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Documente Profesional
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8-9 tonnes
Publ. no UDCT01.02GB
Maintenance Manual in original
MAINTENANCE MANUAL
DCT 8090
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Maintenance Manual
2 Transmission
DCT 8090
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
UDCT01.02GB
A:2
UDCT01.02GB
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.
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.
UDCT01.02GB
A:4
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.
The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
001128
UDCT01.02GB
A:5
Foreword
Safety
Preventive maintenance
Complete machine
Engine
Transmission
Driveline/Axle
Brakes
Steering
Suspension
Load handling
Control system
10
Common hydraulics
11
Common electrics
12
Common pneumatics
Error codes
Error code information is found in the Workshop manual and Operator's manual.
Diagrams
Wiring diagrams and hydraulic diagrams are found in the Workshop manual.
Technical data
UDCT01.02GB
A:6
000264
Product alternatives
UDCT01.02GB
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.
UDCT01.02GB
A:8
4:10
4 Bromsar Parkeringsbromssystem
4.5 Parkeringsbromssy
Parkeringsbromssys
stem
tem, funktionsbeskrivning
12
1
2
11
D790-2
D790-1
D797-1
3
D
4
C
ACK M
10
7
Pa
GHB
HB
P
T
5
6
P
1.
2.
3.
4.
Magnetventil parkeringsbroms
5.
6.
(Y642)
7.
Brytkontakt parkeringsbroms
8.
Ackumulatorer
9.
Ventilblock bromssystem
(S200)
10. Parkeringsbromsok
014684
(S107)
014645
2.
3.
4.
Component list
5.
UDCT01.02GB
6.
7.
8.
A:9
10
1.
2.
Electric force
3.
4.
Hydraulic force
5.
Hydraulic motor
6.
7.
8.
Electric motor
9.
Accumulator
11
12. Radiator
12
13. Bulb
14. Control system, two control units with CAN-bus
D790-1
13
15. Restriction
14
D797-F
15
16
17
18
19
21
23 Pa
20 C
22
Pa
24
25
26
27
28
29
014726
UDCT01.02GB
A:10
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
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.
UDCT01.02GB
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: .................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
UDCT01.02GB
A:12
UDCT01.02GB
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
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under machine ............................................................................. B:9
Lifting heavy components .......................................................................... B:9
Vibrations ................................................................................................... B:9
Noise .........................................................................................................B:11
Solvents ....................................................................................................B:11
Fire and explosion risks............................................................................ B:12
Fluid or gas under pressure ..................................................................... B:14
Coolant ..................................................................................................... B:15
Refrigerant ............................................................................................... B:15
Air pollution .............................................................................................. B:16
Tensioned springs .................................................................................... B:17
Electric motors ......................................................................................... B:17
Rotating components and tools................................................................ B:17
Tyres and rims.......................................................................................... B:18
Lifting equipment ...................................................................................... B:18
Spare parts............................................................................................... B:19
Non-ionised radiation ............................................................................... B:19
Environment.................................................................................................. B:21
General .................................................................................................... B:21
UDCT01.02GB
B:2
UDCT01.02GB
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:
UDCT01.02GB
B:4
Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
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.
Engine off.
009797
UDCT01.02GB
B:5
Turn the start key to position 0 and turn off the system voltage.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
014618
After the work has been finished, close the drain valve and
tighten the lock ring.
UDCT01.02GB
B:6
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to fine filter hydraulic oil.
014620
Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
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.
UDCT01.02GB
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.
UDCT01.02GB
B:8
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.
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.
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
UDCT01.02GB
Move the battery disconnector to position zero and remove the key.
Do not work with drive wheels on the machine's both sides at the
same time.
B:9
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
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:
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.
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.
Maintenance Manual DCT 8090
UDCT01.02GB
B:10
Safety actions
UDCT01.02GB
Vary work position and grip so that the body is not stressed in only
one position by the vibrations.
B:11
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.
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
UDCT01.02GB
B:12
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.
UDCT01.02GB
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.
UDCT01.02GB
B:14
Risks
Risk of damage/injuries in connection with work on:
Fuel system.
Changing tyres.
Cooling system.
Safety actions
UDCT01.02GB
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.
First open the cooling system's cap for the filling point, to release
the high pressure. Hot steam and coolant may otherwise jet out.
B:15
Coolant
The coolant in the machines 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
First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
Refrigerant
Refrigerant is used in the machines 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
UDCT01.02GB
B:16
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:
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.
Safety actions
UDCT01.02GB
B:17
Tensioned springs
Examples of tensioned springs:
1.
2.
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
Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the machines 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.
Cooling fan
Drive belts
Propeller shafts
Drills
Grinding machines
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.
UDCT01.02GB
B:18
Safety actions
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
Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regards
to securing the mast, carriage and attachment.
Get into the habit of always keeping the carriage lowered to the lowest
position when working on the machine.
Risks
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 nature of the
work requires the carriage to be raised, it must be secured in some way.
UDCT01.02GB
B:19
Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
Brake valve
Drive axle
Steering axle
Steering cylinder
Rim
Mast, carriage
Lifting chains
Lift cylinder
Tilt cylinder
Twistlock
Emergency stop
Accumulator
Non-ionised radiation
WARNING
Extra equipment such as two-way radio, telephone, etc.,
may emit non-ionised radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, telephone, etc., when no persons
with active or non-active medical products are nearby.
UDCT01.02GB
B:20
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.
UDCT01.02GB
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.
UDCT01.02GB
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.
UDCT01.02GB
C:1
C Preventive maintenance
UDCT01.02GB
C:2
UDCT01.02GB
C:3
C Preventive maintenance
Preventive maintenance, general
Its 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.
UDCT01.02GB
C:4
Completed maintenance
Operating
hours
Actions
50h
50h-check
250h
250h service
500h
500h service
750h
250h service
1000h
1000 service
1250h
250h service
1500h
500h service
1750h
250h service
2000h
2000h service
2250h
250h service
2500h
500h service
2750h
250h service
3000h
1000 service
3250h
250h service
3500h
500h service
3750h
250h service
4000h
2000h service
4250h
250h service
4500h
500h service
4750h
250h service
5000h
1000 service
5250h
250h service
5500h
500h service
5750h
250h service
6000h
2000h service
6250h
250h service
6500h
500h service
6750h
250h service
7000h
1000 service
7250h
250h service
7500h
500h service
7750h
250h service
8000h
2000h service
8250h
250h service
8500h
500h service
8750h
250h service
UDCT01.02GB
Operating
hours
Date
Signature
C:5
Completed maintenance
Operating
hours
Actions
9000h
1000 service
9250h
250h service
9500h
500h service
9750h
250h service
10000h
2000h service
Operating
hours
Date
Signature
UDCT01.02GB
C:6
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
Oil pressure
2 Transmission
Leakage check
Oil level, check
3 Driveline/Axle
Mounting propeller shaft, check-tightening
4 Brakes
Leakage check
Power-assisted brake, function check
5 Steering
No action
6 Suspension
Tyres and rims, check
7 Load handling
Hose connections, check-tightening
Bolted joints, check-tightening
Mast wheel and slide plates, function check
Slide plates and support rollers, function check
Sensors
Attachment
UDCT01.02GB
C:7
8 Control system
Check that there are no active error codes
10 Common hydraulics
Leakage check, check-tightening as required
Hydraulic oil level, check
11 Common electrics
Batteries, check
UDCT01.02GB
C:8
Service schedule
Service shall be performed every 500 operating hours. Actions are
divided into 250h, 500h, 1000h and 2000h service.
Actions for 250h service are performed between 500h and 1000h
service, which means at 250h, 750h, 1250h, etc.
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
250 h,
750 h,
1,250
h, etc.
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
Comment
Reference
Section B Safety
0 complete machine
Checking
cleanliness and
leakage
Visual check in
connection with greasing.
Lubrication 1000
hours
Checking for
cracks
C*
C*
Lubrication 500
hours
Clean if necessary.
Performance and
exhaust smoke,
check
Fuel tank
UDCT01.02GB
Object, action
Fuel prefilter
Service
250 h,
750 h,
1,250
h, etc.
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C:9
Comment
Reference
Incl. draining of
condensation water.
Shall be done every 50
hours.
C/R
C/R
C/R
Checking indicators,
change when indicated.
C/R
C/R
Turbo
Exhaust system
Intercooler
External cleaning.
Fuel filter
Radiator
NOTE
Do not use high
pressure wash.
Drive belt
C/R
C/R
C/R
C/R
Coolant, freezing
point
Bolted joints,
attachments,
mountings, etc.
Coolant level
Connector
Checks and
check-tightening
Exhaust system
Sealing check.
Sealing check.
Engine oil
Clean if necessary.
Fuel tank
UDCT01.02GB
C:10
Object, action
Service
250 h,
750 h,
1,250
h, etc.
Fuel prefilter
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C/R
C/R
Comment
Reference
Incl. draining of
condensation water.
Shall be done every 50
hours.
C/R
C/R
C/R
Checking indicators,
change when indicated.
C/R
C/R
Radiator
NOTE
Do not use high
pressure wash.
Drive belts
C/R
Drive belt
tensioner
C/R
C/R
C/R
C/R
Level check.
The coolant should be
changed after 2000h
and the cooling system
checked/cleaned during
the change.
Coolant quality,
checking
Bolted joints,
attachments,
mountings, etc.
Valve clearance
Valve clearance
checked/adjusted after
5000h / every 4th year.
Clean if necessary
Vibration damper,
rubber
2 Transmission
Breather filter
UDCT01.02GB
Object, action
Service
250 h,
750 h,
1,250
h, etc.
500h,
1500h,
2500h,
etc.
Transmission oil
filter
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
C:11
Comment
Reference
Drive axle
Mounting drive
axle
Section 3 Driveline/Axle,
group 3.3 Drive axle
3 Driveline/Axle
Propeller shaft
Section 3 Driveline/Axle,
group 3.2 Propeller shaft
Section 3 Driveline/Axle,
group 3.3 Drive axle
Section 3 Driveline/Axle,
group 3.3 Drive axle
4 Brakes
Brake pedal
Hydraulic oil
pump brakes and
steering
Accumulator
C/R
C/R
C/R
C/L
C/L
C/L
Check bearings.
Parking brake
5 Steering
Link arms
6 Suspension
Wheel spindle,
check
Wheel hub
steering axle,
check
Tyres and rims
Wheel nuts
Rim
Check-tightening.
C*
7 Load handling
UDCT01.02GB
C:12
Object, action
Service
250 h,
750 h,
1,250
h, etc.
500h,
1500h,
2500h,
etc.
Comment
Reference
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
Slide plates in
trolley
Attachment
Slide plates
spreader beam
Slide plates
spreader beam
Lifting chains
Mast suspension
Slide plates mast
Tilt cylinder
Twistlocks
C/R
8 Control system
Service indicator,
reset
Checking function.
Air conditioning
Checking function.
Dependent on external
environment, at latest
every 500 h.
unit
Condenser
NOTE
Do not use high
pressure wash.
C/R
C/R
C/R
Windshield wipers
Lighting and
audible signals
Moisture filter
UDCT01.02GB
Checking, change if
indication is grey.
Incl. washer, top up when
needed.
Object, action
Service
250 h,
750 h,
1,250
h, etc.
Comment
Reference
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
Roof window
Cab frame
Cab undercarriage
Check mountings,
isolators and bolted
joints.
Frame
Check occurrence of
any deformation and rust
damage as well as cracks
in welded joints.
Doors
500h,
1500h,
2500h,
etc.
Counterweights
C:13
Paint/coatings
Safety decals
10 Common hydraulics
Cooler hydraulic
oil
NOTE
Do not use high
pressure wash.
Breather filter
hydraulic oil tank
Hydraulic oil
C/R
Change at indication.
Section 10 Common
hydraulics, group 10.6.6
Breather filter hydraulic oil
tank
Section 10 Common
hydraulics, group 10.6.7
Hydraulic oil filter
Section 10 Common
hydraulics, group 10.6.8
Hydraulic oil
UDCT01.02GB
C:14
Object, action
Service
250 h,
750 h,
1,250
h, etc.
Comment
Reference
500h,
1500h,
2500h,
etc.
1000h,
3000h,
5000h
etc.
2000h,
4000h,
6000h
etc.
Fuses
Batteries
Battery cable
Position sensors
Section 10 Common
hydraulics, group 10.6.9
Fine filter hydraulic oil
11 Common electrics
Test-run
After test-run
Instruments
Brakes
Gearshifting
Steering
Any noise
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.
UDCT01.02GB
C:15
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Points lubricated by the central lubrication are
indicated by *.
7
6
9
10
10
4
5
9
6
2-3
2-3
Pos.
Lubrication points
Reference
10
UDCT01.02GB
015014
C:16
Wheel hub
4
Lift the right steering wheel with a jack (40 ton) so that wheel
bearing and wheel spindle are unloaded, do not lift so high that
the wheel hangs freely.
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
009125
Wheel spindle
6
NOTE
It is important that both upper and lower bearings are greased
separately since grease is not pressed between the bearings.
NOTE
On machines with central lubrication, check that the lubrication
reaches the actual lubrication points, see section 9 Frame,
body, cab and accessories, group 9.14 Central lubrication.
009126
2.
Link arms
Lubricate both link arms' outer and inner bearings with grease.
NOTE
On machines with central lubrication, check that the lubrication
reaches the actual lubrication points, see section 9 Frame,
body, cab and accessories, group 9.14 Central lubrication.
Lower the wheel.
009127
Inner bearing
2.
Outer bearing
UDCT01.02GB
C:17
Brake pedal
10 Lubricate the brake pedal's hinge with grease.
11 Wipe off excess grease.
NOTE
Do not lift the door off the hinges.
13 Let the door down and wipe off excess grease.
14 Repeat steps 12-13 on the right-hand door.
15 Lift the battery cover slightly and lubricate the hinges with
lubricating grease.
NOTE
2
1.
Hinge, door
2.
014040
UDCT01.02GB
C:18
Mast
20 Lubricate the chain wheel, mast wheel, slide plates and the slide
plates' contact surfaces with lubricating grease, see section F
Technical data. For lowered lubrication points, lubricate the mast
wheel and the chain wheel down on the mast
.
