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Handler for empty containers

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

Maintenance Manual DCT 8090

UDCT01.02GB

A:2

UDCT01.02GB

Maintenance Manual DCT 8090

A Foreword Foreword

A:3

A Foreword
About the maintenance manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.
The maintenance manual contains information about how the machine
should be maintained for maximal operating reliability and service
life as well as troubleshooting information for fast correction of any
malfunctions.

Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.
Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.

Storage

NOTE
The maintenance manual shall be accessible to service personnel.

About the machine version


The information in this publication corresponds to the machine's
design and appearance when delivered from Cargotec. There may be
differences due to customisation of the machine.
Cargotec reserves the right to change specifications and equipment
without prior notification. The information in the manual is valid at the
time of publication.

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

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

Maintenance Manual DCT 8090

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A:4

A Foreword Reading instructions

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

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

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

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

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

NOTE
Information that is important without being related to safety.

Read operator's manual


000262

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

Read the operator's manual

001128

Read maintenance manual


The symbol to the left is used in certain cases on the machine and
refers to important information in the maintenance manual.

Read the maintenance manual

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Maintenance Manual DCT 8090

A Foreword Reading instructions

A:5

Maintenance manual's content


The information in the maintenance manual is divided into function
groups (0-12) to facilitate searching for information. The manual is
divided in 20 sections A-C, 0-12, D-G. The sections with letters contain
specific information that applies to several function groups and is not
bound to a function, e.g., section "F Technical data". This is described
in greater detail in the table below.
For more information about function groups, see Function group
structure, page A:6.
A

Foreword

General information about the maintenance manual's purpose, content and


reading instructions as well as survey for feedback of views and eventual
inaccuracies.

Safety

Keep in mind for your safety.

Preventive maintenance

General information about preventive maintenance of the machine.

Complete machine

Engine

Transmission

Driveline/Axle

Brakes

Steering

Technical description, description of the machine's functions with schematic


drawings and explanatory texts for the included components.

Suspension

Overviews with the components' position on the machine.

Load handling

Work instructions for preventive maintenance.

Control system

Work instructions for checking and adjusting.

Frame, body, cab and


accessories

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

Technical data, conversion tables, information for conversion of units.

Terminology and index

General terminology and abbreviations, explanations of terms and abbreviations


that may appear in the manual, index for headings in the manual.

Maintenance Manual DCT 8090

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A:6

A Foreword Reading instructions

Function group structure


The information in the manual is divided in a structure of functions
at different levels, based on the machine's design and use, called
function groups.
The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
done at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.
The idea is that the function groups are intended to work as a search
term to find different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.
The maintenance manual and workshop manual contain different
information. The maintenance manual only includes information
needed for preventive maintenance as well as simpler troubleshooting.
The workshop manual includes more in-depth information and repair
instructions.
References between sections in the same manual are indicated with
section and group number, e.g., "see section 4 Brakes, group 4.3.9
Wheel brake". References within a section are indicated with a page
number, e.g., "see Sensor fuel level, description page 24".
References are not given between Maintenance manual and Workshop
manual. If more information is desired for a function group, the primary
recommendation is to search under the same function group in the
other manual.

Product alternatives and optional equipment


The information in the manual is divided in modules. For product
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.
Special equipment is not described in the manual. If you're uncertain
about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:7.
Product alternatives

000264

Product alternatives

Symbol indicating optional equipment

Product alternatives are such options that exclude certain standard


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

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Maintenance Manual DCT 8090

A Foreword Reading instructions

A:7

Optional equipment
Optional equipment are options that can be added to the standard
equipment to obtain additional or improved functions.
Information for optional equipment is described in separate sections
with the standard equipment as starting point. Description of the
optional equipment describes how the standard function is affected by
the option as well as which additional components are added.

Machine card

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

IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
The machine card indicates of which drawings the machine consists,
in many cases these can be associated to options and product
alternatives. For more information on handling product alternatives and
optional equipment, see Product alternatives and optional equipment,
page A:6. The machine card is supplied with the spare parts catalogue
and should be in the cab.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the first and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.
If the information on the machine card does not help, contact Cargotec.

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

Function descriptions
Function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.
The function descriptions describe the function in a logical flow from
input signal to desired output signal. Most functions require that
pre-determined conditions are fulfilled for that function to be activated.
In these cases the conditions are listed above the figure.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.

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A:8

A Foreword Reading instructions

4:10

4 Bromsar Parkeringsbromssystem

4.5 Parkeringsbromssy
Parkeringsbromssys

stem

tem, funktionsbeskrivning

Parkeringsbromsen best r av hydrauloljetank, Hydrauloljepump broms


och styrning, Ventilblock ackumulatorladdnings - och prioriteringsventil,
Ventilblock bromssystem, tryckgivare och parkeringsbromsenhe t.
Hydrauloljepump broms och styrning (fr n tanken). Ventilblock
ackumulatorladdnings - och prioriteringsventil styr tryck till
ackumulatorerna som lagrar trycket. Parkeringsbromsenhe ten lossas
med tryck fr n ackumulatorerna genom att parkeringsbromsventile n i
Ventilblock bromssystem trycks tter parkeringsbromsoket. Slutkontakt
parkeringsbroms ger signal s att Indikeringslampa parkeringsbroms
t nds n r parkeringsbromsen r ansatt.

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.

Str mst llare parkeringsbroms

2.

Reglerenhet hytt (D790 -1)

3.

Reglerenhet ram (D797 1)

4.

Magnetventil parkeringsbroms

5.

Hydrauloljepump broms och styrning

11. Reglerenhet KIT (D790 -2)

6.

Ventilblock ackumulatorladdnings - och


prioriteringsventil

12. Indikeringslampa parkeringsbroms

(Y642)

7.

Brytkontakt parkeringsbroms

8.

Ackumulatorer

9.

Ventilblock bromssystem

(S200)

10. Parkeringsbromsok
014684

(S107)

014645

Example of function description


1.

Electric power (solid single line)

2.

Hydraulic force (solid double line)

3.

Illustration of function, (applied brake)

4.

Component list

5.

Position number in illustration, reference to


component list

UDCT01.02GB

6.

Flag pressure check connection (Check point),


indicates that there is pressure check connection for
checking pressure signal

7.

Flag diagnostic test, indicates that the signal can be


checked with diagnostic test, see section 8 Control
system, group 8.4 Diagnostics

8.

Electric signal (dashed single line)

Maintenance Manual DCT 8090

A Foreword Reading instructions

Symbol explanation function descriptions

Symbol explanation function descriptions


The following symbols are used in function descriptions, the symbols
are based on standard symbols used in wiring and hydraulic diagrams.

A:9

10

1.

Electric control signal

2.

Electric force

3.

Hydraulic control signal

4.

Hydraulic force

5.

Hydraulic motor

6.

Hydraulic oil pump with variable displacement

7.

Hydraulic oil pump with fixed displacement

8.

Electric motor

9.

Accumulator

10. Disc brake


11. Filter

11

12. Radiator

12

13. Bulb
14. Control system, two control units with CAN-bus

D790-1

13

15. Restriction

14

16. Adjustable restriction

D797-F

17. Inductive position sensor

15

16

17

18

18. Electrically controlled servo valve


19. Thermal bypass valve

19

21

23 Pa

20. Temperature-controlled switch


21. Temperature sensor

20 C
22

22. Pressure sensor


23. Pressure-controlled switch

Pa

24. Hydraulic cylinder


25. Double-acting hydraulic cylinder

24

26. Spring brake cylinder


27. Valve block

25

28. Shuttle valve

26

27

28

29

014726

29. Non-return valve

Maintenance Manual DCT 8090

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A:10

A Foreword About the documentation

About the documentation


The documentation's parts
The documentation for the machine consists of the following parts:

Operator's manual
The operator's manual is delivered with the machine in the cab.

Documentation kit
Maintenance manual and spare parts catalogue with machine card are
delivered to the machine as a separate documentation kit.

Supplementary documentation
Supplementary documentation can be ordered for the machine.

Workshop manual

Supplier documentation for engine, transmission and drive axle.

Ordering of documentation
The documentation is ordered from the dealer for Cargotec.
Always specify publication number when ordering.
For publication number, see the machine card.

UDCT01.02GB

Maintenance Manual DCT 8090

A Foreword Feedback

A:11

Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To:

Cargotec Sweden AB
Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93

From:
Company / Sender: ..........................................................................................................................................

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

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

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


Manual information

Name / Publication number: .............................................................................................................................

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


Suggestions,
views, remarks,
etc.

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

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

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

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

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

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

Maintenance Manual DCT 8090

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A:12

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Maintenance Manual DCT 8090

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

Maintenance Manual DCT 8090

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B:2

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Maintenance Manual DCT 8090

B Safety Safety

B:3

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

follow the instructions in this manual

be trained for the work in question

follow local laws, safety rules and regulations

use the correct equipment and tools for the job

wear the correct clothes

use common sense and be careful. Do not take any risks!

Cargotec has in this publication documented and warned for situations


and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.
Therefore, it is very important that all who work with the machine, or
carry out repairs or service work, acquaint themselves with and act
according to the information in the Maintenance Manual and Operator's
Manual.

A near accident is a warning!


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

Maintenance Manual DCT 8090

UDCT01.02GB

B:4

B Safety Safety instructions

Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:

Service position, page B:4

Hydraulic and brake systems, depressurising, page B:5

Oils, page B:6

Fuel system, page B:7

Clothing, etc., page B:8

Several mechanics on the same machine, page B:8

Working under machine, page B:9

Lifting heavy components, page B:9

Vibrations, page B:9

Noise, page B:11

Solvents, page B:11

Fire and explosion risks, page B:12

Fluid or gas under pressure, page B:14

Coolant, page B:15

Refrigerant, page B:15

Air pollution, page B:16

Tensioned springs, page B:17

Electric motors, page B:17

Rotating components and tools, page B:17

Tyres and rims, page B:18

Lifting equipment, page B:18

Spare parts, page B:19

Non-ionised radiation, page B:19

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.

Trolley and attachment in completely lowered position.

Mast fully tilted forward.

Engine off.

System voltage off (with battery disconnector).

009797

Machine with trolley and attachment in completely


lowered position

UDCT01.02GB

Maintenance Manual DCT 8090

B Safety Safety instructions

B:5

Hydraulic and brake systems, depressurising


1

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

Depressurise the hydraulic system.


Turn on the system voltage and turn the start key to position I.
Repeatedly activate the load handling functions.

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

Depressurise the brake system by opening the drain valve on the


accumulator charging valve.

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

NOTE

014618

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

Maintenance Manual DCT 8090

UDCT01.02GB

B:6

B Safety Safety instructions

Depressurise the attachment.


Open relief valve top lift.

CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to fine filter hydraulic oil.

014620

Check that relief valve attachment is closed before the


engine is started.

The figure above shows open valve.

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

Maintenance Manual DCT 8090

B Safety Safety instructions

B:7

Fuel system
The following safety instructions shall be followed for work when
handling fuel.

DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces and
may ignite.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.

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

CAUTION
Always clean the area around components and
connections before loosening them. Dirt in the fuel
system can cause malfunctions and engine stops in
unwanted situations, as well as increased wear and
material damages.

Maintenance Manual DCT 8090

UDCT01.02GB

B:8

B Safety Safety instructions

IMPORTANT
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised for
this work.

Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
Remove jewellery as it may conduct electricity and get caught in
moving parts.
Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.

Several mechanics on the same machine

WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
Movements performed from the operator's station, e.g., all movement
of lifting equipment, may cause severe personal injuries.

Safety actions

UDCT01.02GB

Make sure that the machine's lifting equipment is completely


lowered or secured in another way.

Move the battery disconnector to position zero and remove the key.

Be aware of the risks when several persons work around the


vehicle.

Make your co-workers aware of what you're working with.

Do not work with drive wheels on the machine's both sides at the
same time.

Maintenance Manual DCT 8090

B Safety Safety instructions

B:9

Working under machine


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

Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.

Safety actions

Use axle stands and supports that stand securely.

Lifting tools should be inspected and type approved for use.

Lifting heavy components

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

Risks
Unsuitable lift slings, straps, etc. may break or glide.
The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.
A component lifted with lifting equipment can start to turn if the centre
of gravity changes.
A component lifted using an overhead crane may start to swing
back and forth, which can cause severe crushing injuries or material
damage.

Safety actions
Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs. See the workshop
manual for methods.
If lifting must be performed without lifting device:

Lift near the body.

Keep your back vertical. Raise and lower with your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.

Wear gloves. They're often good protection to reduce crushing


and cutting injuries to fingers.

Always use protective shoes.

Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.
Maintenance Manual DCT 8090

UDCT01.02GB

B:10

B Safety Safety instructions

Safety actions

UDCT01.02GB

Use heavy gloves to protect against the cold and transfer of


vibrations.

Switch between work duties to give the body time to rest.

Vary work position and grip so that the body is not stressed in only
one position by the vibrations.

Maintenance Manual DCT 8090

B Safety Safety instructions

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.

Limit noise with noise-absorbing dividers, for example,


noise-absorbing materials in roof and on walls.

Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, trichloroethylene, toluene.
Many solvents are flammable.

Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the central nervous
system may be injured. This manifests itself as trouble sleeping,
depressions, nervousness, poor memory, and general tiredness.
Continuous inhalation of gasoline and diesel vapours is suspected
of causing cancer.

Safety actions

Avoid inhaling solvent fumes by providing good ventilation, or


wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.

Never leave a solvent container without tight-sealing lid.

Use solvents with a low content of aromatic compounds. This


reduces the risk of injuries.

Avoid skin contact.

Use protective gloves.

Make sure that work clothes are solvent-resistant.

Maintenance Manual DCT 8090

UDCT01.02GB

B:12

B Safety Safety instructions

Fire and explosion risks

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

DANGER
Smoke from a fire may be very toxic.
Smoke anesthetises, suffocates, and kills! Smoke
from fires, even small amounts, can damage lungs and
respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
fire and working with burnt materials.
Examples of flammable and explosive substances are oils, gasoline,
diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.

Risks
Examples of causes of ignition are welding, cutting with a welding
torch, smoking, sparks from grinding machines, contact between
hot machine parts and flammable materials, heat generation in rag
drenched with oil or paint (linseed oil), and oxygen. Oxygen cylinders,
lines, and valves shall be kept free from oil and grease.
Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding flames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.

UDCT01.02GB

Maintenance Manual DCT 8090

B Safety Safety instructions

B:13

Special cases
Gas oil with added gasoline has a reduced flash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive fires.
When a battery is being charged, the battery electrolyte's water is
divided into oxygen and hydrogen gas. This mixture is very explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge device is used since this increases the risk of sparks.
In today's machines there are a lot of electronics. When welding,
all control units must be unplugged and the electric power must be
turned off with the battery disconnector. Powerful welding currents may
otherwise short-circuit the electronics, destroy expensive equipment,
and may cause an explosion or fire.
Never weld on painted surfaces (remove paint, preferably by blasting at
least 10 cm around the welding or cutting point). Use gloves, breathing
protection, and protective safety glasses. Also, never weld near plastic
or rubber materials without first protecting them from the heat. Paint,
plastic, and rubber generate many substances when heated, and these
may be hazardous to health. Be careful with machines that have been
exposed to intense heat or fire.

Safety actions

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

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


compartment before starting the engine and after operation, when
the engine has been stopped. This ensures fast detection if
anything abnormal has happened or is about to occur. Pay special
attention to oil, fuel, or coolant leaks, loose bolts, worn or poorly
tensioned drive belts, loose connections, damaged hoses, and
electrical cables. The inspection only takes a few minutes and may
prevent serious problems and expensive repairs.

Store hazardous substance in approved and sealed container.

Make sure that there is no ignition source near flammable or


explosive substances.

Make sure that ventilation is adequate or there is an air extraction


unit when handling flammable substances.

Maintenance Manual DCT 8090

UDCT01.02GB

B:14

B Safety Safety instructions

Fluid or gas under pressure


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

Risks
Risk of damage/injuries in connection with work on:

Hydraulic systems (e.g., working hydraulics and brake system).

Fuel system.

Changing tyres.

Climate control unit (air conditioning).

Cooling system.

Safety actions

UDCT01.02GB

Use protective goggles and protective gloves.

Never work in a pressurised system.

Never adjust a pressure limiting valve to a higher pressure than


the manufacturer's recommendations.

A hydraulic hose that swells, e.g., at a connection, shows that it


is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.

Use fluid when checking for leaks.

Never blow clothes clean with compressed air.

