . . . . . . . 8:26 Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:18
RMI (Remote Machine Interface) . . . . . . . . . . 11:21 Tyres and rims . . . . . . . . . . . . . . . . . . . 6:9
Roof window . . . . . . . . . . . . . . . . . . . . 9:37
Rotation . . . . . . . . . . . . . . . . . . . . . . 7:38
V
VBFS . . . . . . . . . . . . . . . . . . . . . . . 8:22
S Voltage converter . . . . . . . . . . . . . . . . . 11:16
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3 Voltage feed . . . . . . . . . . . . . . . . . . . 11:12
Safety and emergency equipment. . . . . . . . . . . 9:9
Safety instructions . . . . . . . . . . . . . . . . . B:4
Safety valves. . . . . . . . . . . . . . . . . . . . 10:4 W
Seats . . . . . . . . . . . . . . . . . . . . . . . 9:11
Sensor steering wheel reading . . . . . . . . . . . . 5:9 Wheel brake . . . . . . . . . . . . . . . . . . . . 4:10
Separate top lift attachment . . . . . . . . . . . . . 7:31 Wheel hub . . . . . . . . . . . . . . . . . . . . . 6:7
Service indicator . . . . . . . . . . . . . . . . . . 8:7 Wheel spindle . . . . . . . . . . . . . . . . . . . 6:7
Servo filter . . . . . . . . . . . . . . . . . . . . . 7:11 Wiper/washer system . . . . . . . . . . . . . . . . 9:31

UDCF07.01GB Maintenance Manual DCF 280–520


G Terminology and index – Index G:9

Maintenance Manual DCF 280–520 UDCF07.01GB


last page

Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

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