21 Brush or spray the chains with chain oil. Make sure that the chains
are well lubricated.
009130
Chain wheel
2.
Mast wheel
3.
Slide plates.
Tilt cylinder
22 Grease the tilt cylinder axles with lubricating grease.
NOTE
009128
UDCT01.02GB
C:19
Turn off the engine and turn off the main electric power.
IMPORTANT
On machines with central lubrication, check that the
central lubrication's lubrication points are lubricated,
see section 9 Frame, body, cab and accessories, group
9.14 Central lubrication.
Points lubricated by the central lubrication are
indicated by *.
4-8
1
1
2
015013
Pos.
Lubrication points
Reference
UDCT01.02GB
C:20
Universal joint
5
Trolley
6
013493
Mast wheel
UDCT01.02GB
C:21
Attachment
9
014714
3
Lubrication points for side lift attachment with twistlock
1.
2.
Contact pins
3.
4.
UDCT01.02GB
C:22
13
On machines with central lubrication, check the grease levels in
the pump units on the frame and attachment.
Top up with lubricating grease if the grease levels in the reservoirs
are below the middle.
Filling takes place through the grease nipples on the pump units.
NOTE
If grease has penetrated out from the safety valve, it means
there is a stop in the system, this means that no points are
greased, see section 9 Frame, body, cab and accessories,
group 9.14 Central lubrication.
Electric connectors
14 Grease electric connectors with electric connector grease. Check
that damp does not enter the connectors.
Filling point
2.
Safety valve
DANGER
Risk of dropped load.
FATAL DANGER!
Never use a machine with structural damage to the
mast and attachment.
DANGER
Welds in areas of high stress concentration must be
checked in accordance with recommended intervals.
The interval is calculated according to the machine
being used for normal handling and on a level, smooth
ground surface. For other handling or, e. g., rough
surface, the interval should be shortened.
If the welds show signs of cracking, take the machine
out of operation immediately and contact Cargotec
Support.
UDCT01.02GB
Turn off the engine and turn off the system voltage.
C:23
Check for damage and cracks in the areas with high stress
concentration, see Check points, page C:24. Check the whole
length of every weld.
When uncertain, welds can be tested with magnetic powder and
even penetrating fluid as follows:
a.
b.
005375
Rim
Method:
Alternating current AC
Contrast colour
Checking medium:
a
Wet
Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
005376
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4
Rim
001705
Examples of cracks
1.
Linear crack
2.
Pointed crack
UDCT01.02GB
C:24
Check points
1
3
4
5
2
6
7
009660
8
9
Pos.
Check point
Reference
Mast
Mast mount
Twistlocks
Trolley
UDCT01.02GB
C:25
Check the steering axle mounts in the frame and the steering axle
a.
b.
009663
009662
009664
UDCT01.02GB
C:26
Mast
Check the horizontal support beams in the mast.
Check the welds between the horizontal and the vertical mast
beam.
009667
009666
009672
015528
UDCT01.02GB
C:27
Mast mount
015104
009670
014735
UDCT01.02GB
C:28
Trolley
13 a.
b.
013622
Trolley
a
Wheel pins
009661
UDCT01.02GB
0:1
0 Complete machine
UDCT01.02GB
0:2
UDCT01.02GB
0:3
0 Complete machine
Complete machine, description
Kalmar DCT 80-90 is a forklift truck for empty container handling. The
machine has a lifting capacity of 8-9 tonnes depending on version.
The engine is a straight six-cylinder, four-stroke, turbocharged
low-emission diesel engine with a unit injector, air-to-air intercooler
and electronically controlled fuel injection.
The wheels are mounted on the hubs with studs and nuts. The drive
axle has twin wheels, the steering axle has single wheels.
1.
Steering axle
2.
Engine
3.
Frame
4.
Drive axle
5.
Mast
6.
7.
Cab
014183
Side shift is moving the side lift attachment laterally along the
trolley.
Tilt is for angling the load in the longitudinal direction of the truck
using the mast.
Load carrying is the locking of the load to the side lift attachment.
UDCT01.02GB
0:4
UDCT01.02GB
1:1
1 Engine
Contents 1 Engine
1
Engine..................................................................................................................1:3
1.2
Fuel system......................................................................................................1:9
1.2.1
Fuel tank ...................................................................................................1:10
1.2.3
Fuel prefilter .............................................................................................. 1:11
1.2.4
Fuel filter ...................................................................................................1:15
1.5
Engine's mechanical parts .............................................................................1:17
1.5.4
Valve mechanism ......................................................................................1:17
1.5.6
Crank mechanism .....................................................................................1:21
1.6
Air intake and exhaust outlet..........................................................................1:22
1.6.1
Air cleaning system ...................................................................................1:22
1.6.2
Turbo .........................................................................................................1:24
1.6.3
Exhaust system .........................................................................................1:25
1.6.4
Intercooler .................................................................................................1:26
1.7
Cooling system ..............................................................................................1:27
1.7.4
Radiator and expansion tank ....................................................................1:27
1.7.5
Cooling fan ................................................................................................1:28
1.7.7
Coolant ......................................................................................................1:34
1.8
Lubrication system .........................................................................................1:39
1.9
Control system engine ...................................................................................1:43
1.10
Ignition/heating...............................................................................................1:44
1.11
Start/stop........................................................................................................1:45
UDCT01.02GB
1:2
UDCT01.02GB
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 governing emission
standards. The following engine alternatives are available:
Yuchai YC6A240-30
Cummings QSB6.7
C
.
0
P
bar
I
II
III
D790-2
D795
D790-1
13
D797-1
4
D794
12
11
SENSORS
H2O
H2O
10
015049
1.
Ignition (S150)
8.
2.
9.
3.
4.
5.
6.
7.
UDCT01.02GB
1:4
1 Engine Engine
3
4
14
13
12
8
9
014622
11
10
Engine alternative Yuchai YC6A240-30, left side (in the machine's travel direction)
1.
2.
Expansion tank
3.
Thermostat housing
4.
5.
Coolant pump
6.
7.
UDCT01.02GB
8.
9.
Oil filter
1 Engine Engine
1:5
1
2
3
4
5
10
014641
9
6
Engine alternative Yuchai YC6A240-30, right side (in the machine's travel direction)
1.
6.
2.
Connection intercooler
7.
Fuel filter
3.
8.
Connection intercooler
4.
9.
Fuel pump
5.
Dipstick engine
10. Alternator
UDCT01.02GB
1:6
1 Engine Engine
rpm
kph
0
I
bar
II
III
8 <
D
3
D794
D790-1
12
D790-2
D797-1
D795
13
D
D
H2O
SENSORS
10
11
015050
6
1.
Ignition (S150)
8.
2.
9.
3.
4.
5.
Starter relay
6.
7.
Engine sensor
UDCT01.02GB
1 Engine Engine
1:7
10
015097
8
9
Engine alternative Cummins QSB6.7, left side (in the machine's direction of travel)
1.
Dipstick engine
6.
2.
7.
Intake coolant
3.
8.
Oil filter
4.
9.
Starter motor
5.
Alternator
UDCT01.02GB
1:8
1 Engine Engine
6
5
4
3
2
1
14
13
12
7
8
9
015096
11
10
Engine alternative Cummins QSB6.7, right side (in the machine's direction of travel)
1.
Alternator
8.
Air intake
2.
9.
3.
4.
5.
Dipstick engine
6.
7.
Fuel filter
UDCT01.02GB
1:9
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel may be corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
The fuel system must be bled, e.g., if the fuel tank has been run dry
or after long periods of operation.
1 Machine in service position, see section B Safety.
2
Pump with the hand pump until the flowing fuel is free from air.
NOTE
If only the fuel filter is changed, no further bleeding is necessary.
1.
Hand pump
2.
Wipe off the fuel pre-filter and remove the collection container.
UDCT01.02GB
1:10
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
Machine in service position, see section B Safety.
Tighten the bleed screw and close the fuel hand pump.
015541
Hand pump
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
2
1
Rinse the fuel tank clean through the fuel filler hole.
013534
1.
Fuel filler
2.
Fuel tank
3.
4.
Battery hatch
UDCT01.02GB
1:11
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
NOTE
The fuel pre-filter should be drained of water every 50 operating
hours.
1
014134
UDCT01.02GB
1:12
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
NOTE
Do not over-tighten the drain cock, as the threads may be
damaged.
Close the drain cock by pushing the valve up and tightening it
by hand. Bleed the fuel system, see Fuel system, bleeding air
015539
UDCT01.02GB
), page 1:10.
Wipe off the fuel pre-filter and remove the collection container.
1:13
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1
015012
CAUTION
Fuel prefilter
Lubricate the O-ring on the new fuel filter with engine oil.
UDCT01.02GB
1:14
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1
Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush a small amount of oil onto the gasket.
015540
Fuel prefilter
UDCT01.02GB
), page 1:10.
1:15
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1
Lubricate the O-ring on the new fuel filter with engine oil.
CAUTION
The fuel system is sensitive to impurities.
Risk of product damage.
Only use new fuel from a clean container to reduce the
risk of impurities in the fuel system.
6
01501 1
Fuel filter
Wipe off the fuel filter and remove the collection container.
Turn on the system voltage and start the engine. Check that the
fuel filter seals tight.
UDCT01.02GB
1:16
NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1
NOTE
Do not fill the new fuel filter with fuel before installing. There is
a risk that impurities might get into the fuel system and cause
malfunctions or damage.
015529
Fuel filter
UDCT01.02GB
When needed, bleed the fuel system, see Fuel system, bleeding
), page 1:10.
1:17
NOTE
Coolant temperature must be below 60 C.
Removing
Machine in service position, see section B Safety.
Release the injectors' drain hose from the rear section of the
rocker cover.
Remove the screws that attach the drain hose to the rocker cover.
008025
NOTE
It might be necessary to bend the ventilation hose carefully to
pry it from the valve cover.
7
NOTE
008026
Check that the gasket does not show signs of damage against the
sealing surface. Replace the gasket if it is damaged or if it has
been removed from its groove in the rocker cover.
NOTE
008027
Check the valve cover gasket when it is still sitting in the valve
cover. When the gasket has been removed from the valve
cover, it must be replaced.
UDCT01.02GB
1:18
008029
2. Then push the rest of the gasket down into the valve cover.
008028
Adjusting
11 Use special tool, part number 3824591 to rotate the crankshaft
until cylinder no. 1 is located in the top dead centre (T.D.C.).
The top dead centre (T.D.C.) can be determined by the following
method:
NOTE
008030
The indicator for the top dead centre (T.D.C.) is on the vibration
damper/crankshaft speed indicator.
1.
2.
If the valve lifters for cylinder 1 are not loose, rotate the
crankshaft 360 degrees.
3.
If the valve lifters for cylinder 1 are loose, continue with the
next step.
NOTE
008031
UDCT01.02GB
1:19
008032
MAX
Intake valves
0,152 mm
0,381 mm
Outlet valves
0,381 mm
0,762 mm
008033
NOTE
Valve clearance checks are usually performed as a part of
troubleshooting, and adjustments are normally not necessary
during inspection as long as the valve clearance lies between
the tolerance figures listed above.
NOTE
The valve clearance is correct when the feeler gauge can be
moved forward and backward between the top side of the push
rod and the seat of the valve lifter with only a slight resistance.
14 Measure the valve clearance by placing a feeler gauge, with a
thickness corresponding to the valve clearance to be adjusted,
between the top side of the push rod and the seat of the valve
lifter. If the valve clearance does not correspond, loosen the lock
nut and adjust the valve clearance to the correct value.
008034
Valve clearance
Intake valves
0.254 mm
Outlet valves
0.508 mm
Tighten the lock nut and check the measurement of the valve
clearance again. Torque tighten to 24 Nm.
UDCT01.02GB
1:20
15 Use special tool, part number 3824591, and rotate the crankshaft
360 degrees.
Follow the same steps and specifications as above and measure
the clearance for the following valves:
(E=exhaust valves, I=intake valves)
008030
Installing
16 Reinstall the valve cover.
Reinstall the insulators and mounting screws.
008026
008035
UDCT01.02GB
1:21
Check the rubber part for signs of wear. If any rubber pieces are
missing or if the surface of the rubber is more than 3.18 mm below
the metal surface, replace the vibration damper.
008036
008037
UDCT01.02GB
1:22
2
3
008040
1.
Dust reservoir
2.
Air cleaner
3.
UDCT01.02GB
1:23
NOTE
The filter cartridge should be changed, not cleaned.
8
Check that the hoses from the air filter housing (and other parts)
are intact and sealed.
UDCT01.02GB
1:24
1 Engine Turbo
1.6.2 Turbo
Turbo, check (engine alternative Yuchai YC6A240-30)
1
Check that the impeller rotates freely and that the axial clearance
is max. 1 mm.
In case of deviations, replace or overhaul the turbocharger.
UDCT01.02GB
1:25
WARNING
Hot exhaust system!
Risk of burn injuries.
Never touch the turbo, exhaust pipe, silencer or
catalytic converters when the machine is in operation
or has recently been switched off!
014700
1.
End-pipe
2.
Silencer
3.
Exhaust pipe
UDCT01.02GB
1:26
1 Engine Intercooler
1.6.4 Intercooler
Intercooler, checking
1
NOTE
2
4
Check the sealing and check that the intercooler's hoses and
clamps are in good condition.
014686
1.
Intercooler
2.
3.
Radiator
4.
Condenser AC
007962
Check that there is no oil in the charge-air pipes. If the pipes have
oil on the inside, this indicates leakage by the turbo's turbine shaft
seal. Then replace the whole turbocharger.
NOTE
If there is oil in the intercooler hoses, very carefully clean the
intercooler and all pipes and hoses in the intercooler system on
the inside before the engine is started.
UDCT01.02GB
1:27
NOTE
Do not use high pressure wash.
1
3
2
4
014686
1.
Intercooler
2.
3.
Radiator
4.
Condenser AC
UDCT01.02GB
1:28
Warm up the machine. Check after operating when the belts are
warm.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
008011
Warm up the machine. Check after operating when the belts are
warm.
IMPORTANT
Always change a drive belt that looks to be worn or
has cracks.