Failed pressure accumulators shall first be drained of pressure


and then punctured before being discarded (to avoid risk of
explosion). Carefully drill a hole with 3 mm diameter after draining
the pressure.

Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.

First open the cooling system's cap for the filling point, to release
the high pressure. Hot steam and coolant may otherwise jet out.

Maintenance Manual DCT 8090

B Safety Safety instructions

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

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


splashing or spraying.

First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.

If possible, avoid working on the cooling system when the coolant


is hot.

Refrigerant
Refrigerant is used in the 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

Follow special instructions and equipment for refrigerant according


to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)

Use protective gloves and safety glasses if theres a risk of leaks.

Make sure that heat-producing sources or objects are not close by


(cigarette glow, welding flame).

Maintenance Manual DCT 8090

UDCT01.02GB

B:16

B Safety Safety instructions

Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
The following health-hazardous air pollution is especially prominent in
workshops:

Carbon monoxide (fumes) is found in exhaust gases. Odourless


and therefore extremely dangerous.

Nitrogen oxides (nitrous gases) are present in exhaust fumes.

Welding smoke especially hazardous to health when welding on


oily surfaces, galvanised or lacquered materials.

Oil mist for example, when applying anti-corrosion agent.

Grinding dust and gases generated when grinding and heating


plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.

Isocyanates are present in certain paints, fillers, adhesives and


foam plastics used on machines.

Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates may be released in the form of vapour, dust (or may
be found in aerosol) when cutting, grinding, or welding. May cause
mucous membrane irritation with asthma-like symptoms and impaired
lung function. Even brief exposures to high concentrations may cause
problems with persistent hypersensitivity.

Safety actions

UDCT01.02GB

Make sure of adequate ventilation with fresh air when welding,


battery charging and other work when hazardous gases are
generated.

Use suitable protective gloves and breathing protection when there


is risk of oil mist. Make sure that the protection is oil-resistant.

Apply oil-resistant protective lotion to unprotected skin.

Make sure that an eyewash station is in the immediate vicinity


when working with corrosive substances.

Avoid unnecessary operation of the machine inside the workshop.


Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.

Maintenance Manual DCT 8090

B Safety Safety instructions

B:17

Tensioned springs
Examples of tensioned springs:
1.

Torque springs in, e.g., pedals.

2.

Return spring (cup springs) in parking brake cylinder.

3.

Lock rings

4.

Gas springs

Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.

Safety actions

Use safety glasses.

Lock rings should be of a suitable type and in good condition.

Follow the instructions in this and other manual when performing


maintenance and changing parts and components.

Always use recommended tools.

Electric motors
Safety actions
Always turn off the battery disconnector when working on electric
motors.
Always block the 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.

Rotating components and tools


Examples of rotating components and tools:

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.

Maintenance Manual DCT 8090

UDCT01.02GB

B:18

B Safety Safety instructions

Safety actions

Do not use gloves when working with a drill.

Remove loose, hanging clothing, scarf or tie.

Never use clothing with wide sleeves or pant legs.

Make sure that clothing is intact and in good condition.

Long hair should be gathered up in a hair-net or similar.

Remove large or loose hanging jewellery from hands, arms and


neck.

Tyres and rims

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

Risks
Dismantling wheels: Tyres, rims, and lock rings may be ejected.
Inflating tyres: Tyres, rims, or lock rings may be ejected.

Safety actions

Always deflate the tyre before starting to work on the wheel.

Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.

Wheels shall be inflated on the machine or in a protective device,


designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.

Use protective screen and safety glasses.

Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with 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

Maintenance Manual DCT 8090

B Safety Safety instructions

B:19

Spare parts

WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:

Brake valve

Drive axle

Steering valve (Orbitrol)

Steering valve incl. priority valve

Steering axle

Steering cylinder

Rim

Mast, carriage

Lift cylinder incl. load control valve

Lifting chains

Chain tightener and shaft

Lift cylinder

Valve block lift

Tilt cylinder

Twistlock

Control breaker (for hydraulic function)

Emergency stop

Accumulator

Main valve load handling

Accumulator charging valve

All control units

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.

Maintenance Manual DCT 8090

UDCT01.02GB

B:20

B Safety Safety instructions

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

Maintenance Manual DCT 8090

B Safety Environment

B:21

Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.
Still there are no environmentally safe chemicals, e.g., oils and
coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.
By following the simple rules below, you will contribute to protecting
our environment.

Recycling
Well-planned recycling of the machine is the starting point for finishing
the life cycle and making use of materials for re-use in new products.
According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.

Environmentally hazardous waste


Components such as batteries, oils and other chemicals, and other
materials that may constitute environmentally hazardous waste, must
be handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.

Oils and fluids


Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.

Air conditioning system


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

Working in a contaminated area


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

Maintenance Manual DCT 8090

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

Maintenance Manual DCT 8090

C:1

C Preventive maintenance

Contents C Preventive maintenance


Preventive maintenance ................................................................................... C:3
Preventive maintenance, general ................................................................... C:3
Preventive maintenance, work instructions..................................................... C:3
Check and service log..................................................................................... C:4
50h-check ....................................................................................................... C:6
Service schedule............................................................................................. C:8
Washing ........................................................................................................ C:14
Lubrication 500 hours ................................................................................... C:14
Lubrication 1000 hours ................................................................................. C:19
Checking for cracks ..................................................................................... C:22

Maintenance Manual DCT 8090

UDCT01.02GB

C:2

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

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.

Preventive maintenance, work instructions


1

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


nuts during the first work week until they are seated properly.
This should be done at an interval of 45 operating hours (up to
approx. 4050 operating hours).

For a new machine, perform check actions after 50 operating


hours, see 50h-check, page C:6.
Note completed 50h-check in the service log, see Check and
service log, page C:4.

Regular service shall be performed according to service schedule,


see Service schedule, page C:8. The service schedule shall be
followed to ensure high machine reliability and safety.
Note completed service in the service log, see Check and service
log, page C:4.

Maintenance Manual DCT 8090

UDCT01.02GB

C:4

C Preventive maintenance Preventive maintenance

Check and service log


Model:
Serial number:

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

Maintenance Manual DCT 8090

Signature

C Preventive maintenance Preventive maintenance

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

Maintenance Manual DCT 8090

Signature

UDCT01.02GB

C:6

C Preventive maintenance Preventive maintenance

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

Performance and exhaust smoke, check (engine


alternative Yuchai YC6A240-30)
Bolted joints, attachments, mountings, hose clamps,
wear and chafing of hoses, cable harnesses, etc.
Sealing check oil, coolant, exhaust system
Fuel prefilter, draining condensation

Section 1 Engine, group 1.2.3 Fuel pre-filter

Air filter indicator, check

Section 1 Engine, group 1.6.1 Air cleaning system

Air filter main cartridge, inspection


Air filter safety cartridge, inspection
Drive belt tension, checking

Section 1 Engine, group 1.7.5 Cooling fan

Coolant level, check

Section 1 Engine, group 1.7.7 Coolant

Engine oil and oil filter, change

Section 1 Engine, group 1.8 Lubrication system

Oil pressure

2 Transmission
Leakage check
Oil level, check

Section 2 Transmission, group 2.6 Lubrication system

Transmission oil filter, changing

Section 2 Transmission, group 2.6 Lubrication system

3 Driveline/Axle
Mounting propeller shaft, check-tightening

Section 3 Driveline/Axle, group 3.2 Propeller shaft

Mounting drive axle, inspection

Section 3 Driveline/Axle, group 3.3 Drive axle

4 Brakes
Leakage check
Power-assisted brake, function check

Section 4 Brakes, group 4.3.4 Accumulator

Parking brake, function check

Section 4 Brakes, group, 4.5.4 Parking brake unit

5 Steering
No action

6 Suspension
Tyres and rims, check

Section 6 Suspension, group 6.3 Tyres and rims

Wheel nuts, check-tightening

Section 6 Suspension, group 6.3 Tyres and rims

7 Load handling
Hose connections, check-tightening
Bolted joints, check-tightening
Mast wheel and slide plates, function check
Slide plates and support rollers, function check
Sensors

Check that all sensors are undamaged and free of grease.

Attachment

Check for damage

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

Lifting chains, checking and adjusting

C:7

Section 7 Load handling, group 7.2.9 Mast

Chain tension spreading, checking and adjusting

Section 7 Load handling, group 7.10.5.1 Spreading

8 Control system
Check that there are no active error codes

Section 8 Control system, group 8.3 Error codes

9 Frame, body, cab and accessories


No action

10 Common hydraulics
Leakage check, check-tightening as required
Hydraulic oil level, check

Section 10 Common hydraulics, group 10.6.8 Hydraulic oil

Fine filter hydraulic oil, changing

Section 10 Common hydraulics, group 10.6.9 Fine filter hydraulic


oil

11 Common electrics
Batteries, check

Section 11 Common electrics, group 11.3.1 Start battery

Maintenance Manual DCT 8090

UDCT01.02GB

C:8

C Preventive maintenance Preventive maintenance

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

Check for and remove


traces of combustible
materials in the engine
compartment.

Section B Safety

0 complete machine
Checking
cleanliness and
leakage

Take extra care on hot


surfaces such as exhaust
systems, manifolds or
turbo.
If leaks of oil, fuel, or
coolant are detected, find
the cause and solve the
problem.
Attachments (stub
axles)

Visual check in
connection with greasing.

Lubrication 500 hours, page


C:14

Lubrication 1000
hours

Lubrication 1000 hours, page


C:19

Checking for
cracks

C*

C*

Lubrication 500
hours

* Check every 1000h or


every year.

Checking for cracks , page


C:22

For volume and quality,


see section F F Technical
data.

Section 1 Engine, group 1.8


Lubrication system

Clean if necessary.

Section 1 Engine, group 1.2.1


Fuel tank

1 Engine (engine alternative Yuchai YC6A240-30)


Engine oil

Engine oil filter

Performance and
exhaust smoke,
check

Fuel tank

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

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.

Section 1 Engine, group 1.2.3


Fuel pre-filter

Change filter earlier if


error code is displayed.
R

Change filter earlier if


error code is displayed.

Section 1 Engine, group 1.2.4


Fuel filter

Air filter main


cartridge

C/R

C/R

C/R

Checking indicators,
change when indicated.

Section 1 Engine, group 1.6.1


Air cleaning system

Air filter safety


cartridge

C/R

C/R

Changed every other


time main cartridge is
changed.

Section 1 Engine, group 1.6.1


Air cleaning system

Turbo

Exhaust system

Check sealing and


suspension.

Section 1 Engine, group 1.6.3


Exhaust system

Intercooler

Check sealing and


suspension.

Section 1 Engine, group 1.6.4


Intercooler

External cleaning.

Section 1 Engine, group 1.7.4


Radiator and expansion tank

Fuel filter

Radiator

Section 1 Engine, group 1.6.2


Turbo

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

Change when needed.

Section 1 Engine, group 1.7.5


Cooling fan

For volume and quality,


see section F F Technical
data.

Section 1 Engine, group 1.7.7


Coolant

For volume and quality,


see section F F Technical
data.

Section 1 Engine, group 1.7.7


Coolant

Checks and
check-tightening

Visual check for damage


or corrosion.

1 Engine (engine alternative Cummins QSB6.7

Exhaust system

Sealing check.

Section 1 Engine, group 1.6.3


Exhaust system

Charge air hoses

Sealing check.

Section 1 Engine, group 1.6.4


Intercooler

Engine oil

For volume and quality,


see section F F Technical
data.

Section 1 Engine, group 1.8


Lubrication system

Engine oil filter

At every oil change

Clean if necessary.

Fuel tank

Maintenance Manual DCT 8090

Section 1 Engine, group 1.2.1


Fuel tank

UDCT01.02GB

C:10

Object, action

C Preventive maintenance Preventive maintenance

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.

Section 1 Engine, group 1.2.3


Fuel pre-filter

Change filter earlier if


error code is displayed.
Fuel filter

Change filter earlier if


error code is displayed.

Section 1 Engine, group 1.2.4


Fuel filter
Section 1 Engine, group 1.6.1
Air cleaning system

Air filter main


cartridge

C/R

C/R

C/R

Checking indicators,
change when indicated.

Air filter safety


cartridge

C/R

C/R

Changed every other


time main cartridge is
changed.

Radiator

External check and


cleaning.

Section 1 Engine, group 1.7.4


Radiator and expansion tank

NOTE
Do not use high
pressure wash.
Drive belts

C/R

Drive belt
tensioner

C/R

C/R

Change when needed.

C/R

C/R

* Check every 1000h or


every year.

Section 1 Engine, group 1.7.5


Cooling fan

Change when needed.


Fan hub
Coolant level

* Check every 1000h or


every year.

Level check.
The coolant should be
changed after 2000h
and the cooling system
checked/cleaned during
the change.

Section 1 Engine, group 1.7.7


Coolant

For volume and quality,


see section F F Technical
data.
Coolant, freezing
point

Coolant quality,
checking
Bolted joints,
attachments,
mountings, etc.
Valve clearance

Valve clearance
checked/adjusted after
5000h / every 4th year.

Section 1 Engine, group 1.5.4


Valve mechanism

Check every 2000h or


every other year.

Section 1 Engine, group 1.5.6


Crank mechanism

Clean if necessary

Section 2 Transmission, group


2.2 Torque converter

Vibration damper,
rubber

Check after 1.000h or


every year.

2 Transmission
Breather filter

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

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

The transmission oil


should be changed
every 1,000 hours or 1
time/year.

Section 2 Transmission, group


2.6 Lubrication system

For volume and quality,


see section F F Technical
data.
Transmission oil

For volume and quality,


see section F F Technical
data.

Bolted joints and


universal joint.

Drive axle

Drive axle oil

Mounting drive
axle

Section 3 Driveline/Axle,
group 3.3 Drive axle

Section 4 Brakes, group 4.1.1


Brake pedal

3 Driveline/Axle
Propeller shaft

Section 3 Driveline/Axle,
group 3.2 Propeller shaft
Section 3 Driveline/Axle,
group 3.3 Drive axle

For volume and quality,


see section F F Technical
data.

Section 3 Driveline/Axle,
group 3.3 Drive axle

4 Brakes
Brake pedal
Hydraulic oil
pump brakes and
steering

Section 4 Brakes, group 4.3.1


Hydraulic oil pump brakes and
steering

Accumulator

Section 4 Brakes, group 4.3.4


Accumulator

C/R

C/R

C/R

Check pad thickness,


change when needed.

Section 4 Brakes, group 4.5.4


Parking brake unit

C/L

C/L

C/L

Check bearings.

Lubrication 500 hours, page


C:14

Parking brake

5 Steering
Link arms

6 Suspension
Wheel spindle,
check
Wheel hub
steering axle,
check
Tyres and rims

Wheel nuts
Rim

Section 6 Suspension, group


6.2.2 Wheel spindle

Check bearing pre-load.

Section 6 Suspension, group


6.2.3 Wheel hub

Damage, wear and


pressure, change as
needed.

Section 6 Suspension, group


6.3 Tyres and rims

Check-tightening.

Section 6 Suspension, group


6.3 Tyres and rims

C*

* Checking for cracks,


every 2,000 hours and
in connection with tyre
changes.

Section 6 Suspension, group


6.3.2 Rim

7 Load handling

Maintenance Manual DCT 8090

UDCT01.02GB

C:12

Object, action

C Preventive maintenance Preventive maintenance

Service
250 h,
750 h,
1,250
h, etc.

500h,
1500h,
2500h,
etc.

Comment

Reference

1000h,
3000h,
5000h
etc.

2000h,
4000h,
6000h
etc.

Check wear, change as


needed.

Section 7 Load handling,


group 7.5.4 Spreader beam

Check damage, tension


chain when needed.

Section 7 Load handling,


group 7.2.9 Mast

Checking the wear.

Section 7 Load handling,


group 7.2.9 Mast

Check wear, adjust when


needed.

Section 7 Load handling,


group 7.2.9 Mast

Slide plates in
trolley

Check wear, adjust when


needed.

Section 7 Load handling,


group 7.2.11 Trolley

Attachment

Check for damage.

Slide plates
spreader beam

Check wear, change as


needed.

Slide plates
spreader beam
Lifting chains

Mast suspension
Slide plates mast

Tilt cylinder

Twistlocks

C/R

Section 7 Load handling,


group 7.5.4 Spreader beam
Section 7 Load handling,
group 7.7.7 Tilt cylinder

Check for cracks every


other year or every 4000
operating hours.

Section 7 Load handling,


group 7.9.1 Twistlocks

Replace every 10,000


operating hours.
Reset time counter
for twistlocks after
replacement.

8 Control system
Service indicator,
reset

Section 8 Control system,


group 8.2.4 Service indicator

9 Frame, body, cab and accessories


Instruments and
controls

Checking function.

Air conditioning

Checking function.

Section 9 Frame, body, cab


and accessories, group 9.4.
Check/performance test of air
conditioning.

Dependent on external
environment, at latest
every 500 h.

Section 9 Frame, body, cab


and accessories, group 9.4.1
Fresh air filter

Clean when needed.

Section 9 Frame, body, cab


and accessories, group 9.4.8
Condenser

unit

Fresh air filter

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.

Maintenance Manual DCT 8090

Section 9 Frame, body, cab


and accessories, group 9.4.9
Moisture filter

C Preventive maintenance Preventive maintenance

Object, action

Service
250 h,
750 h,
1,250
h, etc.

Comment

Reference

Section 9 Frame, body, cab,


and accessories, group 9.9.3
Roof window

1000h,
3000h,
5000h
etc.

2000h,
4000h,
6000h
etc.

Roof window

Check damage, change


when needed.

Cab frame

Check rust damage,


deformation or cracks.

Cab undercarriage

Check mountings,
isolators and bolted
joints.

Frame

Check occurrence of
any deformation and rust
damage as well as cracks
in welded joints.

Check that the


counterweights are
positioned properly and
that the mounts and
welding seams are intact
and free of visible cracks.

Doors

500h,
1500h,
2500h,
etc.

Counterweights

C:13

Section 9 Frame, body, cab


and accessories, Group 9.10.2
Doors
Section 9 Frame, body, cab
and accessories, group 9.10.3
Cab undercarriage

Check tightening torque


of bolted joints.
Central lubrication

Paint/coatings

Safety decals

Section 9 Frame, body, cab


and accessories, group 9.14
Central lubrication

Check the machine's


painted surfaces
for stone chips and
scratches.

Check that safety decals


are legible, securely
fastened, and not
damaged. Clean dirty
decals and replace
decals as needed.

External check and


cleaning.

See Operator's manual DCF


80100, section 3 Overview,
group 3.2 Signs

10 Common hydraulics
Cooler hydraulic
oil

NOTE
Do not use high
pressure wash.
Breather filter
hydraulic oil tank

Hydraulic oil filter

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

For volume and quality,


see section F F Technical
data.

Maintenance Manual DCT 8090

Section 10 Common
hydraulics, group 10.6.8
Hydraulic oil

UDCT01.02GB

C:14

Object, action

C Preventive maintenance Preventive maintenance

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

Section 11 Common electrics,


group 11.3.1 Start battery

Battery cable

Section 11 Common electrics,


group 11.3.1 Start battery

Position sensors

Fine filter hydraulic


oil

Section 10 Common
hydraulics, group 10.6.9
Fine filter hydraulic oil

11 Common electrics

Test-run

After test-run

Check that fuses are


intact, change if needed.

Section 11 Common electrics,


group 11.2.2 Fuses

Should be free from


grease and dirt, clean as
needed.

Test-run the machine and check:

Instruments

Brakes

Gearshifting

All load handling functions

Steering

Any noise

Check the following after test-run:

Sealing (no leakage)

Fluid levels

Washing

CAUTION
High-pressure washing of sensitive components can
lead to short-circuiting and may cause malfunctions.
Product damage!
Do not use high-pressure washing on cab, radiator,
battery compartment, electric components, control
units, connectors, cable splices, cylinder seals, stub
axles, axle/shaft seals, and chains.

Lubrication 500 hours

UDCT01.02GB

Machine in service position.

Clean the area around each grease cup before greasing.

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

C:15

Lubricate the lubricating points of the machine with lubricating


grease, see section F Technical data.
Also do a visual check of all lubricated mounts.

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

Overview, lubrication points, 500 hours

Pos.

Lubrication points

Reference

Wheel hubs (2 pc)

Wheel hub, page C:16

Wheel spindles (4 pcs)*

Link arms (4 pcs)*

Link arms, page C:16

Brake pedals (2 pc)

Brake pedal, page C:17

Hinges doors (x2) and cover lid (x1)

Hinge doors and cover lid, page C:17

Mast, mast wheels (4 pc)*

Mast, page C:18

Mast, chain wheels (2 pc)*

Mast, chains (2 pc)

Mast, slide plates (4 pc)

10

Tilt cylinders (4 pc)*

Tilt cylinder, page C:18

Maintenance Manual DCT 8090

UDCT01.02GB

015014

C:16

C Preventive maintenance Preventive maintenance

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

Be careful so that the seal is not damaged.

Grease point wheel hub

Wheel spindle
6

Grease the wheel spindle's upper and lower bearings.

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

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

Lubrication points wheel spindle


1.

Upper lubrication point

2.

Lower lubrication point

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.

Repeat steps 4 - 8 on the left steering wheel.

009127

Lubrication points link arm


1.

Inner bearing

2.

Outer bearing

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

C:17

Brake pedal
10 Lubricate the brake pedal's hinge with grease.
11 Wipe off excess grease.

Grease points brake pedal

Hinge doors and cover lid


12 Lift the left-hand door slightly and lubricate the hinges with
lubricating 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.

Hinge, cover lid

014040

Do not lift the cover lid off the hinges.


16 Let the cover lid down and wipe of excess grease.

Maintenance Manual DCT 8090

UDCT01.02GB

C:18

C Preventive maintenance Preventive maintenance

Mast

17 Start the machine and raise the mast to facilitate access to


lubrication points.

18 Turn off the engine.


19 Secure the mast in a way that ensures safety.

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

Lubrication points for mast


1.

Chain wheel

2.

Mast wheel

3.

Slide plates.

Tilt cylinder
22 Grease the tilt cylinder axles with lubricating grease.

NOTE

009128

Unload the mast when lubricating.

Lubrication points on the tilt cylinder

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

C:19

Lubrication 1000 hours


1

Lower carriage and engage full spreading.

Turn off the engine and turn off the main electric power.

Clean the area around each grease cup before greasing.

Lubricate the machine's grease points with Lubricating grease


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

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

Overview, lubrication points, 1000 hours

Pos.

Lubrication points

Reference

Universal joints (2 pc)

Universal joint, page C:20

Trolley, mast (4 pc)*

Trolley, page C:20

Locking cylinders (2 pc)*

Attachment, page C:21

Contact pins (2 pc)*

Spreading cylinders (4 pc)*

Side shift cylinder (x 4)

Electric connectors (not shown on diagram)

Electric connectors, page C:22

Maintenance Manual DCT 8090

UDCT01.02GB

C:20

C Preventive maintenance Preventive maintenance

Universal joint
5

Grease universal joints with lubricating grease.

Grease nipple for universal joint, example

Trolley
6

Turn off the engine.

Secure the trolley in a way that ensures safety.

Lubricate the mast wheel with lubricating grease, see section F


Technical data.

013493

Lubrication points for trolley.


1.

Mast wheel

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

C:21

Attachment
9

Lubricate the locking cylinder mounts (position 1) with lubricating


grease.

014714

3
Lubrication points for side lift attachment with twistlock
1.

Mounting locking cylinders

2.

Contact pins

3.

Mounting spreading cylinders

4.

Mounting side shift cylinders


10 Lubricate contact pins (position 2) with lubricating grease. Check
that the sensors are undamaged and free from grease.
11 Grease the spreading cylinder mounts (position 3) with lubricating
grease.
12 Grease the side shift cylinder mounts (position 4) with lubricating
grease.

Maintenance Manual DCT 8090

UDCT01.02GB

C:22

C Preventive maintenance Preventive maintenance

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.

Pump unit central lubrication, example illustration


1.

Filling point

2.

Safety valve

Checking for cracks

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.

Clean every weld carefully before inspection.

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

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.

The magnetic particle method is used to determine if there's a


crack or not, and where it is. See Magnetic particle method,
page C:23.

b.

Confirmed cracks are investigated further with penetrating


fluid. See Checking cracks with penetrating fluid, page C:23.

Magnetic particle method


Blast the applicable area clean so that it is completely free of
paint residue.

Test using magnetic particle and the following equipment:

005375

Rim

Equipment: Yoke Tiede

Method:

Alternating current AC

Contrast colour

Checking medium:
a

Wet

Colour (for example, Tiede Ferrolux)

If no cracks are detected with the magnetic particle method,


checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.

Checking cracks with penetrating fluid


1

Clean the area with cleaning fluid part no. 923626.0668.

Spray penetrating fluid part no. 923626.0669 on the cleaned area


and let dry 10 min.

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

Spray detection fluid part no. 923626.0670 on the area.

Let the sprayed area dry 1-2 hours.

Visually inspect the area.

Rim

If the tested area does not show signs of linear or point-shaped


cracks, it is approved.

001705

If the crack check indicates linear or point-shaped cracks, contact


Cargotec Support.

Examples of cracks
1.

Linear crack

2.

Pointed crack

Maintenance Manual DCT 8090

UDCT01.02GB

C:24

C Preventive maintenance Preventive maintenance

Check points
1

Check the following welds extra carefully:

3
4

5
2

6
7

009660

8
9

Check points, overview

Pos.

Check point

Reference

Steering axle mounts

Steering axle mounts, page C:25

Tilt cylinder and tilt cylinder mount.

Tilt cylinder and tilt cylinder mount., page C:25

Mast

Mast, page C:26

Mounting of frame beam to back piece

Mounting of frame beam to back piece, page C:26

Drive axle mount

Drive axle mount, page C:26

Mast mount

Mast mount, page C:27

Side lift attachment

Side lift attachment, page C:27

Twistlocks

Trolley

Trolley, page C:28

Lift cylinder bracket

Lift cylinder bracket, page C:28

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

C:25

Steering axle mounts


2

Check the steering axle mounts in the frame and the steering axle
a.

Steering axle mounts in the frame.

b.

Steering axle mounts in the steering axle cradle.

Tilt cylinder and tilt cylinder mount.


3

Check the attachment lugs on the tilt cylinder.

Check the tilt cylinder's mounting in the mast.

Check the tilt cylinder's mounting in the frame.

009663

009662

009664

Maintenance Manual DCT 8090

UDCT01.02GB

C:26

C Preventive maintenance Preventive maintenance

Mast
Check the horizontal support beams in the mast.

Check the welds between the horizontal and the vertical mast
beam.

009667

009666

Mounting of frame beam to back piece


Check the attachment of the frame beam to the rear section.

009672

Drive axle mount


Check the drive axle mount in frame.

015528

UDCT01.02GB

Maintenance Manual DCT 8090

C Preventive maintenance Preventive maintenance

C:27

Mast mount

015104

10 Check the mast mount in the frame.

009670

11 Check the weld between mast beam and mount tab.

Side lift attachment

014735

12 Check the side lift attachment's welding seams.

Maintenance Manual DCT 8090

UDCT01.02GB

C:28

C Preventive maintenance Preventive maintenance

Trolley
13 a.
b.

Check the trolley's welding seams.


Check the wheel pin welds in the trolley.
Check the inner mast wheel pins as well.

013622

Trolley
a

Examples of welded joints in the trolley

Wheel pins

Lift cylinder bracket

009661

14 Check the mounting of the lift cylinders' lower support mount


against mast beam.

UDCT01.02GB

Maintenance Manual DCT 8090

0:1

0 Complete machine

Contents 0 Complete machine


Complete machine..............................................................................................0:3

Maintenance Manual DCT 8090

UDCT01.02GB

0:2

UDCT01.02GB

Maintenance Manual DCT 8090

0 Complete machine Complete machine

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 transmission is hydro-mechanical with gears in constant mesh


and it has three gears in each direction. The engine's power is
transmitted using a torque converter.
The power transmission consists of propeller shaft and a rigid drive
axle with differential and hub reduction. The machine has front-wheel
drive.
The service brake is of the type disc brake in oil, which is integrated
with the driving wheels' wheel hubs. The parking brake is of the disc
brake type and acts on the drive axle's input shaft.

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


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

The wheels are 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.

Side lift attachment

7.

Cab

014183

Load handling consists of components and functions for handling


loads. Loads are lifted with a side lift attachment secured to a trolley
that is fitted on a mast. Load handling is divided into the functions
lifting/lowering, tilt, side shift, spreading and load carrying.

Lifting/lowering is the function for lifting and lowering the trolley.

Side shift is moving the side lift attachment laterally along the
trolley.

Spreading is adjusting the width between Twistlock on the side


lift attachment.

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.

The control system includes functions to warn the operator of


dangerous situations and faults. The control system has diagnostic
options that facilitate troubleshooting.
The frame supports the machine. The engine, transmission, drive
axle, and steering axle are installed in the frame. On the sides of the
frame are tanks for fuel and hydraulic oil. The cab is located on the
rear section of the frame.
The hydraulic system is supplied by two hydraulic oil pumps. The
pumps are mounted on the transmission's power take-off. One fixed
pump supplies load handling and the other fixed pump supplies the
brake system, steering and cooling circuit over a combined priority
valve and accumulator charging valve. The hydraulic oil tank is fitted
on the right-hand side of the machine. The hydraulic oil filters are
return filters that are fitted in the hydraulic oil tank.

Maintenance Manual DCT 8090

UDCT01.02GB

0:4

0 Complete machine Complete machine

The machine's electrical system is built up around control units at


strategic locations on the machine. The control units receive signals
from sensors and contacts and they control components in the vicinity
of each respective control unit. The control units have redundant
voltage feed and communicate via redundant CAN bus. Engine
and transmission have their own control units from their respective
suppliers. These control units communicate via CAN bus with a control
unit in the cab.

UDCT01.02GB

Maintenance Manual DCT 8090

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

Maintenance Manual DCT 8090

UDCT01.02GB

1:2

UDCT01.02GB

Maintenance Manual DCT 8090

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

Engine alternative Yuchai YC6A240-30,


function description
The Yuchai YC6A240-30 is a straight 6-cylinder, 4-stroke turbocharged
low-emission diesel engine with unit common rail injection and air-to-air
intercooler.
rpm
kph

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.

Accelerator pedal (B690)

2.

Control unit cab (D790-1)

9.

Make-contact (closing switch), coolant level (B759)

3.

Control unit KIT (D790-2)

10. Make-contact (closing switch), water in fuel (B760)

4.

Control unit engine (D794)

11. Sensor fuel level (B757)

5.

Relay, starter motor (K360)

12. Control unit frame (D797-1)

6.

Starter motor (M654)

13. Control unit KID (D795)

7.

Electric components engine

Maintenance Manual DCT 8090

UDCT01.02GB

1:4

1 Engine Engine

Engine alternative Yuchai YC6A240-30,


component location
2

3
4
14
13

12

8
9

014622

11

10

Engine alternative Yuchai YC6A240-30, left side (in the machine's travel direction)
1.

Make-contact (closing switch), low coolant level


(B759)

2.

Expansion tank

3.

Thermostat housing

4.

Connection radiator outlet

5.

Coolant pump

6.

Connection cab heat

7.

Draining the radiator

UDCT01.02GB

8.

Connection radiator inlet

9.

Oil filter

10. Relay, starter motor (K360)


11. Starter motor (M654)
12. Connection exhaust system
13. Turbo
14. Connection air cleaner

Maintenance Manual DCT 8090

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.

Filling point engine oil

6.

Control unit engine (D794)

2.

Connection intercooler

7.

Fuel filter

3.

Relay preheating (K312)

8.

Connection intercooler

4.

Preheating coil (E8000)

9.

Fuel pump

5.

Dipstick engine

10. Alternator

Maintenance Manual DCT 8090

UDCT01.02GB

1:6

1 Engine Engine

Engine alternative Cummins QSB6.7,


function description
The Cummins QSB6.7 is a straight, 6-cylinder, 4-stroke, turbocharged
low-emission diesel engine with common rail injection, air-to-air
intercooler and electronically controlled fuel injection.
C
.

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.

Accelerator pedal (B690)

2.

Control unit KIT (D790-2)

9.

Control unit cab (D790-1)

3.

Control unit engine (D794)

10. Make-contact (closing switch) coolant level (B759)

4.

Preheating coil (E800)

11. Sensor fuel level (B757)

5.

Starter relay

12. Control unit frame (D797-1)

6.

Starter motor (M654)

13. Control unit KID (D795)

7.

Engine sensor

UDCT01.02GB

Maintenance Manual DCT 8090

1 Engine Engine

1:7

Engine alternative Cummins QSB6.7,


component location
4
3
2
5

10

015097

8
9
Engine alternative Cummins QSB6.7, left side (in the machine's direction of travel)
1.