008011
NOTE
The belt tensioners are automatic.
5
UDCT01.02GB
1:29
1.
Tensioning screw
2.
Lock nut
UDCT01.02GB
1:30
Change the drive belt when required. Check that the belt is
aligned correctly in the grooves.
Tighten the drive belt and tighten the attaching bolts to a torque
of 20-30 Nm. It should be possible to press down the drive belt
10-15 mm at a pressure of 40-50 N, measured between the water
pump and alternator.
10 Position the fan belts in the grooves for the pulleys, change if
necessary.
11 Tension the fan belts and tighten the belt tensioner's lock nut. It
should be possible to press down the fan belts 10-15 mm at a
pressure of 40-50 N, measured between the drive belts.
1.
Tensioning screw
2.
Lock nut
UDCT01.02GB
1:31
NOTE
The belt tensioner is tensioned in the direction that the spring is
bent over the tensioner arm. To reduce the tension in the belt,
rotate the belt tensioner in order to tighten the spring more firmly.
008013
CAUTION
Do not use excessive force in either the winding
direction or in the opposite direction after the tensioner
has been wound to its positive stop. Continued winding
can cause the tensioner arm to break.
4
Lift up the belt tensioner and fit the drive belt. If it is difficult to fit
the drive belt (the belt seems too short), first place the belt in the
grooved belt pulley. Then continue to hold up the belt tensioner
and pry the belt over the coolant pump's belt pulley.
Loosen the belt tensioner and check that the belt is sitting correctly
in the grooves and is correctly tensioned.
UDCT01.02GB
1:32
Check that neither the lower nor the upper tension lever stop is
touching the cast stop lugs on the belt tensioner's housing. If any
tension lever stop is touching a stop lug then the drive belt must
be replaced. Check to ensure that the correct drive belt is used.
Check that there are no cracks on the drive belt tensioner's wheels
or levers.
008014
If there are cracks then the belt tensioner must be replaced. See
engine supplier documentation.
4
Check that deposits of dirt have not built up on the drive belt
tensioner.
008015
If they have, the drive belt tensioner must be removed and steam
cleaned.
Check that the lower tension lever stop is in contact with the lower
stop lug for the tension lever on the belt tensioner housing.
008016
If these two are not in contact with each other, the drive belt
tensioner must be replaced.
UDCT01.02GB
1:33
Check the drive belt tensioner for signs of wear and damage
between the tension wheel and the radius of the tension lever.
008017
If there are signs that these two surfaces are rubbing against
each other, then the centre bearing is worn out and the drive belt
tensioner must be replaced.
NOTE
The pulleys may not be more than 3 degrees out of alignment.
Install the drive belt.
008018
), page 1:31.
NOTE
008019
UDCT01.02GB
1:34
1 Engine Coolant
1.7.7 Coolant
Coolant level, check
WARNING
NOTE
014191
If the coolant level becomes too low, the warning light for low coolant
level (position 40) lights up on the instrument panel.
Filling point
NOTE
Sight glass
A low coolant level may cause engine damage or may cause the
engine to stop.
1
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.
4
UDCT01.02GB
1 Engine Coolant
1:35
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.
IMPORTANT
Only use testing equipment that is appropriate for the
type of coolant used in the machine. Coolant type
differs depending on engine alternative.
B
4
014191
), page 1:37.
C
A
Filling point
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
1
UDCT01.02GB
1:36
1 Engine Coolant
014698
Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.
Connect a hose to the drain cock on the engine and route the
other end into the container.
When all the coolant has run out, close the drain taps.
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.
B
10 Turn on the system voltage and start the engine.
11 Set the cab heat to max.
12 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system. Do not operate the machine.
014191
C
A
Filling point
UDCT01.02GB
1 Engine Coolant
1:37
NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
1
014698
Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.
When all the coolant has run out, close the drain taps.
015538
UDCT01.02GB
1:38
1 Engine Coolant
CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
B
9
014191
C
1.
2.
Filling point
3.
UDCT01.02GB
1:39
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1
Remove the drain plug from the engine and drain the engine of oil.
Fit the drain plug when the oil has drained. Tighten with torque
of 27-34 Nm.
NOTE
014696
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
8
Fill engine oil. For volume and quality, see section F F Technical
data.
10 Turn off the engine and check the oil level, see Oil level, check
(engine alternative Yuchai YC6A240-30), page 1:41. Top up as
needed.
11 Close the hood.
UDCT01.02GB
1:40
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1
Remove the drain plug from the engine and drain the engine of oil.
Check that the contact face on the filter bracket is clean and that
no gasket remains from the old filter.
Spin on the filter by hand until the rubber gasket just touches the
contact face on the filter bracket.
Then turn another full turn, not more.
When the oil has drained install the oil plug with a new gasket.
Torque tighten to max. 80 Nm.
015537
NOTE
Oil filter
Do not tighten the oil plug with higher tightening torque, the
threads will be damaged.
10 Fill engine oil. For volume and quality, see section F F Technical
data.
11 Start the engine, let it idle. Check that the oil pressure is normal.
12 Turn off the engine and check the oil level, see Oil level, check
(engine alternative Cummins QSB6.7
as needed.
13 Close the hood.
UDCT01.02GB
1:41
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The engine oil filling pipe (position B) and dipstick (position A) are
under the service hatch in front of the cab.
1 Machine in service position, see section B Safety.
Check the oil level when the engine has been warmed up. The
oil dipstick has two markings, MAX and MIN, between which the
oil level should be.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
3
Fill engine oil (position B) if needed (for volume and grade, see
section F Technical data).
014192
NOTE
Dipstick
Filling point
UDCT01.02GB
1:42
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Check the oil level when the engine has been warmed up. The
oil dipstick has two markings, MAX and MIN, between which the
oil level should be.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
3
Fill engine oil (position B) if needed (for volume and grade, see
section F Technical data).
NOTE
015095
Dipstick
Filling point
UDCT01.02GB
1:43
UDCT01.02GB
1:44
1 Engine Ignition/heating
1.10 Ignition/heating
Ignition/heating, description (engine alternative
Yuchai YC6A240-30)
The engine features preheating of the induction air, for faster start
at low temperatures. Preheating is activated by Control unit engine
(D794) as needed. The indicator light for preheating is on when
preheating is activated.
For position of components see, see Engine alternative Yuchai
YC6A240-30, component location, page 1:4.
UDCT01.02GB
, page 1:7.
1 Engine Start/stop
1:45
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). The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, frame (D797-1). Engine shutdown is controlled by the Control
unit, engine (D794) that cuts off the fuel supply to the engine.
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 turns off automatically after 3-30 minutes
(depending on customer setting) if the machine is at a standstill and
idling.
For position of components, see Engine alternative Yuchai
YC6A240-30, component location, page 1:4 or Engine alternative
Cummins QSB6.7, component location
, page 1:7.
UDCT01.02GB
1:46
UDCT01.02GB
2:1
2 Transmission
Contents 2 Transmission
2
2.2
2.3
2.6
2.7
2.8
Transmission ......................................................................................................2:3
Torque converter/Clutch system ......................................................................2:6
Mechanical transmission..................................................................................2:7
Lubrication system ...........................................................................................2:8
Cooling system .............................................................................................. 2:11
Control system transmission..........................................................................2:12
UDCT01.02GB
2:2
UDCT01.02GB
2 Transmission Transmission
2:3
2 Transmission
Transmission, function description
The transmission transfers the engine power to the drive wheels (drive
axle) via the propeller shaft and also drive the hydraulic oil pumps for
the hydraulic system and the brake system.
The transmission is fully automatic with torque converter. It has three
forward gears and three reverse gears.
The torque converter and transmission work together via a common
hydraulic system. The torque converter is a hydraulic clutch placed
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.
Gear positions are selected by pressurising of clutches by solenoid
valves controlled by Control unit transmission (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.
UDCT01.02GB
2:4
2 Transmission Transmission
2
F
R
4
D 7 9 0 -2
D 7 9 0 -1
D 793
D 794
D 795
D 7 9 7 -1
20
19
21
18
12
13
14
16
15
17
11
10
9
014687
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
UDCT01.02GB
2 Transmission Transmission
2:5
15
16
14
13
17
12
11
10
014685
7
8
1.
2.
3.
4.
5.
6.
15. Thermostat
7.
8.
9.
UDCT01.02GB
2:6
11
6
10
7
8
1.
7.
2.
8.
3.
9.
4.
5.
6.
014694
014692
UDCT01.02GB
2:7
UDCT01.02GB
2:8
1
2
014686
1.
Intercooler
2.
3.
Radiator engine
4.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
NOTE
Do not over-fill the transmission!
1
Remove the drain plug (position 2) and allow the oil drain into
the receptacle.
When the transmission oil has flowed out, refit the suction strainer
(position 3) and the drain plug (position 2).
2
3
1.
2.
Oil plug
3.
Suction strainer
UDCT01.02GB
014693
Make sure that the washer for the drain plug is included.
7
Remove the filter holder (position 1) and change the oil filter.
Tighten to contact and then another two-thirds turn.
2:9
Fill new transmission oil through the oil filler point (position B) to
the marking for low level on the dipstick (position A).
For volume and quality, see section F F Technical data.
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.
014193
11 Check the transmission oil level with the engine running at idle and
top up to the marking for low level.
a
000356
13 Check the oil level. Fill to the MAX mark for oil level.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
The transmission's oil filler pipe and oil dipstick are located under the
hood in front of the cab.
UDCT01.02GB
2:10
Check the oil level with the engine idling, the transmission in
neutral, and at operating temperature (approx. 85 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
014193
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means risk
of transmission damage.
UDCT01.02GB
2:11
UDCT01.02GB
2:12
Mode Limp-Home
For certain malfunctions, the control unit activates "Limp-Home". In
this mode the transmission is shifted to neutral position. To be able to
continue operation, travel direction must be selected again with the
gear selector.
In this mode the operator can use the transmission's two first gears in
each direction. If the malfunction occurs in a higher gear, the operator
has to downshift manually to first or second gear to continue.
Mode Shut-Down
For serious malfunctions, the control unit activates "Shut-Down". In
this mode the transmission is locked in neutral, no solenoid valves
are activated.
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
UDCT01.02GB
3:1
3 Driveline/Axle
Contents 3 Driveline/Axle
3
3.2
3.3
Driveline/Axle......................................................................................................3:3
Propeller shaft..................................................................................................3:3
Drive axle .........................................................................................................3:4
UDCT01.02GB
3:2
UDCT01.02GB
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.
005193
The propeller shaft transmits the engine power from the transmission
to the drive axle.
After 50h:
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission to 98 Nm (oiled bolt).
After 500h:
Clean.
Check clearance in universal joints.
After 1000h:
Grease universal joints with universal grease EP2.
Check-tighten the retaining bolts at the mountings for the drive
axle and transmission to 98 Nm (oiled bolt).
UDCT01.02GB
3:4
10
9
8
004336
1.
Hub reduction
2.
Wheel brake
3.
4.
5.
6.
Differential (internal)
7.
8.
Filling point and level check drive axle oil hub reduction
9.
Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.
Check the oil level in drive axle and the hub reductions.
008046
UDCT01.02GB
3:5
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.
015100
Wheel 2: lift the wheel from the ground (raise the machine under
the mast) and rotate the wheel into the correct position. Lower
the machine.
2.
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.
004337
NOTE
Check that the seals are intact, clean and in the correct position.
1.
2.
3.
Fill oil in the hubs until the oil level is flush with the filling and
level holes (position 2). 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.
015100
1.
2.
NOTE
Check that the seals are intact, clean and in the correct position.
UDCT01.02GB
3:6
10 Fill oil in the differential until the oil level is flush with the filler and
level hole.
004337
NOTE
3
Differential drive axle
Check that the seal is intact, clean and in the correct position.
12 Remove the receptacle.
1.
2.
14 Check the oil level in the drive axle after a short test-drive.
3.
UDCT01.02GB
4:1
4 Brakes
Contents 4 Brakes
4
Brakes..................................................................................................................4:3
4.1
Controls and instruments .................................................................................4:3
4.1.1
Brake pedal .................................................................................................4:3
4.3
Power-assisted brake system ..........................................................................4:4
4.3.3
Accumulator charging valve ........................................................................4:6
4.3.4
Accumulator ................................................................................................4:7
4.3.9
Wheel brake ................................................................................................4:8
4.5
Parking brake system ......................................................................................4:9
4.5.4
Parking brake unit ..................................................................................... 4:11
UDCT01.02GB
4:2
UDCT01.02GB
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 two functions:
Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
Check that the brake pedal returns all the way and that the
clearance between the brake pedal and brake valve is 11.5 mm.
If needed, adjust the brake pedal's stop bolt so that the clearance
becomes correct.
Check that the rubber on the pedal is intact and that the tread
pattern isn't worn out. Change when needed.
UDCT01.02GB
4:4
12
D790-2
B
P
D797-1
10
8
Pa
11
D
13
2
C
9 Pa
ACK M
LB
P
7
6
B
1.
8.
2.
9.
3.
4.
Accumulators
5.
Brake valve
6.
Brake cylinder
7.
Wheel brakes
UDCT01.02GB
014644
4:5
12
11
10
1.
2.
3.
4.
5.
6.
9
7.
8.
9.
Accumulators
UDCT01.02GB
014647
4:6
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1
000475
014653
NOTE
014619
UDCT01.02GB
4 Brakes Accumulator
4:7
Remove the pressure gauge and fit the protective cap on the
pressure check connection.
015021
NOTE
014619
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).
Turn off the engine and turn the start key to position I.
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.
UDCT01.02GB
4:8
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Brake cylinder
1
Start the machine and push down the brake pedal, hold the pedal
down.
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.
UDCT01.02GB
Move the wrench and the hose and collection container and repeat
steps 2-5 on the other side.
4:9
12
1
2
11
D790-2
D790-1
D797-1
4
C
7
Pa
GHB
HB
ACK M
10
6
014645
P
1.
7.
2.
8.
Accumulators
3.
9.
4.
5.
6.
UDCT01.02GB
4:10
3
4
5
6
7
12
11
10
1.
7.
2.
8.
9.
3.
4.
5.
6.