Dipstick engine

6.

Connections cab heat

2.

Filling point engine oil

7.

Intake coolant

3.

Outlet exhaust system

8.

Oil filter

4.

Outlet coolant to radiator

9.

Starter motor

5.

Alternator

10. Crankcase ventilation

Maintenance Manual DCT 8090

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.

Outlet coolant to radiator

9.

Control unit engine (D794)

3.

Air intake turbo

10. Draining the engine oil

4.

Air outlet turbo

11. Vibration damper (rubber)

5.

Dipstick engine

12. Fan drive

6.

Filling point engine oil

13. Water pump

7.

Fuel filter

14. Drive belt tensioner

UDCT01.02GB

Maintenance Manual DCT 8090

1 Engine Fuel system

1:9

1.2 Fuel system


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

Engine alternative Yuchai YC6A240-30, component location,


page 1:4

Engine alternative Cummins QSB6.7, component location


page 1:7

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.

Fuel system, bleeding (engine alternative Yuchai


YC6A240-30)

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

Place a container under the fuel pre-filter.

Open the air bleeder screw on the fuel filter.

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.

Air bleeder screw

Close the screw when clean (air-free) fuel flows out.

Wipe off the fuel pre-filter and remove the collection container.

Maintenance Manual DCT 8090

UDCT01.02GB

1:10

1 Engine Fuel tank

Fuel system, bleeding air (engine alternative


Cummins QSB6.7
)
The fuel system must be bled after fuel filter replacement, if the fuel
tank has been run dry or after long periods of operation for example.

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

Open the bleed screw.

Turn the hand pump anticlockwise to open the pump.

Pump until the fuel is completely free of air bubbles.

Tighten the bleed screw and close the fuel hand pump.

Start the engine and check sealing.

015541

Hand pump

1.2.1 Fuel tank


Fuel tank, cleaning

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

2
1

Machine in service position, see section B Safety.

Empty the fuel tank of fuel. Use a pumping device.

Remove the drain plug from the fuel tank.

Rinse the fuel tank clean through the fuel filler hole.

Reinstall the drain plug.

013534

1.

Fuel filler

2.

Fuel tank

3.

Drain plug, under tank

4.

Battery hatch

UDCT01.02GB

Maintenance Manual DCT 8090

1 Engine Fuel prefilter

1:11

1.2.3 Fuel prefilter


Fuel pre-filter, draining condensation water (engine
alternative Yuchai YC6A240-30)

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

Machine in service position, see section B Safety.

Place a container under the fuel pre-filter.

Drain the fuel pre-filter of water.


Open the drain valve on the underside, close the valve when
clean fuel flows out.
Wipe off the fuel pre-filter and remove the collection container.

014134

Drain cock fuel prefilter

Maintenance Manual DCT 8090

UDCT01.02GB

1:12

1 Engine Fuel prefilter

Fuel prefilter, draining the condensation water (engine


alternative Cummins QSB6.7
)

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

NOTE
Water traps must be emptied of water as necessary or at least every
50 operating hours.
1

Machine in service position, see section B Safety.

Place a container under the fuel pre-filter.

Drain the fuel pre-filter of water.


Open the drain valve on the underside, close the valve when
clean fuel flows out.

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

(engine alternative Cummins QSB6.7

Drain cock fuel prefilter

UDCT01.02GB

), page 1:10.

Wipe off the fuel pre-filter and remove the collection container.

Start the engine and check sealing.

Maintenance Manual DCT 8090

1 Engine Fuel prefilter

1:13

Fuel pre-filter, changing (engine alternative Yuchai


YC6A240-30)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1

Machine in service position, see section B Safety.

Place a container under the fuel pre-filter.

Drain the fuel prefilter of fuel and water.


Open the drain valve on the underside, close the valve when the
filter is empty.
Disconnect the wiring from Sensor water in fuel (B760).

Remove Sensor water in fuel (B760) from the filter insert.

Remove the fuel filter with the filter removal tool.

Install Sensor water in fuel (B760) on the new fuel pre-filter.

Fill the fuel pre-filter with clean fuel.

015012

CAUTION

Fuel prefilter

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.
9

Lubricate the O-ring on the new fuel filter with engine oil.

10 Install the new fuel pre-filter.


Tighten to contact and then an additional one-half to three-quarter
turn.
11 Connect the line supply to the sensor water in fuel.
12 Wipe off the fuel pre-filter and remove the collection container.
13 Turn on the system voltage and start the engine. Check that the
filter seals tight.

Maintenance Manual DCT 8090

UDCT01.02GB

1:14

1 Engine Fuel prefilter

Fuel prefilter, changing (engine alternative Cummins


QSB6.7
)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1

Machine in service position, see section B Safety.

Open the drain cock and drain any water.

Remove the filter cartridge.

Check that the new filter cartridge is absolutely clean and that the
gasket is intact. Brush a small amount of oil onto the gasket.

Screw the filter cartridge onto the filter bracket.

Bleed the fuel system. Fuel system, bleeding air (engine


alternative Cummins QSB6.7

Start the engine and check sealing.

015540

Fuel prefilter

UDCT01.02GB

), page 1:10.

Maintenance Manual DCT 8090

1 Engine Fuel filter

1:15

1.2.4 Fuel filter


Fuel filter, changing (engine alternative Yuchai
YC6A240-30)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1

Machine in service position, see section B Safety.

Place a container under the fuel filter.

Remove the fuel filter with the filter removal tool.

Lubricate the O-ring on the new fuel filter with engine oil.

Fill the fuel pre-filter with clean fuel.

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

Install the new fuel filter.


Tighten to contact and then an additional one-half to three-quarter
turn.

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.

Maintenance Manual DCT 8090

UDCT01.02GB

1:16

1 Engine Fuel filter

Fuel filter, changing (engine alternative Cummins


QSB6.7
)

NOTE
Read safety recommendations for fuel system before starting work,
see section B Safety.
1

Machine in service position, see section B Safety.

Remove the fuel filter.

Clean the filter's contact face on the filter bracket.

Moisten the O-ring on the new filter with fuel.

NOTE
Do not fill the new fuel filter with fuel before installing. There is
a risk that impurities might get into the fuel system and cause
malfunctions or damage.

015529

Install the new filter on the engine.


Screw on the fuel filter until it makes contact with the contact face,
then tighten a further 3/4 turn.
6

Fuel filter

air (engine alternative Cummins QSB6.7


7

UDCT01.02GB

When needed, bleed the fuel system, see Fuel system, bleeding

Start the engine and check sealing.

Maintenance Manual DCT 8090

), page 1:10.

1 Engine Engine's mechanical parts

1:17

1.5 Engine's mechanical parts


1.5.4 Valve mechanism
Valves, checking/adjusting (engine alternative
Cummins QSB6.7
)

NOTE
Coolant temperature must be below 60 C.

Removing
Machine in service position, see section B Safety.

Disconnect the system voltage with the battery disconnector.

Carefully clean all attachments, mountings and joints with


compressed air to remove all loose particles.

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.

Remove mounting screws and insulators from the valve cover.

008025

NOTE
It might be necessary to bend the ventilation hose carefully to
pry it from the valve cover.
7

Remove the valve cover

NOTE
008026

Do not remove the rocker cover gasket on engines where the


gasket is fitted in a groove on the rocker cover; these gaskets
can be re-used. If the gasket is removed from the rocker cover,
it must be replaced.
8

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.

Maintenance Manual DCT 8090

UDCT01.02GB

1:18

1 Engine Valve mechanism

If the valve cover gasket must be replaced, follow these


instructions for installing a new gasket:
1. First press the corners of the gasket down into the groove on
the valve cover.

008029

2. Then push the rest of the gasket down into the valve cover.

008028

10 Check to see if the rubber insulators are cracked. Replace the


insulators if they are cracked or damaged.

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.

Rotate the vibration damper/crankshaft speed indicator ring


until the indicator for the top dead centre (T.D.C.) is pointing
straight up (12 o'clock).

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

Cylinder number 1 is the cylinder nearest the cooling fan.

UDCT01.02GB

Maintenance Manual DCT 8090

1 Engine Valve mechanism

1:19

12 With the engine in this position, the valve clearance can be


checked for the following valves:
(E=exhaust valves, I=intake valves)

008032

Cylinders 1I, 1E, 2I, 3E, 4I and 5E.

13 Check that the valve clearance is within the limits.


Valve clearance tolerance
MIN

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.

Maintenance Manual DCT 8090

UDCT01.02GB

1:20

1 Engine Valve mechanism

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

Cylinders 2E, 3I, 4E, 5I, 6I and 6E.

Installing
16 Reinstall the valve cover.
Reinstall the insulators and mounting screws.

008026

Tighten the screws to a tightening torque of 24 Nm.

17 Lubricate the O-ring on drain hose connection with clean engine


oil.
18 Fit the injectors' drain hose on the rocker cover. Tighten the
screws to a tightening torque of 10 Nm.
19 Close the battery disconnector.

008035

20 Start the engine and check sealing.

UDCT01.02GB

Maintenance Manual DCT 8090

1 Engine Crank mechanism

1:21

1.5.6 Crank mechanism


Vibration damper, rubber, check (engine
alternative Cummins QSB6.7
)
Check that the index lines (A) on the vibration damper hub (B) and
the outer section (C) are in line with each other. If the position
between the lines deviates more than 1.59 mm, replace the
vibration damper.

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.

Check that the damper ring cannot move longitudinally in


relation to the hub. Replace the vibration damper if it can move
longitudinally.

008036

For position of vibration damper, see Engine alternative Cummins


, page 1:7.

008037

QSB6.7, component location

Maintenance Manual DCT 8090

UDCT01.02GB

1:22

1 Engine Air intake and exhaust outlet

1.6 Air intake and exhaust outlet


Air intake and exhaust outlet, description
There is an air cleaner on the machine. The air cleaner is equipped
with an indicator that indicates when the air filter needs replacing. The
air cleaner has two filter inserts, one main insert and a safety insert.
The air cleaner is connected to the engine by the turbocharger.
The exhaust system consists of pipe and silencer. The silencer is
located on the upper rear counterweight, the end-pipe is attached to
the rear of the cab.
As an option the machine can be equipped with a raised air intake.

1.6.1 Air cleaning system


Air filter, changing
1

Machine in service position, see section B Safety.

Clean the outside of the air filter housing.

Remove the cap from the air filter housing.

Remove the filter cartridge.

2
3

008040

1.

Dust reservoir

2.

Air cleaner

3.

Indicator air filter

UDCT01.02GB

Maintenance Manual DCT 8090

1 Engine Air cleaning system

1:23

Clean the dust reservoir.

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


should be changed every other time the filter insert is changed).

Fit a new filter insert.

NOTE
The filter cartridge should be changed, not cleaned.
8

Fit the cover to the air cleaner casing.

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

Maintenance Manual DCT 8090

UDCT01.02GB

1:24

1 Engine Turbo

10 Reset the indicator.

1.6.2 Turbo
Turbo, check (engine alternative Yuchai YC6A240-30)
1

Machine in service position, see section B Safety.

Fold up the hood.

Disconnect the inlet pipe from the turbo.

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

Connect the inlet pipe to the turbo.

Close the hood.

Maintenance Manual DCT 8090

1 Engine Exhaust system

1:25

1.6.3 Exhaust system


Exhaust system, checking

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!

Machine in service position, see section B Safety.

Check the exhaust system's sealing and other wear.

Check that the exhaust system suspension is intact.

014700

1.

End-pipe

2.

Silencer

3.

Exhaust pipe

Maintenance Manual DCT 8090

UDCT01.02GB

1:26

1 Engine Intercooler

1.6.4 Intercooler
Intercooler, checking
1

Machine in service position, see section B Safety.

Fold up the hood.

Clean the intercooler with compressed air.

NOTE

Do not use high pressure wash.

2
4

Check that the intercooler suspension is intact.

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

Close the hood.

014686

1.

Intercooler

2.

Transmission oil cooler

3.

Radiator

4.

Condenser AC

007962

Charge-air pipe, check (engine alternative Cummins


QSB6.7
)

Charge air pipe, principle illustration

Machine in service position, see section B Safety.

Check the charge-air pipes, hose connections, and the condition


of the clamps for visible cracks and external damage. If the pipes
are damaged or if connections leak, the boost pressure will be too
low and engine power is reduced.

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

Maintenance Manual DCT 8090

1 Engine Cooling system

1:27

1.7 Cooling system


Cooling system, description
The engine radiator is located together with the intercooler and the
transmission oil cooler in one unit, a cooling unit.
For position of components see:

Engine alternative Yuchai YC6A240-30, component location,


page 1:4

Engine alternative Cummins QSB6.7, component location


page 1:7

1.7.4 Radiator and expansion tank


Radiator, external cleaning
1

Machine in service position, see section B Safety.

Clean the radiator with compressed air.

NOTE
Do not use high pressure wash.

1
3

Check that the cooling flanges are whole.

2
4

014686

1.

Intercooler

2.

Transmission oil cooler

3.

Radiator

4.

Condenser AC

Maintenance Manual DCT 8090

UDCT01.02GB

1:28

1 Engine Cooling fan

1.7.5 Cooling fan


Drive belt, check (engine alternative Yuchai
YC6A240-30)
1

Warm up the machine. Check after operating when the belts are
warm.

Machine in service position, see section B Safety.

Fold up the hood.

Check the belts' condition and tension. Change when needed.

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

008011

Check that the belts do not have any intersecting cracks.


Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
It should be possible to press down the belts 10-15 mm, measured
between the pulleys, at a pressure of 40-50 N.
5

Close the hood.

Drive belt, check (engine alternative Cummins QSB


6.7)
1

Warm up the machine. Check after operating when the belts are
warm.

Machine in service position, see section B Safety.

Fold up the hood.

Check the belts' condition and tension. Change when needed.

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

008011

Check that the belts do not have any intersecting cracks.


Transverse cracks are acceptable, longitudinal cracks that are
intersected by transverse cracks are not acceptable.
It should be possible to press down the belts approx. 3-4 mm
between the belt pulleys.

NOTE
The belt tensioners are automatic.
5

UDCT01.02GB

Close the hood.

Maintenance Manual DCT 8090

1 Engine Cooling fan

1:29

Drive belts, changing (engine alternative Yuchai


YC6A240-30)
1

Machine in service position, see section B Safety.

Fold up the hood.

Release the AC belt's tension.


Loosen the AC compressor attaching bolts and release the belt
tension.

Remove the AC belt.

Release the fan belt's tension.


Loosen the lock nut at the belt pulley and release the tensioning
screw on the belt tensioner.

1.

Tensioning screw

2.

Lock nut

Remove the fan belts.

Maintenance Manual DCT 8090

UDCT01.02GB

1:30

1 Engine Cooling fan

Release the drive belt's tension.


Loosen the alternator's attaching bolts and release the belt tension.

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

Maintenance Manual DCT 8090

1 Engine Cooling fan

1:31

12 Position the AC belt in the grooves for the pulleys, change if


necessary.
13 Tension the AC belt and tighten the 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.
14 Close the hood.

Drive belt, changing (engine alternative Cummins


QSB6.7
)
1

Machine in service position, see section B Safety.

Fold up the hood.

Lift up the belt tensioner to remove the drive belt.

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.

Close the hood.

Maintenance Manual DCT 8090

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1:32

1 Engine Cooling fan

Drive belt tensioner, check (engine alternative


Cummins QSB6.7
)
Machine in service position, see section B Safety.

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.

Remove the drive belt.

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.

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Maintenance Manual DCT 8090

1 Engine Cooling fan

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.

A worn drive belt tensioner that is slack or a drive belt that


wanders off the pulleys indicates that the pulleys are not in
alignment.
This can be measured with a straight edge and a clinometer.

NOTE
The pulleys may not be more than 3 degrees out of alignment.
Install the drive belt.

008018

Fan hub, check (engine alternative Cummins QSB6.7


)
1

Machine in service position, see section B Safety.

Remove drive belt, see Drive belt, changing (engine alternative


Cummins QSB6.7

), page 1:31.

Permissible length clearance fan hub: Max. 0.15 mm.

NOTE

008019

The fan hub must rotate without wobbling or excessive length


clearance.

Maintenance Manual DCT 8090

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1:34

1 Engine Coolant

1.7.7 Coolant
Coolant level, check

WARNING

The cooling system is pressurised. Steam or hot fluid


may jet out.
Risk of scalding and burn injuries!
Open the filler cap very carefully when the engine is
warm. Wait until the coolant has cooled before topping
up.

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


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

NOTE
014191

Open very carefully as hot coolant may jet up.

If the coolant level becomes too low, the warning light for low coolant
level (position 40) lights up on the instrument panel.

Position for coolant reservoir (expansion tank)

Filling point

NOTE

Sight glass

A low coolant level may cause engine damage or may cause the
engine to stop.
1

Machine in service position, see section B Safety.

Fold up the hood.

If needed, top up (position B) with ready-mixed recommended


coolant. For volume and quality, see section F F Technical data.

CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.
4

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Close the hood.

Maintenance Manual DCT 8090

1 Engine Coolant

1:35

Coolant quality, check (engine alternative Cummins


QSB6.7
)

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.

Machine in service position, see section B Safety.

Fold up the hood.

Check the coolant's quality with test equipment for coolant,


"Quick-Check Coolant Quality Test Strips".

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

Change the coolant if the test equipment indicates poor coolant


quality, see Coolant, changing (engine alternative Cummins
QSB6.7

Close the hood.

014191

), page 1:37.

C
A

Position for coolant reservoir (expansion tank)

Filling point

Sight glass, checking level

Coolant, changing (engine alternative Yuchai


YC6A240-30)

NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
1

Machine in service position, see section B Safety.

Fold up the hood.

Remove the cap on the expansion tank.

Place a container under the radiator and engine. (The cooling


system holds approx. 40 l.)

Maintenance Manual DCT 8090

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1 Engine Coolant

Drain the cooling system.

014698

Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.

Drain cock coolant radiator.


6

Connect a hose to the drain cock on the engine and route the
other end into the container.

Open the drain valve on the engine.

When all the coolant has run out, close the drain taps.

Fill with new ready-mixed coolant of correct type in the expansion


tank. For volume and quality, see section F F Technical data.

Drain cock coolant engine, the figure shows a closed


cock.

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

13 Check the level in the expansion tank, fill if necessary.

C
A

Position for coolant reservoir (expansion tank)

Filling point

Sight glass, checking level

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14 Close the hood.


15 Check the coolant level again after 10 operating hours.

Maintenance Manual DCT 8090

1 Engine Coolant

1:37

Coolant, changing (engine alternative Cummins


QSB6.7 )

NOTE
Read safety instructions for coolant before starting work, see section
B Safety.
1

Machine in service position, see section B Safety.

Fold up the hood.

Remove the cap on the expansion tank.

Place a container under the radiator and engine. (The cooling


system holds approx. 40 l.)

Drain the cooling system.

014698

Open the drain valve on the lower part of the radiator. Collect the
coolant in the container.

Open the drainage on the engine.

When all the coolant has run out, close the drain taps.

015538

Drain point coolant.

Maintenance Manual DCT 8090

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1:38

1 Engine Coolant

Fill with new ready-mixed coolant of correct type in the expansion


tank. For volume and grade, see section F Technical data.

CAUTION
Different types of coolant must not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, only use
coolant of the same type that was used before.

B
9

Turn on the system voltage and start the engine.

10 Set the cab heat to max.


11 Run the engine warm so that the thermostat opens and coolant is
pumped through the whole system.

014191

12 Check the level in the expansion tank, fill if necessary.

C
1.

Position for coolant reservoir (expansion tank)

2.

Filling point

3.

Sight glass, checking level

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13 Close the hood.


14 Check the coolant level again after 10 operating hours.

Maintenance Manual DCT 8090

1 Engine Lubrication system

1:39

1.8 Lubrication system


Lubrication system, description
The engine's lubrication system is completely closed and has no
connections to the machine.
For position of components see:

Engine alternative Yuchai YC6A240-30, component location,


page 1:4

Engine alternative Cummins QSB6.7, component location


page 1:7

Oil and oil filters, changing (engine alternative


Yuchai YC6A240-30)

NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1

Run the engine until warm.

Machine in service position, see section B Safety.

Fold up the hood.

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

Remove the oil filters.

Install new oil filters.


Lube the O-rings on the filters with engine oil and install according
to instructions on the filter.

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.

Start the engine, let it idle.

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.

Maintenance Manual DCT 8090

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1:40

1 Engine Lubrication system

Oil and oil filters, changing (engine alternative


Cummins QSB6.7
)

NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1

Run the engine until warm.

Machine in service position, see section B Safety.

Fold up the hood.

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

Remove the oil filter with the filter tool.

Brush a little oil on the new filter's rubber gasket.

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.

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Maintenance Manual DCT 8090

), page 1:42. Top up

1 Engine Lubrication system

1:41

Oil level, check (engine alternative Yuchai


YC6A240-30)

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

Engine oil, general

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).

Fill wait awhile check on the oil dipstick.

014192

NOTE

Dipstick

Filling point

Work carefully when filling to prevent other fluids or particles


from contaminating the oil, which means risk of engine damage.

Maintenance Manual DCT 8090

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1:42

1 Engine Lubrication system

Oil level, check (engine alternative Cummins


QSB6.7
)

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

Engine oil, general


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).

Fill wait awhile check on the oil dipstick.

NOTE

015095

Work carefully when filling to prevent other fluids or particles


from contaminating the oil, which means risk of engine damage.

Dipstick

Filling point

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Maintenance Manual DCT 8090

1 Engine Control system engine

1:43

1.9 Control system engine


Control system engine, description
The engine is controlled by a control and monitoring system, for which
the central unit is a control unit.
The control unit controls the amount of fuel to the unit injectors by
opening and closing a fuel valve by each injector. The unit injectors are
activated by an extra cam lobe on the camshaft, which compresses the
injector so that fuel is injected into the cylinder.
The fuel quantity is calculated by the control unit based on signals from
the sensors on the engine and a CAN message about the desired
engine speed (from the accelerator pedal via the cab control unit
(D790-1)).
If serious malfunctions are detected by the control and monitoring
system on the engine, then engine power is limited to protect the
engine from further damage.

Maintenance Manual DCT 8090

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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.

Ignition/heating, description (engine alternative


Cummins QSB6.7
)
The engine features preheating of the induction air, for faster start at
low temperatures. Preheating is activated when the ignition key is in
position II or when the engine's control system detects that preheating
is needed. The indicator light for preheating is on when preheating is
activated. The ignition sends signals to Control unit KIT (D790-2) which
sends messages via CAN-bus drivetrain to Control unit engine (D794).
For position of components see, see Engine alternative Cummins
QSB6.7, component location

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Maintenance Manual DCT 8090

, 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

Maintenance Manual DCT 8090

, page 1:7.

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1:46

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Maintenance Manual DCT 8090

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

Maintenance Manual DCT 8090

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2:2

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Maintenance Manual DCT 8090

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.

Maintenance Manual DCT 8090

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.

Multi-function lever (S162)

12. Sensor oil pressure transmission (B765)

2.

Shifting program selector on Control unit KIT (D790-2)

13. Sensor turbine speed (B751)

3.

Control unit KIT (D790-2)

14. Sensor oil temperature (B766)

4.

Accelerator pedal (B690)

15. Oil pump transmission

5.

Declutch pedal (S220-1)

16. Oil filter transmission

6.

Control unit cab (D790-1)

17. Transmission oil cooler

7.

Control unit, transmission (D793)

18. Make-contact declutch (S220-2)

8.

Solenoid valve clutch reverse (Y631)

19. Control unit frame (D797-1)

9.

Solenoid valve clutch 1st gear (Y6067-1)

20. Control unit KID (D795)

10. Solenoid valve clutch 2nd gear (Y6069)

21. Control unit engine (D794)

11. Solenoid valve clutch forward (Y630)

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Maintenance Manual DCT 8090

2 Transmission Transmission

2:5

Transmission, component position

15

16
14

13

17
12
11

10

014685

7
8

1.

Transmission oil cooler

10. Valve block transmission control

2.

Oil pump transmission

11. Return from transmission oil cooler

3.

Oil filter transmission

12. Breather filter transmission

4.

Sensor turbine speed (B751)

13. Outlet to the transmission oil cooler

5.

Solenoid valve clutch reverse (Y631)

14. Sensor oil temperature (B766)

6.

Solenoid valve clutch 1st gear (Y6067-1)

15. Thermostat

7.

Drain plug and strainer transmission oil

16. Sensor oil pressure transmission (B765)

8.

Solenoid valve clutch 2nd gear (Y6069)

17. Output shaft

9.

Solenoid valve clutch forward (Y630)

Maintenance Manual DCT 8090

UDCT01.02GB

2:6

2 Transmission Torque converter/Clutch system

11
6

10
7

8
1.

Accelerator pedal (B690)

7.

Fuse transmission (F51-3)

2.

Control unit KIT (D790-2)

8.

Control unit, transmission (D793)

3.

Control unit KID (D795)

9.

Declutch pedal (S220-1)

4.

Multi-function lever (S162)

10. Make-contact declutch (S220-2)

5.

Control unit cab (D790-1)

11. Control unit frame (D797-1)

6.

Diagnostic socket drivetrain

014694

2.2 Torque converter/Clutch system


Torque converter/clutch, description
The torque converter transmits the engine's power to the transmission.
For position of components see Transmission, component position,
page 2:5.

Breather filter, cleaning


Machine in service position, see section B Safety.

Disconnect the breather filter from the transmission.

Clean the breather filter from dirt.

014692

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Maintenance Manual DCT 8090

2 Transmission Mechanical transmission

2:7

2.3 Mechanical transmission


Mechanical transmission, description
The transmission is built with all gears in constant mesh. It is shifted
by hydraulic pressurising of clutch discs for each of the gears. The
discs connect the input shaft with the main shaft or tubular shaft,
depending on which gear has been selected. Shifting takes place
without disengaging the transmission from the engine.
Clutches for FORWARD and REVERSE are controlled electrically,
shifting between FORWARD and REVERSE, and vice versa, on the
move can take place at a speed lower than the set limit value, see
section 8 Control system, group 8.5.1.5 DRIVETRAIN. When shifting
between FORWARD and REVERSE, two modulating valves in the
transmission enable smooth power transmission between the clutches
without disengaging any clutch.
There are three gears in each direction for the transmission. Declutch
is controlled with a separate declutch pedal that is activated at a certain
brake pressure.
The electric shifting system is automatic.
For position of components see Transmission, component position,
page 2:5.

Maintenance Manual DCT 8090

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2:8

2 Transmission Lubrication system

2.6 Lubrication system


Lubrication system, description
The transmission has its own lubrication system that is used for
lubrication, control, and cooling of the transmission. The transmission
oil cooler is located in the cooling unit behind the engine, a thermostat
in the cooler enables the oil to reach operating temperature faster.
At high oil temperature (120 C) a warning is activated in Control unit
KID (D795) and performance is reduced, if the oil temperature goes
above 125 C the transmission declutches.

1
2

For position of components see Transmission, component position,


page 2:5.

014686

1.

Intercooler

2.

Cooler transmission oil

3.

Radiator engine

4.

Condenser (to AC)

Oil and oil filter, change

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

NOTE
Do not over-fill the transmission!
1

Operate and warm up the transmission oil.

Machine in service position, see section B Safety.

Remove the drain plug (position 2) and allow the oil drain into
the receptacle.

Remove the suction strainer (position 3) and clean the strainer


cloth.

If the suction strainer's cloth has caught up metal particles then


the cause must be investigated before the transmission is filled
with new oil.
5

Replace the suction strainer's gasket.

When the transmission oil has flowed out, refit the suction strainer
(position 3) and the drain plug (position 2).

2
3
1.

Oil filter holder

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.

Maintenance Manual DCT 8090

2 Transmission Lubrication system

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. Dipstick transmission oil


B. Oil filler point transmission oil
12 Warm up the transmission so that the oil temperature is approx.
85 C on the display. Use operating menu oil temperature to check
the transmission oil temperature.

a
000356

13 Check the oil level. Fill to the MAX mark for oil level.

Operating menu oil temperature


a

Transmission oil temperature

Hydraulic oil temperature

Oil level, check

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.

Maintenance Manual DCT 8090

UDCT01.02GB

2:10

2 Transmission Lubrication system

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

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


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

014193

NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means risk
of transmission damage.

A. Dipstick transmission oil


B. Oil filler point transmission oil

UDCT01.02GB

Maintenance Manual DCT 8090

2 Transmission Cooling system

2:11

2.7 Cooling system


Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:8.
For position of components see Transmission, component position,
page 2:5.

Maintenance Manual DCT 8090

UDCT01.02GB

2:12

2 Transmission Control system transmission

2.8 Control system transmission


Control system transmission, description
Control unit transmission controls shifting based on signals from
pressure, temperature, and speed (rpm) sensors. Gear selection takes
place by activation of solenoid valves that distribute control pressure in
the transmission, so that the selected gear gives the right speed.
For position of components see Transmission, component position,
page 2:5 and section 11 Common electrical , group 11.5.3 Control units.
In case of serious transmission malfunctions the control unit uses
two modes with reduced functionality to protect the transmission,
Limp-home and Shut-down.

Mode Limp-Home
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.

Machine assumes neutral position


The machine features a safety function that results in the transmission
shifting to neutral position if the operator leaves the operator's station.
The system uses the same switch in the operator's seat as the warning
for released parking brake to sense when the operator leaves the
operator's station.
If the buzzer sounds when the operator sits down in the seat and
releases the parking brake, the switch in the seat may not be working.
Then it is not possible to select any travel direction.
In an emergency the machine can be operated by bypassing the safety
system, for more information see section 8 Control and monitoring
system, group 8.2.2 Bypassing.

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

UDCT01.02GB

Release the load.

Activate switch for bypassing.

Select travel direction.

Drive the machine to service. Speed is limited to 10 km/h.

Maintenance Manual DCT 8090

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

Maintenance Manual DCT 8090

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3:2

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Maintenance Manual DCT 8090

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.

3.2 Propeller shaft


Propeller shaft, description

005193

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

Propeller shaft, checking

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).

Grease nipple for universal joint, example

Maintenance Manual DCT 8090

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3:4

3 Driveline/Axle Drive axle

3.3 Drive axle


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

10

9
8

004336

1.

Hub reduction

2.

Wheel brake

3.

Drive shaft (internal)

4.

Mounting drive axle

5.

Drive axle housing

6.

Differential (internal)

7.

Drain point drive axle oil hub reduction

8.

Filling point and level check drive axle oil hub reduction

9.

Filling point and level check drive axle oil differential

10. Drain point drive axle oil differential

Drive axle, checking


Check the drive axle's attachment to the frame so that there is no
corrosion on structural elements (e.g., attaching bolts).

Check-tighten the drive axle's attaching bolts to 1530 Nm (oiled


bolt).

Check-tighten the wheel nuts to 650 Nm (oiled bolt).

Check the bolted joint to the parking brake caliper's attaching plate
and brake disc.

Check that drive axle seals tight.

Check the oil level in drive axle and the hub reductions.

008046

Attaching bolts drive axle

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Maintenance Manual DCT 8090

3 Driveline/Axle Drive axle

3:5

Drive axle oil, changing

NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1

Position the machine so that the hub reductions' drain plugs at the
wheels are in the lowest position.
This applies to both drive wheels.

Wheel 1: move forwards or backwards to obtain the correct


position.

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.

Wheel hub, drive axle


1.

Drain plug hub

2.

Level and filling plug hub

Machine in service position, see section B Safety.

Position a receptacle by each hub. Position a piece of sheet metal


or similar in the wheel rim to lead oil into the receptacle.

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.

Position a receptacle under the differential and remove the drain


plug (position 3). Also remove the level and filling plug for the
differential (position 2) to facilitate draining.

Clean the drive axle's breather while the oil is draining.

Install the drain plugs on the hubs and the differential.

004337

NOTE

Differential drive axle

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

1.

Bleeding the drive axle (inside frame)

2.

Level and filling plug differential

3.

Drain plug differential


8

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.

Drain plug hub

2.

Level and filling plug hub

Install the hubs' level and filler plugs.

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

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3:6

3 Driveline/Axle Drive axle

10 Fill oil in the differential until the oil level is flush with the filler and
level hole.

11 Install the level and filler plug on the differential.

004337

NOTE
3
Differential drive axle

Check that the seal is intact, clean and in the correct position.
12 Remove the receptacle.

1.

Bleeding the drive axle (inside frame)

13 Turn on the system voltage and test drive the machine.

2.

Level and filling plug differential

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

3.