UDCT01.02GB
10. Accumulators
11. Hydraulic oil pump brakes and steering
12. Control unit cab (D790-1)
014648
4:11
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
Turn off the engine and turn the start key to position I.
Check that the parking brake caliper can move on the bracket.
Check that the brake disc is clean from oil and dirt.
Turn back the adjusting screw so that the clearance between pad
and disc becomes 0.50.1 mm.
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.
UDCT01.02GB
4:12
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.
UDCT01.02GB
Loosen the adjusting screw so that the brake pads become loose.
Remove the split pin and loosen the nut on the attaching bolt
holding the parking brake caliper.
4:13
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
UDCT01.02GB
4:14
UDCT01.02GB
5:1
5 Steering
Contents 5 Steering
5
Steering ...............................................................................................................5:3
5.2
Power assisted system ....................................................................................5:3
5.2.6
Link arm ......................................................................................................5:4
UDCT01.02GB
5:2
UDCT01.02GB
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.
P
LS
L R
LSO
2
4
014654
1.
3.
Steering valve
2.
4.
Steering cylinder
UDCT01.02GB
5:4
014655
1.
2.
Steering valve
4.
3.
007918
Check the link arms' guide bearings, axles and the bolts that lock
the link arms' axles.
UDCT01.02GB
6:1
6 Suspension
Contents 6 Suspension
6
Suspension .........................................................................................................6:3
6.2
Suspension ......................................................................................................6:3
6.2.1
Steering axle cradle ....................................................................................6:3
6.2.2
Wheel spindle..............................................................................................6:4
6.2.3
Wheel hub ...................................................................................................6:5
6.3
Tyres and rims .................................................................................................6:6
6.3.1
Tyres .........................................................................................................6:13
6.3.2
Rim ............................................................................................................6:14
UDCT01.02GB
6:2
UDCT01.02GB
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.
6.2 Suspension
Suspension, description
The steering axle cradle is mounted to the frame with two bushings,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journalled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journalled wheel hubs where
the wheels are mounted.
Steering spindle
Wheel hub
008047
Steering axle
1.
Wheel hub
2.
Wheel spindle
3.
Link arm
4.
5.
Steering cylinder
6.
UDCT01.02GB
Measure the distance between the frame and the steering axle
cradle. Note the measurement.
008078
6:4
NOTE
Do not lift under the steering axle.
Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
007842
Re-measure measurement A.
008079
UDCT01.02GB
6:5
Wipe off grease from hub cap and hub nut. Handle it as
environmentally hazardous waste.
Bend up the lock washer's tabs, remove the lock nut and the lock
washer.
008080
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
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.
UDCT01.02GB
6:6
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.
UDCT01.02GB
6:7
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.
UDCT01.02GB
6:8
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.
Check that the lock ring and lugs are installed correctly.
015101
1.
Lock ring
2.
Side ring
3.
4.
Rim
2
Check the air pressure in the tyres, see section Tyres, inflating,
page 6:13.
The pressure must be 1.0 MPa, inflate if necessary.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change, page 6:14.
4
If the tyres and rims have no defects, check-tighten the wheel nuts.
Tighten crosswise to a torque of:
650 Nm oiled screw.
008153
UDCT01.02GB
6:9
Removing
1
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.
Release the air from the tyres by:
a)
b)
If this does not work, undo the valve in the rim and release the air.
014571
NOTE
014573
UDCT01.02GB
c)
If this does not work, break off, cut or saw off the valve pipe.
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. 5 mm.
005123
014572
6:10
Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
Lift the wheel away and position it safely so that it does not fall or
move.
NOTE
The spacer ring is heavy.
Remove the inner drive wheel and position it safely so that it does
not fall or move.
005124
Installing
10 Fit the inner drive wheel. Take care that the screw threads are
not damaged.
11 Fit the spacer ring.
12 Install the outer drive wheel. Take care that the screw threads
are not damaged.
13 Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
14 Inflate the tyres, see Tyres, inflating, page 6:13.
15 Lower the machine and remove the jack.
16 Test-drive the machine and check that the wheels are secure.
17 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.
UDCT01.02GB
6:11
Removing
1
Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.
b)
If this does not work, undo the valve in the rim and release the air.
014571
a)
NOTE
014573
UDCT01.02GB
c)
If this does not work, break off, cut or saw off the valve pipe.
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. 5 mm.
005123
014572
6:12
Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
Remove the wheel and position it safely so that it does not fall or
move.
Installing
7
Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.
005124
11 Test-drive the machine and check that the wheels are secure.
UDCT01.02GB
6 Suspension Tyres
6:13
6.3.1 Tyres
Tyres, inflating
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:6.
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.
008153
NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1
Make sure that the lock ring and lock lugs are in the correct
position before inflating.
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.
UDCT01.02GB
6:14
6 Suspension Rim
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
6:14.
6.3.2 Rim
Rim, check
DANGER
Perform the following checks to minimise risks of
accidents for all split rims.
Always use the right tyre size and a design
corresponding to the manufacturer's rim type and size.
Over-dimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or
mounting parts.
Dismantle the rim, see Tyre, change, page 6:14.
Carefully clean the outside of the rim edge with a steel brush.
005375
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
UDCT01.02GB
005377
6 Suspension Rim
6:15
005374
O. Circumference
D. Diameter
5
2.
001702
005375
Rim
Method:
Alternating current AC
Contrast colour
Checking medium:
a
Wet
Wash off penetrating fluid with cleaning fluid part no. 923626.0668.
005376
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4
Rim
UDCT01.02GB
6:16
6 Suspension Rim
001705
Examples of cracks
1.
Linear crack
2.
Pointed crack
UDCT01.02GB
7:1
7 Load handling
UDCT01.02GB
7:2
UDCT01.02GB
7:3
7 Load handling
Load handling, general
The function load handling refers to, e.g. lifting/lowering, side shift, tilt
and securing a load. Load handling also includes help functions to
handle loads, e.g. container counter.
Load handling is divided into different sub-functions.
Lifting/lowering
Side shift
Spreading
Tilt
Other
009149
- Container counter
Load handling is primarily controlled with the control levers while
certain functions have separate switches.
Lifting/lowering
014022
009150
Side shift
014023
Tilt
Spreading
UDCT01.02GB
7:4
7.2 Lifting/lowering
Lifting/lowering, function description
Damping
009149
Damping
Damping means that the speed of functions is reduced automatically
close to the upper end position. This entails that mechanical parts are
exposed to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When
damping is activated, the relevant control unit reduces the control
current to the solenoid valve for the relevant function.
UDCT01.02GB
Condition
Reference value
Control switch
Not activated
Twistlocks
Contact
1b
7:5
1a
D
D790-1
D797-1
D794
11
4
D
D
10
C
9
P2
12
014656
8
1.
7.
8.
Accumulator lift
3.
9.
Lift cylinder
4.
5.
6.
UDCT01.02GB
7:6
5
6
7
12
015005
10
11
1.
7.
2.
8.
3.
Lift cylinder
9.
4.
5.
Mast
6.
7.2.9 Mast
Mast suspension, checking
Machine in service position, see section B Safety.
Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
015104
UDCT01.02GB
7:7
WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.
Machine in service position, see section B Safety.
Also check that the mast's mounting points and welding seams
are intact. Check both inside and outside.
009673
Check that the slide surfaces in the mast and trolley have a normal
appearance and do not show signs of damage or unevenness.
Check the clearance in the mast and between the trolley and mast.
NOTE
Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
UDCT01.02GB
7:8
Wear checking
1
The chain must not have extended more than 3%. Measure the
length of the 25 links that first (and most often) travel over the
chain wheel during lifting. This is where the extension is greatest.
Compare with the value in the table. If the 3% limit is exceeded,
the chains must be replaced.
005670
P-measurement
[in]
P-measurement
[mm]
Max.
measurement
3/4
19.05
476.25
490
25.4
635
654
1.1/4
31.75
793.75
817
1.1/2
38.1
952.5
981
50.8
1270
1308
Adjusting
3
Check that the pins for the outer washers are securely fastened.
Check that the chain bends easily over the pulley (does not jam
when bending).
Place the machine on level surface with the mast vertical (0 tilt).
NOTE
009153
UDCT01.02GB
7:9
11 Adjust the chains so that the carriage is lifted evenly in the mast.
4
1.
Locking washer
2.
Lower nut
3.
Upper nut
4.
Chain tightener
NOTE
Reinstall only new 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.
When the chains are aligned, lock the nuts with locking
washers.
Check that the distance between sensor and inner mast (when it
is directly opposite the sensor) is 101 mm
014740
009152
UDCT01.02GB
7:10
7.2.11 Trolley
Slide plates trolley, checking
1
Turn off the engine and turn off the system voltage.
NOTE
The thickness of the slide plate should be at least 10 mm.
4
NOTE
The thickness of the slide plate should be at least 10 mm.
5
Check the clearance between the side lift attachment and the
trolley.
NOTE
If the measured clearance between the trolley's slide plates
and the attachment's main beam is greater than 5 mm, the
clearance must be adjusted using adjustment shims.
013681
2
3
Check that the slide surface is clean and lubricate the slide surface
of the side lift attachment.
Start the machine and side shift the attachment to both of its
end positions. Check that the clearance between trolley and
attachment is sufficient along the whole of the attachment and
that there is no metallic contact.
UDCT01.02GB
7:11
014022
The side shift function is controlled with control lever or linear control
levers
. The control lever sends a voltage signal proportional
to deflection to the control system in order to control the side shift
function. Hydraulic oil pump load handling pumps hydraulic oil to
control valve lift, tilt and attachment which pressurises control valve
attachment when the function is used. Control valve attachment
pressurises the side shift cylinder that moves the attachment's main
beam in relation to the trolley.
Condition
Reference value
Control switch
Not activated
1b
1a
D
2
D790-1
D797-1
D791-1
D
D
P2
P1
11
T1 A
1.
014658
10
7.
8.
9.
2.
3.
4.
5.
6.
UDCT01.02GB
7:12
10
5
11
1.
7.
2.
8.
3.
9.
4.
5.
6.
UDCT01.02GB
015007
7:13
7.5 Spreading
Spreading, function description
Damping
014023
Damping
Damping means that the speed of functions is reduced automatically
close to end-positions. Four seconds after damping has been
activated the function is cancelled. This entails that mechanical parts
are exposed to less stress when stopping in end-positions.
Position sensors sense when damping should be activated. When
damping is activated the control unit reduces the control current to
the solenoid valves.
UDCT01.02GB
7:14
Condition
Reference value
Control switch
Not activated
Twistlocks
1a
1b
D
D790-1
D797-1
D
2
D791-1
3
D
D
8
C
P2
P1
15
10
T1 B
13
1.
11
9.
12
14
2.
3.
4.
5.
6.
7.
8.
UDCT01.02GB
014659
7:15
Condition
Reference value
Control switch
Not activated
Twistlocks
2a
35
30-
D790-1
D797-1
D
3
D791-1
6
D
D
30'
1.
2.
4.
5.
6.
7.
8.
9.
30'
014660
2b
UDCT01.02GB
7:16
Condition
Reference value
Control switch
Not activated
Twistlocks
Doors
Closed
Parking brake
Released
D
2b
2a
D790-1
4
D797-1
D
11
D795
D791-1
5
1.
2.
10
9
7.
8.
3.
9.
4.
5.
6.
UDCT01.02GB
014661
7:17
1
9
8
7
4-6
10
11
16
12
15
14
015008
17
13
1.
Spreader beam
9.
2.
Spreading cylinders
3.
4.
5.
6.
7.
8.
UDCT01.02GB
7:18
014737
Spreader beams
UDCT01.02GB
Turn off the engine and turn off the system voltage.
013683
1000 mm
7:19
Check that the clearance between slide plates and main beam is
maxmax 5 mm both laterally and vertically. This is equivalent to
the dimensions X1X2 = max 5 mm and Y1Y2 = max 5 mm.
013690
X1
Y2
X2
Y1
Y1
Y2
NOTE
Left side
X1
013689
X2
Right side
4
UDCT01.02GB
7:20
7.7 Tilt
Tilt, function description
Tilt means the angling of the mast in relation to the machine.
009150
The tilt function is controlled with control lever or linear control levers
. The control lever sends a voltage signal proportional to deflection
to the control system in order to control the tilt function. Hydraulic oil
pump load handling pumps hydraulic oil to control valve lift, tilt and
attachment which pressurises the tilt cylinders. The tilt cylinders angle
the mast in relation to the machine. The load holding valves on the tilt
cylinders rod side prevent the mast being tilted due to the load.
Condition
Reference value
Control switch
Not activated
1b
1a
D790-1
D797-1
2
3
D
8
5
C
P2
10
9
1.
014657
6.
7.
8.
9.
Tilt cylinder
2.
3.
4.
5.
UDCT01.02GB
7:21
11
10
015006
1.
6.
2.
7.
8.
3.
Mast
9.
4.
Tilt cylinder
5.
visually that the frame's mounting points and welding seams are
intact.
that the tilt fork is securely fastened to the tilt cylinder (136 Nm
tightening torque).
7.7.8 Mast
Mast suspension, checking
See Mast suspension, checking, page 7:6.
UDCT01.02GB
7:22
7.8 Levelling
Mechanical levelling, function description
014021
UDCT01.02GB
7:23
7.9.1 Twistlocks
Twistlocks, function description
The container is secured in place on the side lift attachment with two
twistlocks.
Twistlocks are controlled by Switch twistlocks. Hydraulic oil pump load
handling pumps hydraulic oil to control valve lift, tilt and attachment
which pressurises control valve attachment when the function is used.
A section in Solenoid valve attachment pressurises two hydraulic
cylinders, connected in parallel, one on each side of the side lift
attachment. Each hydraulic cylinder acts on a linkage that turns a
twistlock. Four position sensors, two on each side of the side lift
attachment, detect the position of the linkage and indicate whether
twistlocks are open or locked. Control lights on the side lift attachment
and in the cab show status for twistlocks.
A contact pin and a sensor at each twistlock indicate when the
attachment is in contact with the container. This is used to control when
twistlocks can be activated. Indicator lights on the side lift attachment
and in the cab show when the side lift attachment has full contact and
whether the twistlocks are open or locked. An event menu shows
which twistlocks have contact (12). To activate twistlocks, contact is
required at both twistlocks.