Drain plug differential

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Maintenance Manual DCT 8090

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

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Maintenance Manual DCT 8090

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:

Power-assisted brake system, function description, page 4:4

Parking brake system, function description, page 4:9

4.1 Controls and instruments


4.1.1 Brake pedal
Brake pedal, checking and adjusting
1

Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.

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 pedal's travel is smooth.

Grease the pedal hinges with EP2 universal grease.

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

Stop bolt screw for adjusting clearance between brake


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

Brake pedal grease points. (Figure shows unattached


brake pedal)

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4:4

4 Brakes Power-assisted brake system

4.3 Power-assisted brake system


Power-assisted brake system, function
description
The power assisted brake system consists of a hydraulic oil tank,
hydraulic oil pump, valve block, accumulator, brake valve, pressure
sensors, brake cylinder and wheel brake units.
Hydraulic oil pump, brakes and steering, pumps oil (from the tank).
Valve block, accumulator charging valve and priority valve, controls the
pressure to the steering, the accumulators or cooling circuit for the
brakes and the hydraulic oil. The brake valve directs pressure from the
accumulators to the brake cylinders. The brake cylinders compress the
discs in the brake units that brake the machine. Make-contact (closing
switch) brake pressure emits a signal so that the brake light is switched
on when the brake cylinders are pressurised.
When the accumulators are charged the valve block for the accumulator
charging valve and priority valve controls hydraulic oil through the
hydraulic oil's cooling circuit, see section 10 Common hydraulics, group
10.6 Temperature control, cleaning and hydraulic oil.

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.

Hydraulic oil pump brakes and steering

8.

Make-contact brake lights (S216)

2.

Valve block, accumulator charging valve and priority


valve (part of the main valve)

9.

Break contact (opening switch) (S204)

10. Control unit frame (D797-1)

3.

Valve block brake system

4.

Accumulators

5.

Brake valve

12. Control unit KIT (D790-2) warning lamp, brake


pressure

6.

Brake cylinder

13. Distribution block drive axle

7.

Wheel brakes

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11. Brake lights (H411L & H411R)

Maintenance Manual DCT 8090

014644

4 Brakes Power-assisted brake system

4:5

Power-assisted brake system, component


location
2
3
4
5
6

12

11

10

1.

Control unit KIT (D790-2) warning lamp, brake


pressure

2.

Brake cylinder and wheel brake

3.

Valve block brake system

4.

Valve block, accumulator charging valve and priority


valve (part of the main valve)

5.

Break contact (opening switch) (S204)

6.

Distribution block drive axle

9
7.

Make-contact brake lights (S216)

8.

Control unit frame (D797-1)

9.

Accumulators

10. Hydraulic oil pump brakes and steering


11. Brake valve
12. Brake lights (H411L and H411R)

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014647

4:6

4 Brakes Accumulator charging valve

4.3.3 Accumulator charging valve


Accumulator charging, check

NOTE
Read safety instructions for oil before starting work, see section B
Safety.
1

Operate and warm up the machine so that the hydraulic oil


reaches operating temperature, 50 C.

Depressurise the hydraulic system, see section B Safety.

Connect a pressure gauge (0-25 MPa) to the measuring outlet for


accumulator charging pressure on the accumulator charging valve.

Start the engine and let it idle.

Close the accumulator drain valve.

000475

014653

Operation menu hydraulic oil temperature

Measuring outlet accumulator charging pressure [ACK


M]

NOTE

014619

Check that the accumulator drain valve is completely closed


and tighten the lock ring.

Close the accumulator drain valve

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Maintenance Manual DCT 8090

4 Brakes Accumulator

4:7

Check that the pressure slowly rises to the specified accumulator


charging pressure on the pressure plate.

Brake repeatedly and check at which pressure the accumulator


charging valve switches to charging.
The valve shall switch to cooling at 130.5 MPa.
Depressurise the hydraulic system, see section B Safety.

Remove the pressure gauge and fit the protective cap on the
pressure check connection.

015021

Pressure plate, accumulator charging pressure


10 Close the accumulator drain valve.

NOTE

014619

Check that the accumulator drain valve is completely closed


and tighten the lock ring.

Close the accumulator drain valve

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.

Maintenance Manual DCT 8090

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4:8

4 Brakes Wheel brake

4.3.9 Wheel brake


Wheel brake, bleeding

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

Brake cylinder
1

Machine in service position, see section B Safety.

Place a box wrench on the breather nipple and connect a


transparent hose to the breather nipple.
Direct the other end of the hose down into a collection container.

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.

Breather nipple brake cylinder, top side of drive axle at


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

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Close the breather nipple.

Move the wrench and the hose and collection container and repeat
steps 2-5 on the other side.

Maintenance Manual DCT 8090

4 Brakes Parking brake system

4:9

4.5 Parking brake system


Parking brake system, function description
The parking brake system consists of hydraulic oil tank, hydraulic oil
pump brakes and steering, valve block accumulator charging valve and
priority valve, valve block brake system, pressure sensor and parking
brake unit.
Hydraulic oil pump, brakes and steering, pumps oil (from the tank).
Valve block accumulator charging valve and priority valve controls the
pressure to the accumulators that store the pressure. The parking
brake unit is released with pressure from the accumulators by means
of the parking brake valve in the valve block brake system pressurising
the parking brake caliper. Make-contact (closing switch) parking brake
emits a signal so that indicator light for parking brake is switched on
when the parking brake is applied.

12

1
2

11

D790-2

D790-1
D797-1

4
C

7
Pa

GHB
HB

ACK M

10

6
014645

P
1.

Switch parking brake (S107)

7.

Break-contact parking brake (S200)

2.

Control unit cab (D790-1)

8.

Accumulators

3.

Control unit frame (D797-1)

9.

Valve block brake system

4.

Solenoid valve, parking brake (Y642)

10. Parking brake caliper

5.

Hydraulic oil pump brakes and steering

11. Control unit KIT (D790-2)

6.

Valve block, accumulator charging valve and priority


valve (part of the main valve)

12. Indicator light parking brake

Maintenance Manual DCT 8090

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4:10

4 Brakes Parking brake system

Parking brake system, component location


1

3
4
5
6
7

12

11

10

1.

Switch parking brake (S107)

7.

Parking brake disc

2.

Control unit KIT (D790-2), indicator light parking


brake

8.

Parking brake caliper

9.

Control unit frame (D797-1)

3.

Solenoid valve, parking brake (Y642)

4.

Valve block brake system

5.

Valve block, accumulator charging valve and priority


valve (part of the main valve)

6.

Break-contact parking brake (S200)

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10. Accumulators
11. Hydraulic oil pump brakes and steering
12. Control unit cab (D790-1)

Maintenance Manual DCT 8090

014648

4 Brakes Parking brake unit

4:11

4.5.4 Parking brake unit


Parking brake unit, checking and adjusting

DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1

Start the engine and run up hydraulic pressure until the


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

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

Release the parking brake.

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

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

Remove the cover from the brake caliper.


Check that there is no oil inside the cover.

Loosen the lock nut.

Adjust the adjustment screw so that the brakes are applied.

Turn back the adjusting screw so that the clearance between pad
and disc becomes 0.50.1 mm.

10 Tighten the lock nut.

NOTE
To avoid turning the adjustment screw as well, it must be held
still when tightening the lock nut.
11 Refit the cover on the caliper.
12 Check the function of the parking brake.

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4:12

4 Brakes Parking brake unit

4.5.4.2 Parking brake pads

Brake pads, changing

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

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Machine in service position and blocked wheels, see section B


Safety.

Remove the cover from the brake caliper.

Loosen the lock nut.

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.

Maintenance Manual DCT 8090

4 Brakes Parking brake unit

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

Remove the parking brake pads.

Clean the brake disc with methylated spirit.

Fit the new parking brake pads.

10 Press back the attaching bolt.


11 Fit the nut and fit a new split pin.
12 Adjust the parking brake, see section 4 Brakes, group 4.5.4
Parking brake unit.

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Maintenance Manual DCT 8090

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

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5:2

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Maintenance Manual DCT 8090

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.

5.2 Power assisted system


Power assisted system, function description
The function power assisted system refers to steering the machine.
The machine's steering is power-assisted with pressure from the
hydraulic oil pump for brakes and steering.
The steering consists of steering wheel, steering wheel shaft, steering
valve, hydraulic oil pump brakes and steering, valve block accumulator
charging valve and priority valve, steering cylinder, link arms and wheel
spindles.
The steering wheel (via the steering wheel shaft) acts on the steering
valve which in turn directs oil pressure from the hydraulic oil pump
brakes and steering to the steering cylinder. Between the hydraulic oil
pump for brakes and steering and the steering valve is the valve block
for accumulator charging valve and priority valve that gives priority to oil
supply to the steering valve ahead of accumulator charging and cooling
of the brakes. The steering cylinder acts on the wheel spindles. The
link arms are located between the steering cylinder and wheel spindles.

P
LS

L R

LSO

2
4
014654

1.

Hydraulic oil pump

3.

Steering valve

2.

Valve block, accumulator charging valve and priority


valve (part of the main valve)

4.

Steering cylinder

Maintenance Manual DCT 8090

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5:4

5 Steering Link arm

Power assisted system, component position

014655

1.

Steering axle with steering cylinder

2.

Steering valve

4.

3.

Hydraulic oil pump brakes and steering

Valve block, accumulator charging valve and priority


valve (part of the main valve)

5.2.6 Link arm


Link arm, checking

007918

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

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Maintenance Manual DCT 8090

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

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Maintenance Manual DCT 8090

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.

Suspension, component location


2

Suspension refers to:

Steering axle cradle

Steering spindle

Wheel hub

008047

Steering axle
1.

Wheel hub

2.

Wheel spindle

3.

Link arm

4.

Steering axle cradle

5.

Steering cylinder

6.

Spindle bolt / bearing

6.2.1 Steering axle cradle


Steering axle cradle, checking
1

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


wheels.

Maintenance Manual DCT 8090

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6 Suspension Wheel spindle

Check that the bushings in the suspension are intact.

Measure the distance between the frame and the steering axle
cradle. Note the measurement.

Lift the machine under the rear counterweight.

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.

Calculate the difference between the two measurements. The


difference may be max. 3 mm. If the difference is greater, the
bushing must be replaced.

007842

The figure shows front mounting

6.2.2 Wheel spindle


Wheel spindle bearing, checking
1

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


wheels.

Measure dimension A with a feeler gauge. Note the measurement.

Lift the machine under the rear counterweight.

Re-measure measurement A.

Calculate the difference between the two measurements. The


difference must be max. 0.25 mm.
If the difference is greater, shimming must be repeated, see
Workshop manual.

008079

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Maintenance Manual DCT 8090

6 Suspension Wheel hub

6:5

6.2.3 Wheel hub


Wheel hub, checking
Clean the hub covers on the control wheels.

Remove the hub cover.

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.

Torque the bearing nut as follows.

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

Fit the lock washer and outer lock nut.

Tighten to at least 250 Nm or as tight as required to fold the


locking washer into the closest groove.

Fill the bearing cap with grease and fit it.

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.

Maintenance Manual DCT 8090

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6:6

6 Suspension Tyres and rims

6.3 Tyres and rims


Tyres and rims, safety

DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air should always be released through the valve. If
this is not possible - drill holes in the tread to release
the air. Damaged tyres may explode.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.

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Maintenance Manual DCT 8090

6 Suspension Tyres and rims

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.

Tyre and rim system, description


The tires are the points of contact between the machine and the
ground, and the tires absorb unevennesses and provide suspension.
The drive axle is exposed to high forces during operation, if the drive
wheels' rolling circumference is different the stresses increase on
the drive axle. It is important that the tyres on the drive axle are the
same model, type and make, and have equal wear and proper inflation
pressure.

Tyres and rims, check


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

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6:8

6 Suspension Tyres and rims

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 the rims.

Check that the lock ring and lugs are installed correctly.

Check that there are no cracks in the rims' parts.

015101

In case of damage, the tyre and rim must be removed and


checked.

1.

Lock ring

2.

Side ring

3.

Rim bead seat taper

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.

Check the tyres.

Check for uneven and fast wear, this is caused by mechanical


defects such as, e.g., uneven brake action. Make sure that
such defects are repaired immediately.

Remove penetrating objects such as crushed glass, pieces of


wood, metal filings, etc.

If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change, page 6:14.
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

Examples: The figure shows inflation of drive wheel.

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Maintenance Manual DCT 8090

6 Suspension Tyres and rims

6:9

Tyre and rim system, removing and fitting (drive


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

Removing
1

Machine in service position, see section B Safety.

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)

Unscrewing the valve and releasing the air.

b)

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

014571

NOTE

014573

Only applies to tubeless tyres.

Maintenance Manual DCT 8090

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6 Suspension Tyres and rims

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.

Remove all wheel nuts.

Lift the wheel away and position it safely so that it does not fall or
move.

Secure the inner drive wheel with lifting equipment.

Remove the spacer ring.

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

Maintenance Manual DCT 8090

6 Suspension Tyres and rims

6:11

Tyre and rim system, removing and fitting


(steering axle)
Read the safety instructions before working with tyres and rim, see
Tyres and rims, safety, page 6:6.

Removing
1

Machine in service position, see section B Safety.

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

Release the air from the tyres by:


Unscrewing the valve and releasing the air.

b)

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

014571

a)

NOTE

014573

Only applies to tubeless tyres.

Maintenance Manual DCT 8090

UDCT01.02GB

6 Suspension Tyres and rims

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 nuts.

Remove the wheel and position it safely so that it does not fall or
move.

Installing
7

Fit the wheel.

Fit the wheel nuts. Tighten the wheel nuts crosswise in turn with
increasing torque to 650 Nm.

Inflate the tyre, see Tyres, inflating, page 6:13.

10 Lower the machine and remove the jack.

005124

11 Test-drive the machine and check that the wheels are secure.

UDCT01.02GB

12 Check-tighten the wheel nuts crosswise to a torque of 650 Nm.

Maintenance Manual DCT 8090

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

Never inflate tyres before all parts are in place.


Wheels shall be inflated on the machine or in a
protective device, designed and dimensioned so that
it can handle or dissipate a shock wave from a tyre
explosion as well as catch the ejected parts.

Examples: The figure shows inflation of drive wheel.

Do not exceed the prescribed tyre pressures which


must be checked at ambient temperature. When
changing tyre or rim version, another air pressure
may apply, contact Cargotec. Plate for air pressure
in tyres must be replaced with a plate that shows
applicable pressure.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Check that all parts are in place when the tyre
pressure is 30 kPa.

NOTE
An air filter and water trap should be installed on the line from the
compressor that is used to inflate tyres to avoid rim corrosion.
1

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

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


on the tyre.

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.

Inflate the tyre to prescribed pressure, see specifications.


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

Maintenance Manual DCT 8090

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.

Measure wear after the lock ring.

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

Maintenance Manual DCT 8090

6 Suspension Rim

6:15

Check the rim's diameter.


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

005374

O. Circumference
D. Diameter
5

Check for damage in the areas with high stress concentration.


Checking is done in two steps:
1.

The magnetic particle method is used to determine if there's a


crack or not, and where it is.

2.

Confirmed cracks are investigated further with penetrating


fluid.

001702

Typical rim damages are circumference cracks, corrosive damage,


rust, warping and wear.

Magnetic particle method


Blast the applicable area clean so that it is completely free of
paint residue.

Test using magnetic particle and the following equipment:

005375

Rim

Equipment: Yoke Tiede

Method:

Alternating current AC

Contrast colour

Checking medium:
a

Wet

Colour (for example, Tiede Ferrolux)

If no cracks are detected with the magnetic particle method,


checking is finished and the applicable area is approved.
If cracks are indicated, the crack should be investigated further
with penetrating fluid.

Checking cracks with penetrating fluid


1

Clean the area with cleaning fluid part no. 923626.0668.

Spray penetrating fluid part no. 923626.0669 on the cleaned area


and let dry 10 min.

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

Spray detection fluid part no. 923626.0670 on the area.

Let the sprayed area dry 1-2 hours.

Rim

Maintenance Manual DCT 8090

UDCT01.02GB

6:16

6 Suspension Rim

Visually inspect the area.


If the tested area does not show signs of linear or point-shaped
cracks, it is approved.

001705

If the crack check indicates linear or point-shaped cracks, contact


Cargotec Support.

Examples of cracks
1.

Linear crack

2.

Pointed crack

UDCT01.02GB

Maintenance Manual DCT 8090

7:1

7 Load handling

Contents 7 Load handling


7
Load handling .....................................................................................................7:3
7.2
Lifting/lowering .................................................................................................7:4
7.2.9
Mast ............................................................................................................7:6
7.2.10
Position sensor mast ...................................................................................7:9
7.2.11
Trolley........................................................................................................7:10
7.4
Side shift ........................................................................................................ 7:11
7.5
Spreading.......................................................................................................7:13
7.5.4
Spreader beam .........................................................................................7:18
7.7
Tilt ..................................................................................................................7:20
7.7.7
Tilt cylinder ................................................................................................7:21
7.7.8
Mast ..........................................................................................................7:21
7.8
Levelling.........................................................................................................7:22
7.9
Load carrier....................................................................................................7:23
7.9.1
Twistlocks ..................................................................................................7:23
7.10
Other functions...............................................................................................7:31
7.10.1
Container counter......................................................................................7:31
7.10.2
Speed reduction ........................................................................................7:31

Maintenance Manual DCT 8090

UDCT01.02GB

7:2

UDCT01.02GB

Maintenance Manual DCT 8090

7 Load handling Load handling

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

Load carrier (side lift attachment with twistlock locking)

Other

009149

- Container counter
Load handling is primarily controlled with the control levers while
certain functions have separate switches.

Lifting/lowering

Certain sub-functions (e.g. Load carrier) can in turn be divided into


different technical solutions. In these cases, the sub-function is
broken down into further sub-functions.

014022

Many functions change depending on the options with which the


machine is equipped. In these cases the basic function is described
first, then there is a description of how the different options affect
the basic function.

009150

Side shift

014023

Tilt

Spreading

Maintenance Manual DCT 8090

UDCT01.02GB

7:4

7 Load handling Lifting/lowering

7.2 Lifting/lowering
Lifting/lowering, function description
Damping

Lifting/lowering means that the mast's components are raised and


lowered so that the attachment is raised and lowered. The machine is
equipped with a duplex lift mast. During lifting, the inner mast is raised
with the lift cylinders. The chain, which is secured in the carriage and
in the outer mast, runs over the chain wheel at the top of the inner
mast and lifts the carriage at the same time as the inner mast is lifted.

009149

The lifting/lowering function is controlled by control lever or linear


. The control lever sends a voltage signal
control levers
proportional to lever deflection to the control system in order to control
the lifting/lowering function. Hydraulic oil pump load handling pumps
hydraulic oil to control valve lift, tilt and attachment which pressurises
the lift cylinders. Load control valves on the lift cylinders prevent
uncontrolled lowering.
Engine speed is increased automatically if the machine is
disconnected when lift is activated in order to increase the lifting
speed.

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

Maintenance Manual DCT 8090

7 Load handling Lifting/lowering

Condition

Reference value

Control switch

Not activated

Twistlocks

Locked or unlocked, not intermediate position

Contact

Mast down: no contact

1b

7:5

1a
D

D790-1
D797-1

D794

11

4
D
D

10

C
9

P2

12

014656

8
1.

a. Control lever lifting/lowering (R8071)

7.

Control valve lift, tilt and attachment (part of the main


valve)

b. Control lever (S815-P1)


2.

Control unit cab (D790-1)

8.

Accumulator lift

3.

Control unit frame (D797-1)

9.

Lift cylinder

4.

Relay control switch lifting/lowering (K3007)

10. Position sensor mast (B7211-2)

5.

Solenoid valve lifting (Y6005) and lowering (Y6004)

11. Control unit engine (D794)

6.

Hydraulic oil pump load handling

12. Hydraulic oil filter

Maintenance Manual DCT 8090

UDCT01.02GB

7:6

7 Load handling Mast

Lifting/lowering, component location


1

5
6
7

12

015005

10

11

1.

Solenoid valve lifting (Y6005) and lowering (Y6004)

7.

Control lever (S815-P1)

2.

Control valve lift, tilt and attachment (part of the main


valve)

8.

Control lever lifting/lowering (R8071)

3.

Lift cylinder

9.

Control unit cab (D790-1)

4.

Position sensor mast (B7211-2)

5.

Mast

6.

Hydraulic oil pump load handling

10. Relay control switch lifting/lowering (K3007)


11. Accumulator lift
12. Control unit frame (D797-1)

7.2.9 Mast
Mast suspension, checking
Machine in service position, see section B Safety.

Visually check that the frame's mounting points and welding


seams are intact.

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

015104

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Maintenance Manual DCT 8090

7 Load handling Mast

7:7

Mast suspension, checking bearings


1

Raise and secure the trolley

WARNING
Never work under a trolley that is not secured.
Risk of crushing!
Secure the trolley properly before beginning work.
Machine in service position, see section B Safety.

Visually check that the frame's mounting points and welding


seams are intact.

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

Make a marking on the mast.

Remove the load from the mast mountings in an appropriate


manner.

Make a new marking on the mast. Measure the distance between


the markings. The measurement should be max. 1 mm.

If the difference is greater, the bearings in the mast mountings


must be replaced, see Workshop manual.

009673

Slide plates, checking


1

Machine in service position, see section B Safety.

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.

When a noticeable clearance arises, which corresponds to a


minimum clearance of 2 mm, the clearance must be reduced by
using adjustment shims, see Workshop manual. If less than 5 mm
wear limit remains on the slide plates they must be replaced.

NOTE
Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.

Lifting chains, checking and adjusting


With the aim of increasing safety, the lifting chains should be checked
regularly according to the following:
The chains must be thoroughly cleaned over their entire length. The
check is performed without a load on the side lift attachment.

Maintenance Manual DCT 8090

UDCT01.02GB

7:8

7 Load handling Mast

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.

P-measurement = the distance between 2 pins

005670

P-measurement
[in]

P-measurement
[mm]

Measurement over 25 links


[mm]
New chain

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

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


measuring tape intended to measure the wear.
The measuring tape is marked with:

Zulssige Verlngerung = permitted lengthening.

Kette austauschen = chain must be replaced.

The measuring tape can be ordered from Cargotec.

Adjusting
3

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

Check that the washers are free of visible cracks.

Check that the chain is free from mechanical damage.

Check that the chain is free of rust.

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).

Lower the carriage to the bottom position.

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


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

NOTE

009153

If the chain is slack when the carriage is in its lowest position,


the chain must be tightened.

Inspection hole, distance between carriage and mast.

UDCT01.02GB

Maintenance Manual DCT 8090

7 Load handling Position sensor mast

7:9

11 Adjust the chains so that the carriage is lifted evenly in the mast.

Loosen the locking washers (position 1) and remove the lower


nut (position 2).

Lift the chain tightener (position 4) out of the carriage and


remove the old locking washer.

Reinstall with new locking washer, chain tightener, locking


washer and lower nut. Repeat on the other side.

4
1.

Locking washer

2.

Lower nut

3.

Upper nut

4.

Chain tightener

NOTE
Reinstall only new locking washers.

Adjust the nuts on each side to balance the carriage so that


the distance between carriage and mast is 10-20 mm.

Tighten the nuts.

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.

12 Lubricate the chains after completed inspection.

7.2.10 Position sensor mast


Position sensor, checking
1

Machine in service position, see section B Safety.

Wipe the sensors clean with a rag or similar item.

Check that they are secured properly.

Check that the distance between sensor and inner mast (when it
is directly opposite the sensor) is 101 mm

014740

009152

Maintenance Manual DCT 8090

UDCT01.02GB

7:10

7 Load handling Trolley

7.2.11 Trolley
Slide plates trolley, checking
1

Park the machine with attachment lowered as far down as possible


and spreaders in their narrowest position.

Turn off the engine and turn off the system voltage.

Clean the lower slide plates (position 2) and measure the


thickness.

NOTE
The thickness of the slide plate should be at least 10 mm.
4

Clean the upper slide plates (position 1) and measure the


thickness.

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.

For adjustment and replacement, see Workshop manual.

The illustration shows slide plates between trolley and


attachment.
1. Upper slide plates
2. Lower slide plates
3. Attachment's mounting

UDCT01.02GB

Maintenance Manual DCT 8090

7 Load handling Side shift

7:11

7.4 Side shift


Side shift, function description
Side shift means to move the attachment sideways. The attachment
can be side-shifted 600 mm in relation to the trolley.

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

a. Control lever side shift (R8072)

7.

Control unit attachment (D791-1)

b. Control lever (S815-P3)

8.

Solenoid valve, side shift left (Y6020) and right


(Y6021)

9.

Control valve attachment

2.

Control unit cab (D790-1)

3.

Control unit frame (D797-1)

4.

Solenoid valve hydraulic attachment (Y6062-2)

5.

Hydraulic oil pump load handling

6.

The control valve lift, tilt and attachment

10. Side shift cylinder


11. Hydraulic oil filter

Maintenance Manual DCT 8090

UDCT01.02GB

7:12

7 Load handling Side shift

Side shift, component location


2
4
3

10
5

11

1.

Side shift cylinder

7.

Control unit cab (D790-1)

2.

Hydraulic oil pump load handling

8.

Control unit frame (D797-1)

3.

Control valve lift, tilt and attachment (part of the main


valve)

9.

Control unit attachment (D791-1)

4.

Solenoid valve hydraulic attachment (Y6062-2)

10. Solenoid valve side shift right (Y6021) and left


(Y6020)

5.

Control lever (S815-P3)

11. Control valve attachment

6.

Control lever side shift (R8072)

UDCT01.02GB

Maintenance Manual DCT 8090

015007

7 Load handling Spreading

7:13

7.5 Spreading
Spreading, function description
Damping

Spreading means changing the width between the twistlocks. The


spreading distance is between 20 feet (side lift attachment retracted)
and 40 feet (side lift attachment maximum extension).
The spreading function is controlled by control lever or switch

014023

The control lever or switch


sends a voltage signal to the control
system to control the spreading 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.
The control valve attachment pressurises the spreading cylinders,
which actuate the spreading booms in and out. Inductive position
sensors indicate the position of the spreader booms.

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.

Maintenance Manual DCT 8090

UDCT01.02GB

7:14

7 Load handling Spreading

Condition

Reference value

Control switch

Not activated

Twistlocks

Unlocked or bypass activated

1a

1b

D
D790-1
D797-1
D

2
D791-1

3
D

D
8

C
P2
P1

15

10

T1 B

13

1.

a. Switch spreading 20'-40' (S1012)

11

9.

b. Control lever (S815-T1.1 and S815-T1.2)

12

14

Solenoid valve, spreading out left (Y6018L) and


spreading in left (Y6019L)

10. Control valve attachment

2.

Control unit cab (D790-1)

3.

Control unit frame (D797-1)

4.

Solenoid valve hydraulic attachment (Y6062-2)

5.

Hydraulic oil pump load handling

6.

Control valve lift, tilt and attachment (part of the main


valve)

11. Spreading cylinder, right


12. Spreading cylinder, left
13. Sensor, end-position 20'-40' right (B769R)

7.

Control unit attachment (D791-1)

8.

Solenoid valve, spreading out right (Y6018R) and


spreading in right (Y6019R)

UDCT01.02GB

014659

14. Sensor, end-position 20'-40' left (B769L)


15. Hydraulic oil filter

Maintenance Manual DCT 8090

7 Load handling Spreading

7:15

30-foot stop, function description


30-foot stop is an additional function for spreading and is activated with
Switch stop at 30'. When 30-foot stop is activated spreading stops at
30 feet, to spread further the spreading must be activated once again.
Two inductive position sensors indicate the position of the spreading
beams and activate damping. At 30 foot stop, two sensors are used
to control the stop.

Condition

Reference value

Control switch

Not activated

Twistlocks

Unlocked or bypass activated

2a

35

30-

D790-1

D797-1
D

3
D791-1

6
D

D
30'

1.

Switch stop at 30' (S1004)

2.

a. Switch spreading 20'-40' (S1012)

Control unit cab (D790-1)

4.

Control unit frame (D797-1)

5.

Solenoid valve hydraulic attachment (Y6062-2)

6.

Control unit attachment (D791-1)

7.

Solenoid valve spreading out left (Y6018L) and


Solenoid valve spreading out right (Y6018R) or
Solenoid valve spreading in left (Y6019L) and
Solenoid valve spreading in right (Y6019R)

8.

Sensor end-position 30' left (B777L) and Sensor


end-position 30' right (B777R)

9.

Sensor end-position 20'-40' left (B769L) and Sensor


end-position 20'-40' right (B769R)

b. Control lever (S815-T1.1 and S815-T1.2)


3.

30'

014660

2b

Maintenance Manual DCT 8090

UDCT01.02GB

7:16

7 Load handling Spreading

Automatic spreading 20-40 foot, function


description

Automatic spreading 20'-40' is an option for spreading that is activated


with Switch automatic spread 20'-40'. When the switch is activated,
spreading automatically switches to the next end position when
spreading is activated using the control lever. The buzzer on the trolley
sounds during automatic spreading. Automatic spreading works for
both spreading in and spreading out.
If the machine is equipped with 30-foot stop and it is activated,
then spreading stops at 30'. Activate spreading again to go to the next
position.

Condition

Reference value

Control switch

Not activated

Twistlocks

Unlocked or bypass activated

Doors

Closed

Parking brake

Released

D
2b

2a

D790-1
4

D797-1
D

11

D795

D791-1

5
1.
2.

Switch automatic spreading 20'-40' (S1012-2)

10

9
7.

Solenoid valve spreading out (Y6018L & Y6018R)


Solenoid valve spreading in (Y6019L & Y6019R)

a. Switch spreading 20'-40' (S1012)


b. Control lever (S815-T1.1 and S815-T1.2)

8.

Sensor end-position 20'-40' (B769L & B769R)

3.

Control unit cab (D790-1)

9.

Sensor end-position 30' (B777L & B777R)

4.

Control unit frame (D797-1)

10. Buzzer automatic spreading (H9003)

5.

Solenoid valve hydraulic attachment (Y6062-2)

11. Control unit KID (D795)

6.

Control unit attachment (D791-1)

UDCT01.02GB

Maintenance Manual DCT 8090

014661

7 Load handling Spreading

7:17

Spreading, component location


1

1
9

8
7

4-6

10
11

16

12

15

14

015008

17

13

1.

Spreader beam

9.

Hydraulic oil pump load handling

2.

Spreading cylinders

10. Control lever (S815-T1.2 and S815-T1.2)

3.

Indicator plate 20'

11. Switch spreading 20'-40' (S1012)

4.

Indicator plate 30'

12. Control unit cab (D790-1)

5.

Indicator plate 40'

13. Control unit frame (D797-1)

6.

Sensor end-position 20'-40' (B769L & B769R)

14. Control unit attachment (D791-1)

Sensor end-position 30' (B777L & B777R)

15. Control valve attachment

7.

Control valve lift, tilt and attachment (part of the main


valve)

16. Solenoid valve spreading in (Y6019R & Y6018R)

8.

Solenoid valve hydraulic attachment (Y6062-2)

17. Solenoid valve spreading out (Y6019L & Y6018L)

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7 Load handling Spreader beam

7.5.4 Spreader beam


Spreader beam, description
The spreader beams are the part of the attachment that grips the
container. Two spreader beams run inside the main beam. The
spreader beams are slid in and out with hydraulic cylinders.

014737

Twistlocks are fitted in the spreader beam, see 7.9.1 Twistlocks,


page 7:23.

Spreader beams

Slide plates spreading beam, checking

UDCT01.02GB

Park the machine with attachment lowered as far down as possible


and spreading extended approx. 1000 mm.

Turn off the engine and turn off the system voltage.

013683

1000 mm

Maintenance Manual DCT 8090

7 Load handling Spreader beam

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

If the measured clearance between slide plates and beams


is greater than 5 mm, the clearance must be adjusted using
adjustment shims.

Y1

Y2

NOTE

Left side

X1

013689

X2
Right side
4

For adjustment and replacement, see Workshop manual.

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7 Load handling Tilt

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

a. Control lever tilt (R8072)

6.

Hydraulic oil pump load handling

b. Control lever (S815-P2)

7.

Control valve lift, tilt and attachment (part of the main


valve)

8.

Load holding valve

9.

Tilt cylinder

2.

Control unit cab (D790-1)

3.

Control unit frame (D797-1)

4.

Relay control switch tilt (K3002)

5.

Solenoid valve tilt in (Y6011) and Solenoid valve tilt


out (Y6010)

UDCT01.02GB

10. Hydraulic oil filter

Maintenance Manual DCT 8090

7 Load handling Tilt cylinder

7:21

Tilt, component location


1

11

10

015006

1.

Solenoid valve tilt in (Y6011) and Solenoid valve tilt


out (Y6010)

6.

Hydraulic oil pump load handling

2.