UDCT01.02GB
7:24
Condition
Reference value
Control switch
Not activated
Contact
17
2b
2a
16
D790-1
D790-2
D797-1
D791-1
15
D795
8
D
13
14
12
P2
18
P1
T1
10
11
12
D
13
14
1.
2.
3.
4.
5.
6.
7.
8.
9.
UDCT01.02GB
014662
7:25
10
11
6
19
12
13
17
16
15
1.
2.
3.
4.
5.
Contact pin
6.
Twistlocks
7.
8.
9.
14
UDCT01.02GB
015009
18
7:26
Twistlocks, checking
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
5
1.
Sensor contact
2.
3.
4.
Lift pin
5.
Contact pin
Under the rubber cover for twistlocks: check pin, link arm and
lock nut.
Press in the alignment pin so that the head is flush with the
spreader beam's underside. Check the distance to sensor contact,
the distance should be 51 mm. Adjust when needed.
014716
NOTE
The contact pin should move easily and spring back completely.
Put a crowbar between the lift pin (position 5) and the lift pin's
guide, check the clearance max. clearance: 11.5 mm. If
necessary, replace the wear washer (position 1) between
twistlocks and holder.
015527
1. Wear washer
UDCT01.02GB
7:27
Turn twistlocks to locked position and check wear of the lift pin.
Change the lift pin as needed.
Max. 4 mm
009776
in
.7
UDCT01.02GB
7:28
DANGER
Twistlocks should be checked in accordance with
recommended intervals. The interval is calculated
according to the machine being used for normal
handling and on a level, smooth ground surface. For
other handling or, e.g., rough surface, the interval
should be shortened.
If there are signs of cracking, the machine must be
immediately taken out of operation and Cargotec
Service contacted.
WARNING
Make sure that the engine is off when working on the
twistlocks.
Twistlocks can be locked automatically if all sensors for
contact are activated manually.
DANGER
Material fatigue, reduced strength.
Fatal danger!
Change twistlocks that shows signs of cracks or
other external damage, or twistlocks with more than
10 000 operating hours.
NOTE
Check for cracks shall take place every other year or every 4000
operating hours.
1
NOTE
009777
Check for cracks within the marked area on the lift pins without
causing damage.
If the lift pins show signs of cracking, they must be replaced with
new ones.
NOTE
Use new bearing cap, new bolts and new lock nuts.
UDCT01.02GB
7:29
014717
Check that the alignment pins in the corner boxes can move freely
up and down. The contact pins shall spring down when not loaded.
Turn the start key to position I and check that the light indicators
on the sensor are turned off.
Lift the container a little bit so that the Indicator light contact is
switched off.
If necessary, loosen the lock nut and screw the sensor in/out until
the distance between the sensor and the contact pin is 51 mm.
1.
Sensor contact
2.
Contact pin
014718
Right side
Left side
1.
Sensor contact
2.
Contact pin
UDCT01.02GB
7:30
Turn the start key to position I and check that the light indicator
on the sensor for unlocked twistlock is lit.
If necessary, loosen the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 51 mm.
Check that the light indicator on the sensor for locked twistlock
is lit.
If necessary, loosen the lock nut and screw the sensor in/out until
the distance between the sensor and the indicator plate is 51 mm.
014719
Right side
1.
2.
014720
Left side
1.
2.
UDCT01.02GB
7:31
Condition
Reference value
Control switch
Not activated
D795
D791-1
D
2
004297
1.
3.
2.
4.
UDCT01.02GB
7:32
UDCT01.02GB
8:1
8 Control system
UDCT01.02GB
8:2
UDCT01.02GB
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
UDCT01.02GB
8:4
A
A
Display (KID)
Alarm indicator
000053
The function keys are used to navigate in the display menus for
service and troubleshooting, for example.
Function keys
Function keys
000055
The function keys (A) are used to navigate in the menu system. They
are also used to enter values in the system, change light contrast in
the keys/indicator panel, and to acknowledge a warning.
UDCT01.02GB
Operating menus
8:5
Operating menus
Operating menu Engine and transmission are shown in the display
when the machine is started. This menu is shown until another
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).
For overview of operating menus see, section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments.
014182
Service menu
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.
For overview of the event menus see, section 9 Frame, body, cab and
accessories, group 9.1 Controls and instruments.
Warnings are described in connection with each function. The following
event menus are available:
Service menu
Locked/unlocked twistlock
Open door
Automatic spreading
000056
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:
UDCT01.02GB
8:6
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:
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and rolling
over!
Only use bypassing in emergency situations!
UDCT01.02GB
8:7
000056
1 23
4 5
000060
NOTE
The code determines which service menu shall be activated
(Service, Diagnostics, Initiation or Calibration).
4
004908
SERVICE INTERVALL
NEXT SERVICE
XXXXh
SERVICE INTERVALL
STORED
XXXXh
PRESENT
XXXXh
UDCT01.02GB
8:8
53
54
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:
36
000348
003817
Automatically on display.
The error code is acknowledged with function key Reset (R).
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.
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.
UDCT01.02GB
001998
8:9
NOTE
If error code isnt included in the error code list, it may be due
to the following:
UDCT01.02GB
8:10
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:
UDCT01.02GB
8:11
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
The diagnostic tests are built up of menus. The menus are grouped
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
output signals are sent by the control unit.
2(X)
2
11
0
005592
1.
2.
3.
Menu number
4.
5.
Variable
6.
Signal value
7.
Menu heading
Pos.
Designation
Description
DIAG
Indicates that diagnosis has been selected. There is also initiation (INIT) and calibration (CALIB).
CAB
Number of current menu (menu group CAB contains several menus in a loop).
(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).
Variable
Signal value
Measuring value or status for the signal for the variable on the same line.
FRONT WIPER
Name of the function that can be controlled. FRONT WIPER means front windshield wiper.
UDCT01.02GB
8:12
000056
1 23
4 5
000060
NOTE
UDCT01.02GB
005263
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
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)
PRESENT REDCAN STATUS
COMMUNICATION MODE X
NUMBERS OF UNITS
X
SEGMENT ERROR
X
DIAG CAN/POWER
2(X)
PRESENT REDCAN STATUS
CONNECTED CITIES
D797-1 D797-2
XX
D795
D791-1
XX
DIAG CAN/POWER
3(X)
PRESENT OPTION KDU
DIAG CAN/POWER
4(X)
PRESENT DRIVE-TRAIN
CAN BUS STATUS
ENGINE
X
TRANSMISSION
X
DIAG CAN/POWER
IGNITION
KEY IN
RELAY K315-1
RELAY K315-2
DIAG CAN/POWER
6(X)
EMERGENCY STOP, SW X
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY
DIAG CAN/POWER
7(X)
790-1 CAB
POWER
XX.XXV
5V REF
X.XXV
DIAG CAN/POWER
8(X)
790-1 CAB
24V SENSOR SUPPLY XY
24V SUPPLY,RPM>500 XY
DIAG CAN/POWER
795 DISPLAY
DIAG CAN/POWER
10(X)
797-1 FRAME
POWER
XX.XXV
RED.POWER LE X RI X
POWER 2
X
DIAG CAN/POWER
797-1 FRAME
DIAG CAN/POWER
12(X)
793 TRANSMISSION
POWER
XX.XXV
IGNITION POWER XX.XXV
SENSOR SUPPLY XX.XXV
DIAG CAN/POWER
NOT USED
DIAG CAN/POWER
NOT USED
DIAG CAN/POWER
16(X)
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY
5V REF
X.XXV
X
XY
XY
11(X)
X.XXV
14(X)
RED.POWER
XY
XY
LE X
9(X)
RI X
DIAG CAN/POWER
15(X)
791-1 ATTACHMENT(OPT)
EME POWER
XX.XXV
RED.POWER LE X RI X
EME POWER 2
X
DIAG CAN/POWER
17(X)
REDCAN STATUS CHECK
PRESS ENTER
SEGMENT ERROR
015038
13(X)
5V REF
5(X)
KDU D797-2
KDU D791-1
UDCT01.02GB
8:14
8.4.2 LIGHTS
LIGHTS, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
1(X)
DIAG LIGHTS
2(X)
PRESENT OUTPUT SIGNAL
X
SIDE LIGHTS
REAR LIGHTS
XY
XY
DIAG LIGHTS
HEAD LIGHTS
SWITCH
HEAD LE/RI
DIMMED LE/RI
3(X)
X
XY
XY
DIAG LIGHTS
4(X)
PRESENT INPUT SIGNAL
HAZARD SWITCH
X
FLASH.SW. LE X RI X
DIAG LIGHTS
5(X)
PRESENT OUTPUT SIGNAL
HAZARD/FLASHER
LEFT F/R
XY
RIGHT F/R
XY
DIAG LIGHTS
ROTATION BEACON
SWITCH
OUTPUT
6(X)
DIAG LIGHTS
7(X)
PRESENT INPUT SIGNAL
BRAKE LGT SWITCH
X
REVERSE LGT SIGNAL X
DIAG LIGHTS
8(X)
PRESENT OUTPUT SIGNAL
BRAKE LGT LE XY RI XY
REV. LGT LE XY RI XY
REVERSE ALARM
XY
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT
9(X)
DIAG LIGHTS
10(X)
WORKING LIGHT MAST
SWITCH
X
OUTPUT LE/RI
XY
DIAG LIGHTS
11(X)
WORKING LIGHT EXTRA
OUTPUT
D797-1 C1 P42
XY
D797-2 C1 P42
XY
DIAG LIGHTS
12(X)
WORKING LIGHT CAB
SWITCH
X
DIAG LIGHTS
SWITCH LIGHTS
DIAG LIGHTS
STEP LIGHT
SWITCH
OUTPUT
DIAG LIGHTS
13(X)
WORKING LIGHT ATTACH
SWITCH
X
OUTPUT
LE XY RI XY
UDCT01.02GB
OUTPUT
14(X)
XXX
OUTPUT
X
XY
X
X
XXX
20' XY 40' XY
15(X)
X
XXX
009154
DIAG LIGHTS
MAIN LIGHT
SWITCH
8:15
8.4.3 CAB
CAB, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
1(X)
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK
4(X)
DIAG CAB
FUEL
SENSOR VALUE
PROC
7(X)
X
XY
XY
X
XY
X
XXXohm
XXX
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
2(X)
DIAG CAB
HORN
SWITCH
SWITCH 2
OUTPUT
5(X)
DIAG CAB
SEAT HEATER
SWITCH
OUTPUT
X
XY
X
X
X
XY
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK
3(X)
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
6(X)
X
X
X
X
X
XY
X
8(X)
X
XY
009155
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR ROOF
8.4.4 CLIMATE
CLIMATE, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG
TEMP
TEMP
TEMP
TEMP
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(X)
XXX
XXX
XXX
XXX
DIAG CLIMATE
3(X)
PRESENT INPUT SIGNAL
PRESSURE SWITCH
X
DIAG CLIMATE
4(X)
PRESENT INPUT SIGNAL
WATER VALVE
XX.XXV
DRAUGHT VALVE XX.XXV
DIAG CLIMATE
5(X)
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV
REQ. DRAUGHT
XX.XXV
REQ. FAN SPEED XX.XXV
DIAG CLIMATE
6(X)
PRESENT OUTPUT SIGNAL
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
DIAG CLIMATE
7(X)
OUTPUT WATER VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
DIAG CLIMATE
8(X)
OUTPUT DRAUGHT VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
005596
DIAG CLIMATE
1(X)
PRESENT INPUT SIGNAL
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
WATER VALVE FEEDB. XXX
UDCT01.02GB
8:16
8.4.5 HYD
HYD, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
1(X)
DIAG HYDRAULIC
NOT USED
2(X)
XXX
XY
X
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
BRAKE LIGHT PRESS. X
DECLUTCH PRESSURE
X
DIAG HYDRAULIC
P-BRAKE
SWITCH
FEEDBACK SWITCH
VALVE
DIAG HYDRAULIC
NOT USED
DIAG HYDRAULIC
8(X)
PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM.
VALVE
XY
SET OUTPUT +/X
UDCT01.02GB
7(X)
5(X)
DIAG HYDRAULIC
3(X)
HYDRAULIC PRESSURE
LIFT CYLINDER
TILT CYLINDER
XXX
XXX
DIAG HYDRAULIC
NOT USED
6(X)
X/Y
X
XY
015039
DIAG HYDRAULIC
HYDRAULIC OIL
TEMP
FAN
SET OUTPUT +/-
8:17
8.4.6 ENGINE
ENGINE, menu overview (engine alternative Yuchai
YC6A240-30)
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG ENGINE
1(10)
PRESENT INPUT SIGNAL
ACCELERATOR
X.XXV
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX
DIAG ENGINE
2(10)
PRESENT INPUT SIGNAL
ENGINE SPEED EDC XXXX
DIAG ENGINE
3(10)
PRESENT INPUT SIGNAL
PRESENT TORQUE
XXX
DIAG ENGINE
4(10)
PRESENT INPUT SIGNAL
PREHEAT SWITCH
X
CRANK ENGINE SWITCH X
D+
X
DIAG ENGINE
5(10)
PRESENT OUTPUT SIGNAL
PREHEAT
X
CRANK ENGINE
X
CRANK ENGINE WIRE XY
DIAG ENGINE
6(10)
PRESENT INPUT SIGNAL
OIL PRESSURE
XX.X
BOOST PRESSURE
XX.X
DIAG ENGINE
7(10)
PRESENT INPUT SIGNAL
OIL TEMP
XXX
COOLANT TEMP
XXX
INTAKE MAIN.TEMP XXX
DIAG ENGINE
8(10)
PRESENT EDC ERROR
NR OF ACT ERROE
XX
SPN
XXXX
FMI
XX
DIAG ENGINE
9(10)
FUEL CONSUMPTION
MOMENTARY l/h
XXX
015040
DIAG ENGINE
10(10)
PRESENT INPUT SIGNAL
PRE-HEAT FEEDBACK X
WATER IN FUEL SW. X
COOLANT LEVEL SW. X
UDCT01.02GB
8:18
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG ENGINE
1(X)
PRESENT INPUT SIGNAL
ACCELERATOR
X.XXV
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX
DIAG ENGINE
2(X)
PRESENT INPUT SIGNAL
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX
DIAG ENGINE
3(X)
PRESENT INPUT SIGNAL
PRESENT TORQUE
XXX
REQUIRED TORQUE
XXX
PRES TORQUE @ PRM XXX
DIAG ENGINE
4(X)
PRESENT INPUT SIGNAL
PREHEAT SWITCH
X
CRANK ENGINE SWITCH X
D+
X
DIAG ENGINE
5(X)
PRESENT OUTPUT SIGNAL
PREHEAT
X
CRANK ENGINE CAN
X
CRANK ENGINE WIRE XY
DIAG ENGINE
6(X)
PRESENT INPUT SIGNAL
OIL PRESSURE
XX.X
BOOST PRESSURE
XX.X
OIL LEVEL
XXX
DIAG ENGINE
7(X)
PRESENT INPUT SIGNAL
OIL TEMP
XXX
COOLANT TEMP
XXX
INTAKE MAIN.TEMP XXX
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
DIAG ENGINE
FUEL CONSUMPTION
MOMENTARY l/h
XXX
10(X)
015041
DIAG ENGINE
NOT USED
9(X)
UDCT01.02GB
8:19
8.4.7 TRANSM
TRANSM, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG TRANSM.
1(14)
PRESENT INPUT SIGNAL
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
DECLUTCH PRESS SW. X
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE
4(14)
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR
3(14)
DIAG TRANSM.
5(14)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X
DIAG TRANSM.
NOT USED
6(14)
DIAG TRANSM.
NOT USED
7(14)
DIAG TRANSM.
NOT USED
8(14)
DIAG TRANSM.
NOT USED
9(14)
DIAG TRANSM.
NOT USED
10(14)
DIAG TRANSM.
NOT USED
11(14)
DIAG TRANSM.
NOT USED
12(14)
DIAG TRANSM.
13(14)
ACT ERROR AREA
XXX
TYPE
XXX
NUMBER OF OCCU. XXXXX
TIME AGO
XXXXX
X
X
X
X
X
X
DIAG TRANSM.
14(14)
MANUAL GEAR SHIFT
GEAR
(+/-)
015042
X
X
X
2(14)
UDCT01.02GB
8:20
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG ELSERVO
1(X)
PRESENT INPUT SIGNALS
P1
XX.XXV
P2
XX.XXV
P3
XX.XXV
DIAG ELSERVO
NOT USED
DIAG ELSERVO
OUTPUT LOWER
REFERENCE
REQUIRED VALUE
FEEDBACK
DIAG ELSERVO
OUTPUT TILT IN
REFERENCE
REQUIRED VALUE
FEEDBACK
4(X)
XY
XXXmA
XXXmA
2(X)
5(X)
XY
XXXmA
XXXmA
DIAG ELSERVO
OUTPUT LIFT
REFERENCE
REQUIRED VALUE
FEEDBACK
3(X)
XY
XXXmA
XXXmA
DIAG ELSERVO
6(X)
OUTPUT TILT OUT
REFERENCE
XY
REQUIRED VALUE XXXmA
FEEDBACK
XXXmA
7(X)
DIAG ELSERVO
NOT USED
8(X)
DIAG ELSERVO
NOT USED
9(X)
DIAG ELSERVO
NOT USED
10(X)
DIAG ELSERVO
NOT USED
11(X)
DIAG ELSERVO
NOT USED
12(X)
DIAG ELSERVO
13(X)
PRESENT INPUT SIGNALS
SPREADER
IN X OUT X
PISTOL
X
UNLOCK TW
X
DIAG ELSERVO
NOT USED
14(X)
DIAG ELSERVO
NOT USED
15(X)
UDCT01.02GB
015044
DIAG ELSERVO
NOT USED
8:21
8.4.9 ATTACH
ATTACH, menu overview
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG ATTACHMENT
1(X)
PRESENT INPUT SIGNALS
P3
XX.XXV
P4
XX.XXV
P7
XX.XXV
DIAG ATTACHMENT
2(X)
PRESENT INPUT SIGNALS
P5
XX.XXV
DIAG ATTACHMENT
3(X)
PRESENT INPUT SIGNALS
SPREADER
IN X OUT X
AUTO 20/40
X
30/35 STOP
X
DIAG ATTACHMENT
4(X)
PRESENT INPUT SIGNALS
DIAG ATTACHMENT
5(X)
PRESENT INPUT SIGNALS
LOCK CONT
X
UNLOCK CONT
X
DIAG ATTACHMENT
6(X)
PRESENT INPUT SIGNALS
LE RI
LOW SPEED 20/40 X X
30/35 STOP
X X
DIAG ATTACHMENT
7(X)
PRESENT INPUT SIGNALS
ALIGNMENT
LE
RI
X
X
DIAG ATTACHMENT
8(X)
PRESENT INPUT SIGNALS
LE
RI
LOCKED CONT
X
X
UNLOCKED CONT X
X
DIAG ATTACHMENT
9(X)
PRESENT OUTPUT SIGNAL
LOCK CONT
XY
UNLOCK CONT
XY
DIAG ATTACHMENT
NOT USED
13(X)
DIAG ATTACHMENT
NOT USED
DIAG ATTACHMENT
NOT USED
DIAG ATTACHMENT
NOT USED
16(X)
14(X)
15(X)
XY
015043
PISTOL
8.4.10 OLS
OLS, menu overview
Not used.
Maintenance Manual DCT 8090
UDCT01.02GB
8:22
8.4.11 EXTRA
8.4.11.1 VBFS
VBFS, menu overview
Not used.
8.4.11.2 EL-STEERING
EL-STEERING, menu overview
Not used.
8.4.11.3 EXT-ATTACH
EXT-ATTACH, menu overview
Not used.
8.4.11.4 FREELIFT
FREELIFT, menu overview
Not used.
8.4.11.5 MOVE-CAB
MOVE-CAB, menu overview
Not used.
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)
OPTION SWITCH
S199-1 X
S199-4 X
S199-2 X
S199-3 X
DIAG OPTION
2(X)
PRESENT OUTPUT SIGNAL
CENTRAL LUBRICATION
FRAME
XY
ATTACHMENT
XY
DIAG OPTION
NOT USED
DIAG OPTION
5(X)
PRESENT OUTPUT SIGNAL
D791-1 C1 P14
XY
D791-1 C1 P28
XY
015045
4(X)
DIAG OPTION
3(X)
PRESENT OUTPUT SIGNAL
D797-1 C1 P42
XY
UDCT01.02GB
8:23
8.4.11.7 I/O
I/O, menu overview
Not used.
8.4.11.8 RMI
RMI, menu overview
Not used.
UDCT01.02GB
8:24
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.
UDCT01.02GB
9:1
UDCT01.02GB
9:2
UDCT01.02GB
9 Frame, body, cab and accessories Frame, body, cab and accessories
9:3
UDCT01.02GB
9:4
Overview
11
10
15
12
13
12
015102
14
1.
2.
3.
4.
Steering wheel
5.
6.
7.
8.
9.
UDCT01.02GB
9:5
24..28
19..23
18
16
Left instrument panel
17
UDCT01.02GB
9:6
32
33
35
34
36
37..41
49
42..46
47 48
50
51
52
53
64
63
62
54
55
61
Steering wheel panel
60
59 58 57
008132
56
UDCT01.02GB
9:7
68
70
67. Side shift (R8073)
72
74
74
73
014179
69
65
66
68
67
7
69
70
71
72
74
74
014178
73
UDCT01.02GB
9:8
11
12
13
14
1.
8.
2.
9.
3.
4.
5.
6.
7.
014668
10
014669
UDCT01.02GB
1.
2.
3.
4.
9:9
6,7,10
2
4
3
1
9
5
1.
Back-up alarm
2.
Revolving beacon.
3.
Horn.
4.
5.
Fire extinguisher
7.
8.
9.
014175
11
Seat belt.
UDCT01.02GB
9:10
9.3 Seats
Seat, description (product alternative Hao Bang)
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.
angle of seat
armrest right
head restraint
The seat features a sensor that senses if the seat cushion is pressed
down. It is used to activate buzzer if the operator leaves the seat
without applying the parking brake and shifts the transmission to
neutral if the operator leaves the seat.
5
4
1.
Head restraint
2.
3.
4.
5.
6.
7.
Longitudinal adjustment
UDCT01.02GB
014151
9:11
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.
5
8
006825
6
7
armrest right
seat heating
head restraint
armrest left
Controls
1.
2.
3.
4.
5.
6.
7.
8.
Longitudinal adjustment
UDCT01.02GB
9:12
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.
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 the cab.
2
3
5
8
006826
6
7
2.
3.
4.
5.
6.
7.
8.
Longitudinal adjustment
UDCT01.02GB
armrest right
seat heating
armrest left
head restraint
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:13
001839
At the air inlet before the cab fan there is a filter that cleans the air
before it is forced into the machine.
Defroster nozzles
UDCT01.02GB
9:14
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
2
D
D
7
D790-1
D795
11
D794
10
C 9
14
M
13
D790-2
M
C
16
15
17
M
12
009891
M
1.
2.
3.
4.
5.
6.
7.
8.
Engine
9.
UDCT01.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:15
001839
Defroster nozzles
UDCT01.02GB
9:16
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
D
7
D790-1
D790-2
15
D794
12
M
5
D795
D797-1
16
25
26
D
22
14
Pa
M
13
M
D
19
18
20 C
23
C
21
24
17
M
C
11
007690
10
1.
2.
3.
4.
18. Compressor
5.
19. Condenser
6.
7.
8.
Engine
9.
UDCT01.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:17
16
15
13
5
6
7
12
005221
11
9, 14
10
1.
2.
3.
4.
5.
6.
7.
8.
9.
Expansion valve
UDCT01.02GB
9:18
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
1b
1a
2
6
5
7
014695
1.
Compressor
4.
Condenser
5.
6.
Moisture filter
2.
7.
Sight glass
3.
UDCT01.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:19
CAUTION
Authorisation is required to perform repairs on the
climate control unit.
WARNING
If there is a rupture of a cooling hose or leakage on the
plant turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
WARNING
Electric fans can injure hands.
Risk of personal injury.
Avoid placing hands near the cooling fans when the
engine is running.
NOTE
The air conditioning does not work at temperatures below approx.
0 C 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 drain for the cooling element's condensation water
is not clogged.
UDCT01.02GB
9:20
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
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 C, the cooling function will not start due to low pressure
in the system.)
Set the fan to intermediate speed.
013669
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.
UDCT01.02GB
All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
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 C,
the compressor cuts out via the thermostat or ECC and cuts in
again when the temperature has increased approx. 3-7 C. (If the
compressor does not cut out, there is a risk of the evaporator icing
up and cooling performance decreasing.)
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:21
WARNING
If there is a rupture of a cooling hose or leakage on the
plant turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.
NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 C.
UDCT01.02GB
9:22
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
Check that no bubbles are visible in the sight glass on the particle
and moisture filter.
013669
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.
Connect the pressure gauge's red hose to the service valve on the
compressor's pressure side marked with D, DIS or DISCHARGE.
Connect the yellow filler and vacuum hose to the nitrogen tube.
Open the cock on the tube and then the cock on the pressure
side. Open the valve on the cylinder and then the valve on the
pressure side. Now the gas flows through the system and back
to the suction side of the compressor, which can be seen on the
blue pressure gauge which slowly indicates a pressure equivalent
to the pressure in the cylinder (see red pressure gauge). (If the
blue pressure gauge does not move then there is a stop in the
system.) Turn off the valve on the pressure side and then the
cock on the tube.
10 Now the system contains a mix of nitrogen gas and air. This gas
amount is enough to indicate a leak.
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.
UDCT01.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:23
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 valves 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
valve 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.
19 Open the valve 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.
013669
Close the valve on the suction side and then the valve 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
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.
UDCT01.02GB
9:24
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
UDCT01.02GB
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.
9:25
9.4.8 Condenser
Condenser, cleaning
1.
014732
Condenser
UDCT01.02GB
9:26
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
Working on the air conditioning requires special
authorisation.
3
Fit the pressure switch and connect the hoses to the moisture filter.
Leak test and refill the machine with refrigerant R134a, using the
intended equipment.
For volume, see section F Technical data.
UDCT01.02GB
9:27
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
bracket is made of a mild die cast material.
A
A
Wiper, front
002214
When installing it is important to make sure that the splines are free
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 (1620 Nm
tightening torque).
The wipers turn off automatically 2 minutes after the operator has left
the cab. The wipers are activated automatically when the operator sits
in the set, selects a gear, or if the accelerator pedal is pressed down.
UDCT01.02GB
9:28
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
9
10
12
6
13
13
16
14
7
D790-1
D790-2
D797-1
19
20
21
22
23
24
25
11
D791
17
18
Pa
26
28
27
29
1.
2.
3.
4.
5.
6.
7.
8.
9.
29.
UDCT01.02GB
014663
15 M
9:29
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
The following lighting is available:
3,8,10
12
24
23
19, 20, 21
17
18
16
15
11, 13, 14
1.
2.
3.
4.
5.
6.
7.
8.
9.
UDCT01.02GB
014664
22
9:30
NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
4
6
17
15
16
D6
18
D790-1 5
9
D797-1
10
D790-2
D791-1
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
NOTE
UDCT01.02GB
20
21
12
19
D795
009767
13
14 M
9:31
19 18
17
16
15
14
13
3 4 5
12 10,1 1 9 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
UDCT01.02GB
014665
9:32
UDCT01.02GB
9:33
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component location
The function of the window panes is to enclose the cab and to give
the operator good visibility. Tempered glass windows are standard on
all trucks. Roof windows are a safety feature and are therefore always
made of polycarbonate plastic.
C
D
Side windows
Roof window
Rear window
001512
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!
UDCT01.02GB
9:34
3
4
1.
Cab frame
2.
Door
3.
Cab suspension
4.
Cab undercarriage
003206
9.10.2 Doors
Doors, description
The cab has two doors, the left is the driver's door and the right is the
emergency exit. The doors have:
hand rail
handle
keylock
There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be controlled with the diagnostics menu, see section
8 Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5
MOVE-CAB, menu 1.
Doors, checking
1
006914
UDCT01.02GB
9:35
Check that the welding seams at the cab's mounting points are
intact and free of visible cracks.
Check that the isolators are intact. Replace any damaged isolator.
Check that bolted joints are tightened and that the brackets are
undamaged. Attend to as needed.
008393
UDCT01.02GB
9:36
UDCT01.02GB
Instrument panels
Insulation
9:37
9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:
1.
4.
2.
5.
6.
3.
UDCT01.02GB
014666
9:38
UDCT01.02GB
1.
Counterweight
2.
3.
Fenders
014667
9:39
Pump unit
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.
UDCT01.02GB
9:40
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
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.
2.
Safety valve
3.
4.
Indicator pin
5.
UDCT01.02GB
Fill grease in the pump unit through the filler nipple, see section
F Technical data.
9:41
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.
UDCT01.02GB
9:42
UDCT01.02GB
10:1
10 Common hydraulics
UDCT01.02GB
10:2
UDCT01.02GB
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 the supply load handling, brakes and
steering with hydraulic pressure.
Pressure plate
On the machine there is a pressure plate with the most important
pressure information (stamped in). The pressure plate is located on
the left side of the frame in front of the cab steps.
Pressure levels vary with the equipment and therefore they are unique
to each machine. When checking pressure the pressures must
correspond with the pressure plate.
3
8
4
7
5
014670
1.
5.
Servo pressure
2.
Brake pressure
6.
3.
Precharging accumulators
7.
4.
Steering pressure
8.
UDCT01.02GB
10:4
NOTE
014683
1.
2.
UDCT01.02GB
10:5
Tank
1.
2.
3.
4.
5.
008086
Accumulator
Accumulator
1.
2.
Accumulator lift
014672
UDCT01.02GB
10:6
10.4 Pumps
Pumps, general
1
The machine's hydraulics are supplied from two hydraulic oil pumps
with fixed displacement. One pump supplies brakes and steering
and the other supplies load landing. The pumps are mounted on
the transmission's power take-off.
014671
The hydraulic oil pump for brake pressure and steering (position 2)
supplies brakes, steering and the hydraulic system's cooling circuit
via Valve block accumulator charging valve and priority valve, see
section 4 Brakes.
1.
2.
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 C.
000475
014649
UDCT01.02GB
10:7
Close the accumulator drain valve and check the pump pressure
during charging.
NOTE
Check that the accumulator drain valve is completely closed
and tighten the lock ring.
014619
Remove the pressure gauge and fit the protective cap on the
pressure check connection.
015023
NOTE
014619
UDCT01.02GB
10:8
Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 C.
000475
014650
014619
UDCT01.02GB
10:9
Check that the feed pressure corresponds with the pressure plate.
015024
10 Remove the pressure gauge and fit the protective cap on the
pressure check connection.
NOTE
014619
UDCT01.02GB
10:10
10
D795
D790-2
D797-1
15
9
4
C
SPOL
11
P2
16
M
5
7
C
12
14
8 C
13
014646
1.
9.
2.
3.
4.
5.
Wheel brake
6.
7.
15. Control valve lift, tilt and attachment (part of the main
valve)
8.
UDCT01.02GB
10:11
1
2
10
9
3
014673
1.
6.
2.
7.
3.
8.
Main valve
4.
Cooling fan
9.
5.
UDCT01.02GB
10:12
Turn off the engine and turn off the main electric power.
008084
1.
2.
3.
4.
Reset the filter indicator by pressing down the button in the middle
on the glass centred on the filter cartridge.
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
On machines with raised cab: Remove the footstep over the
covers and clean the covers and the area around them.
UDCT01.02GB
Remove the cover plates (position 1) over the hydraulic oil filters.
Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
Part the filter unit and remove the filter insert. Handle the filter
cartridge as environmentally hazardous waste. Note position of
the parts.
Install the filter units and cover plates. Tighten the bolts crosswise.
008084
10:13
1.
2.
3.
4.
9
On machines with raised cab: Fit the footstep over the covers.
10 Check the oil level, see Hydraulic oil, level check, page 10:13.
Magnetic rod
NOTE
The oil level is checked with the mast lowered and the attachment in
the 20-foot position.
1
Check the oil level in the hydraulic oil tank. The oil level should be
in the centre of the sight glass. Fill oil as required. For oil grade,
see section F Technical data.
UDCT01.02GB
10:14
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.
Remove the filler cap and pump out the hydraulic oil in a collection
container.
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.
008084
NOTE
1.
2.
3.
4.
Make sure that the drain plug's washer seal is also removed.
5
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.
UDCT01.02GB
10:15
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
Lift up the filter cartridge and place it in the receptacle. Let the
hydraulic oil drain.
Install the new filter cartridge and put the cover on the fine filter.
UDCT01.02GB
10:16
UDCT01.02GB
11:1
11 Common electrics
UDCT01.02GB
11:2
UDCT01.02GB
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.
1.
Control switch
2.
3.
4.
5.
Battery disconnector
014691
UDCT01.02GB
11:4
11.2.2 Fuses
Fuses, description
Main fuses
Main fuses
1
2
IMPORTANT
3
4
014690
The electrical system has three main circuits (30-, 15-, and
15E-voltage), see Distribution of electricity, description, page 11:10.
The main circuits are fused several times with main fuses and circuit
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.
Main fuses
1.
Electric power feed relay K315-1, electric power By the cab's and frame's electrical distribution boxes there are fuse
plates that describe the different fuses.
to ignition voltage (15), (50 A)
2.
3.
4.
014197
The terminal blocks for the electrical system are located in the front
of the frame and the rear of the carriage. They are used when
removing/fitting the mast and carriage.
UDCT01.02GB
Circuit fuses
11:5
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.
F58-4 30
MAIN POWER
CAB
A1
B2
C3
10A SERVICE
D4
E5
F6
G7
H8
A1
B2
C3
D4
E5
F6
X2044980 1
G7
H8
014689
F58-4 15
SUPPLY POWER
CAB
A
B
014198
C
D
Fuses on frame
A
Fuses in cab
15-fuses (ignition voltage) and 30-fuses (battery
voltage), 58-4
014688
UDCT01.02GB
11:6
Fuses, changing
IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.
UDCT01.02GB
11:7
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.
000354
With engine at max. engine speed (2,000 rpm), the battery voltage
should be 2729 V.
2
Turn off the engine and turn off the system voltage.
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.
Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
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.
UDCT01.02GB
11:8
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
UDCT01.02GB
11:9
11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. See section 1 Engine.
UDCT01.02GB
11:10
Start-up
Start-up
D791
The following takes place at start-up:
Startup signal
D790-2
2.
3.
D795
D797-1
014674
D790-1
1.
D791
D790-1
D790-2
D795
4.
D797-1
Redundant CAN-bus communication
UDCT01.02GB
014675
6.
11:11
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 11:13.
2.
3.
4.
5.
6.
Starter motor
Engine
Transmission
UDCT01.02GB
11:12
A
D791
Startup signal
D790-1
D790-2
D795
When all control units have redundant voltage feed and bus
communication, the system is ready to receive, process signals.
D797-1
1.
2.
3.
D791
D790-2
D795
Control unit cab (D790-1) has four outputs for voltage feed, other
control units have two inputs for redundant voltage feed. In case
of failure of one feed, the control unit is supplied from the other
feed.
D797-1
A
014676
D790-1
Startup
2
D790-1
D1 D2
1.
2.
Switch for start-up signal gives pulse to Control unit cab (D790-1).
D795
3
K1
D790-2
D797-1
4.
D793
5.
D3
D4
D794
014677
K4
UDCT01.02GB
11:13
S250
D1
1
2
D790-1
D5
D2
D4
K3009-1
D3
K3009-2
D791
D4
Y6010
1.
2.
3.
4.
5.
K3002
5
D797-1
Y6011
D4
Y6004
K3007
Y6005
014678
As extra safety the cab control unit (D790-1) also sends status
for Switch, control breaker (S250) on the CAN bus. In this way
functions are also cut off at signal level.
UDCT01.02GB
11:14
UDCT01.02GB
11:15
3
14
2
6
15
7
16
17
8
9
10
11
12
13
014679
18
1.
2.
3.
4.
5.
6.
Main fuses
7.
8.
9.
UDCT01.02GB
11:16
Light 2
4
3
006767
2
1
Light 4
Indicator lamps control units on frame and attachment
1
2
Light 1
Light 2
3
006766
Light 4
UDCT01.02GB
11:17
1.
5.
2.
6.
3.
7.
4.
8.
UDCT01.02GB
014680
11:18
11.6 Communication
Communication, general
The machine's communication is handled by a so-called CAN bus
system. The CAN bus system consists of control units connected
together to form a network.
1
D791
D790-1
D790-2
D795
D797-1
014681
2
D794
D793
1.
Segment
2.
CAN-bus drivetrain
The idea with the network is to share information. Signal values are
sent out by the control unit that, e.g., is connected to a sensor, other
control units can use the signal for their functions.
CAN L
D790-1
CAN R
D795
D790-2
CAN L
CAN R
CAN L
CAN L
CAN R
D797-1
Principle illustration redundant CAN-bus
014682
D791
D790-1
D794
D793
003171
UDCT01.02GB
D:1
D Error codes
D Error codes
Information is found in the Workshop
manual
See Workshop manual DCT 8090, section D Error codes.
For information how to order Workshop manual, see section A
Foreword.
UDCT01.02GB
D:2
UDCT01.02GB
E:1
E Diagrams
E Diagrams
Information is found in the Workshop
manual
See Workshop manual DCT 8090, section E Diagrams.
For information how to order Workshop manual, see section A
Foreword.
UDCT01.02GB
E:2
UDCT01.02GB
F:1
F Technical data
UDCT01.02GB
F:2
UDCT01.02GB
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.
1. Motor
Yuchai YC6A240-30
Max. rpm
2200 rpm
2200 rpm
Number of cylinders
6 cylinders
6 cylinders
2640 W
2240 W
Alternator, power
System voltage, voltage capacity
Cummings QSB6.7
2. Transmission
Dana HR32000
3 3
3. Driveline/Axle
Drive axle, type
Kessler D81
Kessler D91
4. Brakes
Footbrake system - wheels affected
Parking brake system - wheels affected
5. Steering
Hydraulic servo
Steering system
6. Wheels
12.00x24
14.00x24
Tyre pressure, also see pressure plate
Tyre type, front and rear
1.0 MPa
Air filled. Spare and replacement tyres must be of a brand approved by Cargotec.
Spirit Delta
9. Cab
Equivalent sound pressure level
in cab according to EN12053 with
measurement uncertainty R = 2.5 dB.
Measuring value with standard engine.
Whole-body vibration in accordance
with EN13059 with measurement
uncertainty k = 0.3 x measured value.
Yuchai YC6A240-30
Cummings QSB6.7
LpAZ 67 dB(A)
LpAZ 65 dB(A)
0.4 - 0.7 m/s2
UDCT01.02GB
F:4
Rating (W)
Socket
Control lights
1.2
W2x4.6d
Interior lighting
10
S8.5
Rear lights
BA15s
Brake lights
21
BA15s
Direction indicators
21
BA15s
Running lights
W2.1x9.5d
75/70
P43t-38 (H4)
Back-up lights
70
PK22s (H3)
Work light
70
PK22s (H3)
35
70
PK22s (H3)
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
Yuchai YC6A240-30
Cummings QSB6.7
380 L
Fuel quality
32 L
29 L
ES Compleat, Premix
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
Oil type, quality
Oil volume incl. filter
UDCT01.02GB
20 L
F:5
HR32000
See Oils and lubricants, recommendation, page F:8.
32 L
Oil volume
Kessler D81
Oil grade
Kessler D91
42 L
54 L
2x4 l
2x4 l
7 Load handling
Oil grade
10 Common hydraulics
Oil grade
320 L
450 L
UDCT01.02GB
F:6
A2
100
100
H4
H5
B S
H3
R2
R1
H6
H8
H10
014020
100
100
L3
L
L2
A1
DCT80
E5
DCT90
E6
E7
E8
E5
E6
E7
E8
Lifting capacity
Classification [kg x 103]
Centre of gravity distance (L4 [mm])
1220
1220
Dimensions
6900
6900
4050
4100
3940
4000
2800
2860
1185
1185
4550
4550
3270 2250
3270 2200
6750
7000
1150
1500
UDCT01.02GB
F:7
DCT80
E5
DCT90
E6
E7
E8
E5
E6
250
300
10600
10850
14200
14350
E7
E8
16220
18720
21220
15280
16280
18780
21280
8540
9040
10290
11540
8600
9100
10350
11600
15040
16040
18540
21040
15100
16100
18600
21100
3 3
3 3
2220
2280
600
600
Attachment
Height under twistlock (H10 [mm])
Height under lifting hooks (H10 [mm])
Side shift (V1 [mm])
Weight
Kerb weight [kg x 10 3]
35,5
36,1
37,6
39,1
36,4
37,0
38,5
40,0
22,7
23,3
24,8
26,3
22.9
23,5
25,0
26,5
34,9
35,5
37,0
38,5
36,7
37,3
38,8
40,3
12800
13500
8600
8700
UDCT01.02GB
F:8
-20
-10
+10
+20
+30
+40
-4
+14
+32
+50
+68
+86
+104
Cummings QSB6.7
API CH-4 or ACEA E5
SAE 50
SAE 40
Caterpillar TO-4
SAE 30
MIL-PRF-2104G
SAE 20
SAE 10W
NOTE
SAE 0W-20
SAE 80W-140
API GL-5
SAE 75W-90
10 Common hydraulics
ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oil is conditional on the sulphur
content in the fuel not exceeding 0.5%.
*) The oil in the brake system must meet one of the quality standards
as well as be a UTTO-oil (Universal Tractor Transmission Oil).
ACEA = Association des Constructeurs Europenne d'Automobiles
API = American Petroleum Institute
UDCT01.02GB
F:9
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.
Sealant silicone
Sealant silicone 923107.0308.
Silicone adhesive
Silicone adhesive 923854.0100.
Coolant
Only use ready-mixed recommended coolant. Select mixture of the
coolant that is adapted for correct temperature.
NOTE
It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protecting properties
decline with time, therefore the coolant must be changed according
to stated intervals.
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.
UDCT01.02GB
F:10
State
Nut
Screw
Lubrication
untreated
untreated
oil
bright galvanised
dry or oil
hot-galvanised
untreated
dry or oil
8.8
Quality
10.9
12.9
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
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
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
State
Fine M-thread
M-thread
UNC-thread
UDCT01.02GB
F:11
8.8
Quality
10.9
12.9
7/8
594 Nm
528 Nm
671 Nm
839 Nm
990 Nm
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
Thread
Tightening torque
inch
inch
Nm
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
3/8"
7-13 Nm
mm
Pressure switch
7/16"
The above values should be considered guidelines and may vary
depending on installation.
UDCT01.02GB
F:12
UDCT01.02GB
Pipe diameter
Tightening torque
mm
Nm
inch
6
1/4
5/16
10
3/8
12
1/2
14
15
16
5/8
18
3/4
20
22
7/8
25
1"
28
30
32
1"1/4
35
38
1"1/2
23-25
33-38
51-57
80-90
120-130
150-170
180-200
200-240
Wrench size
Tightening torque
mm
Nm
inch
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
F:13
Goods coupling
UNF-UN
Metric-ISO
BSSP
Thread (inch)
Tightening torque
(Nm)
Thread
(mm)
Tightening torque
(Nm)
Thread (inch)
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
Unit explanations
Unit
Abbreviation
Newton metre
Nm
Kilopond metre
kpm
Kilopascal
kPa
Megapascal
MPa
Kilowatt
kW
Kilojoule
kJ
Btu
Calorie
ca
Inch
in
Feet
ft
Yard
yd
Mile
mile
Centimetre
cm
Meter
Kilometre
km
UDCT01.02GB
F:14
Conversion SI-units
SI-unit
Conversion factor
Non-SI
Conversion factor
SI
Nm
x 10.2
= kg cm
x 0.8664
= lb in
Nm
x 0.74
= lbf ft
x 1.36
= Nm
x 0.102
= kg m
x 7.22
= lb ft
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
Torque
Nm
Pressure (Pa = N/
m2)
kp/cm
x 14.22
= psi
x 0.070
= kp/cm2
N/mm
x 145.04
= psi
x 0.069
= bar
x 145
= psi
x 0.00689
= MPa
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
x 0.74
= ft lb/s
x 1.36
= W
kJ
x 0.948
= Btu
x 1.055
= kJ
x 0.239
= calorie
x 4.19
= J
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
MPa
Power (W = J/s)
Energy (J = Nm)
Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft)
Temperature
C = (F 32)/1.8
F = (C x 1.8) + 32
Flow factor
l/min (dm3 /min)
UDCT01.02GB
x 0.264
= US gal/min x 3.785
= litre/min
F:15
cm
km
in
ft
yd
mile
cm
0.01
0.00001
0.3937
0.03281
0.01094
0.000006
100
0.001
39.37
3.2808
1.0936
0.00062
km
100000
1000
39370.7
3280.8
1093.6
0.62137
in
2.54
0.0254
0.000025
0.08333
0.02777
0.000015
ft
30.48
0.3048
0.000304
12
0.3333
0.000189
yd
91.44
0.9144
0.000914
36
0.000568
mile
160930
1609.3
1.6093
63360
5280
1760
1 mm = 0.1 cm - 1 mm = 0.001 m
cm2
m2
km2
ft2
yd2
in2
cm2
0.0001
0.000001
0.001076
0.000012
0.155000
m2
10000
0.000001
0.01
10.764
1.1958
1550.000
km2
1000000
10000
1076400
1195800
0.01
100
0.0001
1076.4
119.58
ft2
0.092903
0.000929
0.1111
144.000
yd2
0.83613
0.008361
1296.00
in2
6.4516
0.000645
0.006943
0.000771
cm3 = cc
m3
in3
ft3
yd3
cm3 = ml
0.000001
0.001
0.061024
0.000035
0.000001
m3
1000000
1000
61024
35.315
1.30796
dm3 (l)
1000
0.001
61.024
0.035315
0.001308
in3
16.387
0.000016
0.01638
0.000578
0.000021
ft3
28316.8
0.028317
28.317
1728
0.03704
yd3
764529.8
0.76453
764.53
46656
27
kg
oz
lb
0.001
0.000001
0.03527
0.0022
kg
1000
0.001
35.273
2.20459
1000000
1000
35273
2204.59
oz
28.3495
0.02835
0.000028
0.0625
lb
453.592
0.45359
0.000454
16
UDCT01.02GB
F:16
kp/cm2
bar
Pa=N/m2
kPa
lbf/in2
lbf/ft2
kp/cm2
0.98067
98066.5
98.0665
14.2233
2048.16
bar
1.01972
100000
100
14.5037
2088.6
Pa=N/m2
0.00001
0.001
0.001
0.00015
0.02086
kPa
0.01020
0.01
1000
0.14504
20.886
lbf/in2
0.07032
0.0689
6894.76
6.89476
144
lbf/ft2
0.00047
0.00047
47.88028
0.04788
0.00694
UDCT01.02GB
G:1
UDCT01.02GB
G:2
UDCT01.02GB
G:3
Description
Accumulator
Attachment
Anti-corrosion agent
Working hydraulics
All load handling functions, i.e. lift and lower, tilt, side shift, spreader and levelling.
Axle distance
Bar
Battery disconnector
Daily inspection
The actions that should be performed daily to ensure the machines functionality.
Decitonne
Display
Operating hours
Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle
Drivetrain
ECC
EHC
Electrolyte level
Expansion tank
Fixed displacement
Hanging load
Lifted load.
FMI
Main fuse
Located by battery. Cuts the power to all systems in the whole machine.
Hydraulic oil
Hydraulic system
Indicator
Manual "sensor", e.g., shows that a filter is clogged and needs to be replaced.
Refrigerant
Low-emission engine
LC
Load centre.
Lift capacity
Lifting point
Trolley
Solenoid 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: DCT 8090. See also type designation.
UDCT01.02GB
G:4
Term
Description
Environmental waste
Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter
Hub reduction
Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.
Planetary gear
Product alternatives
Proportional valve
Frame beam
Recirculation
Serial number
Service position
Servo
A small user movement results in a big machine movement, e.g. power steering.
Servo pressure
Side lift
Side shift
Levelling
Spirit Delta
SPN
Spreading
Widening of attachment.
Mast
Dust reservoir
The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.
Steering axle
Buzzer
Option
Tilting
Transmission oil
Oil for transmission and torque converter. See specifications in operator's manual.
Twistlocks
Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container for lifting.
Type designation
Maintenance
Periodic maintenance actions so that machine functions safely and for long life.
Wet brakes
Valve slide
UDCT01.02GB
Index
A
About the documentation . . .
About the maintenance manual .
Accumulator . . . . . . . . .
Accumulator charging valve . .
Air cleaning system . . . . . .
Air intake and exhaust outlet . .
Alternator . . . . . . . . . .
ATTACH . . . . . . . . . . .
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A:10
A:3
4:7
4:6
1:22
1:22
11:9
8:21
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. 11:7
11:11
. 9:38
. 4:3
. 4:3
10:12
. 8:6
B
Batteries. . . . . . . . . . .
Battery voltage (30) . . . . . .
Body structure . . . . . . . .
Brake pedal . . . . . . . . .
Brakes . . . . . . . . . . .
Breather filter hydraulic oil tank .
Bypass . . . . . . . . . . .
ENGINE . . . . . . . . . . . .
Engine's mechanical parts . . . .
Entertainment and communication
Environment . . . . . . . . . .
Error codes . . . . . . . . . .
Exhaust system . . . . . . . .
EXT-ATTACH . . . . . . . . .
EXTRA . . . . . . . . . . . .
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. . 1:17
. . 9:32
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B:21
8:8, D:1
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F
Feedback . . . . . . . . . . .
Fine filter hydraulic oil . . . . . .
Foreword . . . . . . . . . . .
Frame . . . . . . . . . . . . .
Frame, body, cab and accessories
FREELIFT . . . . . . . . . . .
Fresh air filter . . . . . . . . .
Fuel filter . . . . . . . . . . .
Fuel prefilter . . . . . . . . . .
Fuel system . . . . . . . . . .
Fuel tank . . . . . . . . . . .
Fuses . . . . . . . . . . . . .
. A:11
10:15
. A:3
. 9:37
. 9:3
. 8:22
. 9:25
. 1:15
. 1:11
. 1:9
. 1:10
. 11:4
C
CAB . . . . . . . . . . .
Cab interior . . . . . . . .
Cab structure and suspension
Cab undercarriage . . . . .
CAN bus . . . . . . . . .
CAN-bus drivetrain . . . . .
CAN/POWER . . . . . . .
Central lubrication . . . . .
CLIMATE . . . . . . . . .
Common electrics . . . . .
Common hydraulics . . . . .
Communication. . . . . . .
Complete machine . . . . .
Condenser . . . . . . . . .
Container counter. . . . . .
Control system . . . . . . .
Control system engine. . . .
Control system transmission .
Control units . . . . . . . .
Controls and instruments . .
Coolant . . . . . . . . . .
Cooling fan . . . . . . . .
Cooling system . . . . . . .
Crank mechanism . . . . .
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8:15
9:36
9:34
9:35
11:18
11:18
. 8:13
. 9:39
. 8:15
. 11:3
. 10:3
11:18
. 0:3
. 9:25
. 7:31
. 8:3
. 1:43
. 2:12
11:16
4:3, 9:4
. . 1:34
. . 1:28
1:27, 2:11
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. 8:10
. E:1
11:10
. 9:34
. 3:4
. 3:3
EL-STEERING . . . . . . . . . .
ELECTRIC SERVO . . . . . . . .
Electrical distribution box . . . . .
Electrical protection . . . . . . . .
Emergency stop switch voltage (15E)
Engine . . . . . . . . . . . . .
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. 8:22
. 8:20
11:15
. 11:3
11:13
. 1:3
D
Diagnostics . . . . .
Diagrams . . . . . .
Distribution of electricity
Doors . . . . . . . .
Drive axle . . . . . .
Driveline/Axle . . . .
G:5
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H
Heating, ventilation and air conditioning
HYD . . . . . . . . . . . . . . .
Hydraulic oil . . . . . . . . . . . .
Hydraulic oil filter . . . . . . . . . .
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. . 9:13
. . 8:16
. 10:13
. 10:12
I
I/O . . . . . . . .
Ignition voltage (15) .
Ignition/heating . . .
Intercooler . . . . .
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. . 8:23
. 11:12
. . 1:44
. . 1:26
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. . 7:22
. . 7:4
. . 9:28
. . 8:14
. . 5:4
. . 7:23
. . 7:3
1:39, 2:8
Mast . . . . . . . . .
Mechanical transmission.
Moisture filter . . . . .
Monitoring . . . . . . .
MOVE-CAB . . . . . .
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7:6, 7:21
. . 2:7
. . 9:26
. . 8:6
. . 8:22
L
Levelling. . . . .
Lifting/lowering . .
Lighting system. .
LIGHTS . . . . .
Link arm . . . . .
Load carrier . . .
Load handling . .
Lubrication system
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O
OLS . . . . . . . . . . . . . . . . . . . . . . . 8:21
OPT . . . . . . . . . . . . . . . . . . . . . . . 8:22
UDCT01.02GB
G:6
P
Paint/coatings . . . . . . .
Parking brake pads . . . . .
Parking brake system . . . .
Parking brake unit . . . . .
Position sensor mast . . . .
Power assisted system . . .
Power-assisted brake system
Preventive maintenance . . .
Propeller shaft . . . . . . .
Pumps . . . . . . . . . .
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9:41
4:12
4:9
4:11
7:9
5:3
4:4
C:3
3:3
10:6
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. 1:27
. A:4
. 9:33
11:18
11:12
. 6:14
. 8:23
. 9:33
UDCT01.02GB
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7:18
7:13
11:7
1:45
5:3
6:3
6:3
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. 10:5
. F:3
10:10
. G:3
. G:3
. 7:20
. 7:21
. 2:6
. 8:19
. 2:3
. 7:10
. 1:24
. 7:23
. 6:13
. 6:6
T
Tanks and accumulators . . . . . . . . . .
Technical data . . . . . . . . . . . . . .
Temperature control, cleaning and hydraulic oil
Terminology . . . . . . . . . . . . . . .
Terminology and index . . . . . . . . . .
Tilt . . . . . . . . . . . . . . . . . . .
Tilt cylinder . . . . . . . . . . . . . . .
Torque converter/Clutch system . . . . . .
TRANSM . . . . . . . . . . . . . . . .
Transmission. . . . . . . . . . . . . . .
Trolley. . . . . . . . . . . . . . . . . .
Turbo . . . . . . . . . . . . . . . . . .
Twistlocks . . . . . . . . . . . . . . . .
Tyres . . . . . . . . . . . . . . . . . .
Tyres and rims . . . . . . . . . . . . . .
S
Safety . . . . . . . . . . . . .
Safety and emergency equipment.
Safety instructions . . . . . . .
Safety valves. . . . . . . . . .
Seats . . . . . . . . . . . . .
Service indicator . . . . . . . .
Settings . . . . . . . . . . . .
Side shift . . . . . . . . . . .
Signalling system . . . . . . . .
Speed limitation . . . . . . . .
Speed reduction . . . . . . . .
Spreader beam . . .
Spreading . . . . .
Start battery . . . .
Start/stop . . . . .
Steering . . . . . .
Steering axle cradle .
Suspension . . . .
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B:3
9:9
B:4
10:4
9:10
8:7
8:24
7:11
9:30
8:6
7:31
Valve mechanism .
VBFS . . . . . .
Voltage converter .
Voltage feed . . .
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. . 1:17
. . 8:22
. 11:14
. 11:10
Wheel brake . . . .
Wheel hub . . . . .
Wheel spindle . . .
Wiper/washer system
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. 4:8
. 6:5
. 6:4
. 9:27
G:7
UDCT01.02GB
last page
Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 00
fax +46 372 263 90
www.cargotec.com