Control valve lift, tilt and attachment (part of the main


valve)

7.

Control lever (S815-P2)

8.

Control lever tilt (R8072)

3.

Mast

9.

Control unit cab (D790-1)

4.

Tilt cylinder

10. Relay control switch tilt (K3002)

5.

Load holding valve

11. Control unit frame (D797-1)

7.7.7 Tilt cylinder


Tilt cylinder, checking
Check:

visually that the frame's mounting points and welding seams are
intact.

that the tilt fork is securely fastened to the tilt cylinder (136 Nm
tightening torque).

that the tilt cylinders are correctly adjusted.


that the tilt cylinders are properly aligned, so that both cylinders
reach their end positions simultaneously.

7.7.8 Mast
Mast suspension, checking
See Mast suspension, checking, page 7:6.

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7 Load handling Levelling

7.8 Levelling
Mechanical levelling, function description

014021

Mechanical levelling means that the twistlock mountings can spring


outwards and adjust the height of the twistlocks to the inclination of
the container being lifted. This means that the machine can handle
loads on uneven ground, up to 3 levelling.

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Maintenance Manual DCT 8090

7 Load handling Load carrier

7:23

7.9 Load carrier


Load carrier, description
Load carrier means holding any loads. The load is held by the
twistlocks that secure the load with rotatable lift pins.

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.

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7:24

7 Load handling Twistlocks

Condition

Reference value

Control switch

Not activated

Contact

Full contact or bypass activated

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.

Switch lock twistlocks (S1003)

10. Control valve attachment

2.

a. Switch open twistlocks (S1002)

11. Over centre valve

b. Control lever (S815-T2)

12. Lock cylinder

3.

Control unit cab (D790-1)

13. Sensor contact left and right (B7203L and B7203R)

4.

Control unit frame (D797-1)

5.

Solenoid valve hydraulic attachment (Y6062-2)

14. Sensor unlocked twistlocks (B7204L and B7204R),


Sensor locked twistlocks (B7205LL and B7205RL)

6.

Control valve lift, tilt and attachment (part of the main


valve)

7.

Hydraulic oil pump load handling

17. Indicator lights attachment

8.

Control unit attachment (D791-1)

18. Hydraulic oil filter

9.

Solenoid valve open twistlocks (Y6039) and lock


twistlocks (Y6040)

UDCT01.02GB

15. Control unit KID (D795)


16. Control unit KIT (D790-2)

Maintenance Manual DCT 8090

014662

7 Load handling Twistlocks

7:25

Twistlocks, component location


1
2

10

11
6

19
12

13

17

16

15

1.

Sensor locked twistlock (B7205LL/RL)

11. Switch lock twistlocks (S1003)

2.

Lock cylinder twistlocks

12. Control lever (S815-T2)

3.

Sensor contact (B7203L/R)

13. Switch open twistlocks (S1002)

4.

Sensor unlocked twistlock (B7204L/R)

14. Control unit cab (D790-1)

5.

Contact pin

6.

Twistlocks

7.

Indicator lights attachment

8.

Over centre valve

9.

Control valve lift, tilt and attachment (part of the main


valve)

14

15. Hydraulic oil pump load handling


16. Control unit frame (D797-1)
17. Control unit attachment (D791-1)

10. Solenoid valve hydraulic attachment (Y6062-2)

18. Control valve attachment


19. Solenoid valve lock twistlocks (Y6039)
Solenoid valve open twistlocks (Y6040)

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015009

18

7:26

7 Load handling Twistlocks

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.

Sensor unlocked twistlock

3.

Sensor locked twistlock

4.

Lift pin

5.

Contact pin

Check that the twistlocks function correctly.


Lock and open the twistlocks, check that the indicator lights work,
both in cab and on attachment.

Clean the twistlocks from any dirt.

Under the rubber cover for twistlocks: check pin, link arm and
lock nut.

Clean the area around sensor contact.

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

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Maintenance Manual DCT 8090

7:27

Turn twistlocks to locked position and check wear of the lift pin.
Change the lift pin as needed.

Repeat steps 1-8 on both twistlocks.

Max. 4 mm

009776

in
.7

7 Load handling Twistlocks

Wear limits lift pin.

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7:28

7 Load handling Twistlocks

Twistlock, checking for cracks

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

Remove the lift pins from the attachment.

NOTE

009777

Twistlocks are heavy, be careful when removing.

Area for checking for cracks on lift pins

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.

Install approved twistlocks.

NOTE
Use new bearing cap, new bolts and new lock nuts.

UDCT01.02GB

Maintenance Manual DCT 8090

7 Load handling Twistlocks

7:29

014717

Sensor contact, checking and adjusting


1

Check that the alignment pins in the corner boxes can move freely
up and down. The contact pins shall spring down when not loaded.

Check that the sensor is free of damage and dirt.

Turn the start key to position I and check that the light indicators
on the sensor are turned off.

Lower the attachment onto a container and check that Indicator


light contact is lit.

Lift the container a little bit so that the Indicator light contact is
switched off.

With the container raised, check how much movement on the


contact pins is needed to detect contact (light indicator on the
sensor is lit). The movement should be 34 mm.

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

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7:30

7 Load handling Twistlocks

Sensor twistlocks, checking and adjusting


1

Check that the sensors are free of damage and dirt.

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 indicator light twistlocks open is lit.

Lower the attachment over a container and lock twistlocks.

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.

Sensor unlocked twistlock

2.

Sensor locked twistlock

Check that indicator light twistlocks locked is lit.

014720

Left side
1.

Sensor unlocked twistlock

2.

Sensor locked twistlock

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Maintenance Manual DCT 8090

7 Load handling Other functions

7:31

7.10 Other functions


7.10.1 Container counter
Container counter, function description

Container counters count the number of containers lifted. The counter


has two counter units that can be reset separately.
The container counter uses Sensor alignment and Sensor twistlocks to
decide when a container is lifted. The container counter counts a lift
when contact disappears with locked twistlocks and twistlocks do not
open again within eight seconds.

Condition

Reference value

Control switch

Not activated

D795
D791-1

D
2
004297

1.

Sensor contact left and right (B7203L and B7203R)

3.

Control unit attachment (D791-1)

2.

Sensor locked twistlock left and right (B7205LL and


B7205RL)

4.

Control unit KID (D795)

7.10.2 Speed reduction


Speed reduction with load
When operating with a load the machine's speed is limited to 15 km/h.

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7:32

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Maintenance Manual DCT 8090

8:1

8 Control system

Contents 8 Control system


8
Control system ...................................................................................................8:3
8.2
Monitoring ........................................................................................................8:6
8.2.2
Bypass ........................................................................................................8:6
8.2.3
Speed limitation...........................................................................................8:6
8.2.4
Service indicator..........................................................................................8:7
8.3
Error codes ......................................................................................................8:8
8.4
Diagnostics ....................................................................................................8:10
8.4.1
CAN/POWER ............................................................................................8:13
8.4.2
LIGHTS .....................................................................................................8:14
8.4.3
CAB ...........................................................................................................8:15
8.4.4
CLIMATE ...................................................................................................8:15
8.4.5
HYD...........................................................................................................8:16
8.4.6
ENGINE ....................................................................................................8:17
8.4.7
TRANSM ...................................................................................................8:19
8.4.8
ELECTRIC SERVO ...................................................................................8:20
8.4.9
ATTACH ....................................................................................................8:21
8.4.10
OLS ...........................................................................................................8:21
8.4.11
EXTRA ......................................................................................................8:22
8.5
Settings ..........................................................................................................8:24

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Maintenance Manual DCT 8090

8 Control system Control system

8:3

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

Monitoring functions

Error codes

Diagnostics

Settings

Software

Monitoring functions describe the machine's monitoring functions that


warn the operator or limit the machine's functions in the event of a
dangerous situation.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machines display.
Settings is the tool for setting and adapting the machines functions.
The software creates the functions in the control system.

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8:4

8 Control system Control system

Control system, description


B

The machine is equipped with an electronic system used for


controlling and monitoring the machines different functions.

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


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

A
A

Function keys (KIT)

Warning and indicator lights

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

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


enter value 1.

Function key 2: Scroll clockwise in menu system as well as enter


value 2.

Function key 3 (Reset): Abort selection of menu/session in


progress as well as enter value 3. Confirm alarm.

Function key 4: Enter value 4, gradually adjust settings (for


example, contrast in guide lights for function keys) and gradually
change values in operating menus.

Function key 5: Enter value 5, gradually adjust settings (for


example, contrast in guide lights for function keys) and gradually
change values in operating menus.

Function key 6 (Return): Confirm selection of menu and


sub-menu, as well as confirm entered value.

Maintenance Manual DCT 8090

8 Control system Control system

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

The following operating menus are available to aid the operator:

Examples of available operating menus

Operating menu engine and transmission

Operating menu engine

Operating menu transmission and hydraulics

Operating menu electrical system

Service menu

Operating menu heating and air conditioning

Operating menu service interval

Operating menu statistics

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

Contact side lift attachment, twistlock

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:

Error codes, description, page 8:8

Diagnostics, general, page 8:10

Setup, general, page 8:24

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8 Control system Monitoring

8.2 Monitoring
Monitoring functions, general
The machine is equipped with a number of control functions to increase
safety during load handling:

Bypass

Speed limitation

Service indicator

8.2.2 Bypass
Bypass, description
Bypass is activated with the bypass switch.
Bypassing the safety system makes it possible to:

lock and open twistlocks without full contact

Spread 20'-40' with locked twistlocks

lower load with contact on side lift attachment

manual steering of recirculation damper by ECC or EHC

release of parking brake in case of malfunction of switch parking


brake

output signal to solenoid valves with active error codes

machine engages neutral when no one is sitting in the driver's seat

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

8.2.3 Speed limitation


Speed limitation, description

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


value by limiting gear position and engine rpm.

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Maintenance Manual DCT 8090

8 Control system Service indicator

8:7

8.2.4 Service indicator


Service indicator, resetting

Machine in service position, see section B Safety.

Navigate first to the service menu and press Enter.

Enter code for resetting service indicator.

000056

The code is obtained from Cargotec Support.

1 23
4 5
000060

NOTE
The code determines which service menu shall be activated
(Service, Diagnostics, Initiation or Calibration).
4

Reset the service indication by pressing Enter. NEXT SERVICE is


changed to indicated interval.
To change duration of the service interval, set the desired interval
with the plus and minus key.

004908

SERVICE INTERVALL
NEXT SERVICE
XXXXh
SERVICE INTERVALL
STORED
XXXXh
PRESENT
XXXXh

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8 Control system Error codes

8.3 Error codes


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

53

Error code indication

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:

STOP is indicated with a STOP-sign on the display together


with a flashing red light from indicator for control and monitoring
system (position 54) and activated Indicator for active error codes
(position 36).

WARNING is indicated on the display, together with a flashing red


light for control and monitoring system (position 54) and activated
Indicator for active error codes (position 36).

Error code with level STOP shown automatically on display.

36

Error code with level WARNING shown automatically on display.

INFORMATION is indicated with activate Indicator for active error


codes (position 36).

000348

Error code with level INFORMATION shown in error code list


under operating menu for service.

B. Symbol error code level


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

Error code display


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

003817

Example of automatic display figure

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.

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Maintenance Manual DCT 8090

8 Control system Error codes

001998

Example of display in error code list

8:9

In the error code list under operating menu for service.


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

NOTE
If error code isnt included in the error code list, it may be due
to the following:

condition for error detection no longer exists, e.g.,


control lever is released or engine is off.

loose connection/poor contact.

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8:10

8 Control system Diagnostics

8.4 Diagnostics
Diagnostics, general
The machine has built-in functions for troubleshooting called diagnostic
test. The diagnostic test consists of several menus that are shown in
the display. The menus are grouped for faster access.
The following pages show compilations of the diagnostic menus. The
workshop manual has a more detailed description of each diagnostic
menu.
The diagnostic test is divided into the following groups:

CAN/POWER, menu overview, page 8:13

LIGHTS, menu overview, page 8:14

CAB, menu overview, page 8:15

CLIMATE, menu overview, page 8:15

HYD, menu overview, page 8:16


ENGINE, menu overview (engine alternative Yuchai YC6A240-30),
page 8:17
ENGINE, menu overview (engine alternative Cummins QSB6.7
), page 8:18

TRANSM, menu overview, page 8:19

ELECTRIC SERVO, menu overview, page 8:20

ATTACH, menu overview, page 8:21

OLS, menu overview, page 8:21


EXTRA

UDCT01.02GB

OPT, menu overview, page 8:22

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8 Control system Diagnostics

8:11

Diagnostic menu, description

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

Signal values (position 6) in the menu indicate measured values by


the relevant control unit. The control units have internal voltmeters
and ammeters that measure the signal on the connectors out to
components or in from components.

1.

DIAG = Diagnostic menus

2.

Menu group (CAB = cab functions)

3.

Menu number

4.

Total number of menus in the loop. The number


The figure shows an example of a menu, here for diagnostics of
of menus depends on how the machine is
equipped, which is why the number of menus is windshield wiper. The table below indicates what you can read out
from the menu figure.
indicated by (X) in this manual.

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

Indicates which menu group is selected. These groups are available:

Output signals are control of solenoid valves, lights, relays, etc.


Input signals are sensor signals, signals from controls and switches,
feedback control signals, etc.

CAN/POWER - for diagnosis of CAN-bus and electric power supply.


LIGHTS - for diagnosis of lighting and lights.
CAB - for diagnosis of components in cab.
CLIMATE - for diagnosis heat and ventilation system.
HYD - for diagnosis of common hydraulics and brakes.
ENGINE - for diagnosis of engine.
ELECTRIC SERVO - for diagnosis of lifting/lowering and tilt.
ATTACH - for diagnosis of attachment.
OLS - for diagnosis of overload system.
EXTRA - for diagnosis of optional functions.
3

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

Which signal is being measured. Here are a few examples.


SWITCH refers to switch windshield wipers.
OUTPUT refers to status of a feed, in this case feed to the wiper motor.
FEEDBACK refers to feedback signal, in this case signal from the wiper motor when it operates.

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.

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8:12

8 Control system Diagnostics

Diagnostics, operating instructions


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

Enter the code for diagnostics.

000056

The code is obtained from Cargotec Support.

1 23
4 5
000060

NOTE

UDCT01.02GB

005263

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

The code determines which service menu shall be activated


(Service, Diagnostics, Initiation or Calibration).
Select group by scrolling with the arrow keys (1 and 2) and confirm
with Enter.
Each group consists of a sequence of numbered menus. The first
menu for selected diagnostic menu is shown in the display, use
arrow keys (1 and 2) to change menu.

Maintenance Manual DCT 8090

8 Control system CAN/POWER

8:13

8.4.1 CAN/POWER
CAN/POWER, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG CAN/POWER
1(X)
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

Maintenance Manual DCT 8090

015038

13(X)

5V REF

5(X)

KDU D797-2
KDU D791-1

UDCT01.02GB

8:14

8 Control system LIGHTS

8.4.2 LIGHTS
LIGHTS, menu overview

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

Maintenance Manual DCT 8090

OUTPUT

X
XY

X
X
XXX

20' XY 40' XY
15(X)
X
XXX

009154

DIAG LIGHTS
MAIN LIGHT
SWITCH

8 Control system CAB

8:15

8.4.3 CAB
CAB, menu overview

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

Maintenance Manual DCT 8090

005596

DIAG CLIMATE
1(X)
PRESENT INPUT SIGNAL
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
WATER VALVE FEEDB. XXX

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8:16

8 Control system HYD

8.4.5 HYD
HYD, menu overview

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

Maintenance Manual DCT 8090

015039

DIAG HYDRAULIC
HYDRAULIC OIL
TEMP
FAN
SET OUTPUT +/-

8 Control system ENGINE

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

Maintenance Manual DCT 8090

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8:18

8 Control system ENGINE

ENGINE, menu overview (engine alternative Cummins


QSB6.7
)

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

Maintenance Manual DCT 8090

8 Control system TRANSM

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
(+/-)

Maintenance Manual DCT 8090

015042

X
X
X

2(14)

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8:20

8 Control system ELECTRIC SERVO

8.4.8 ELECTRIC SERVO


ELECTRIC SERVO, menu overview

DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
OLS EXTRA
DIAG ELSERVO
1(X)
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

Maintenance Manual DCT 8090

8 Control system ATTACH

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 10(X)


PRESENT OUTPUT SIGNAL
IND. LOCKED CONT
XY
IND. UNLOCKED CONT XY
IND. ALIGNMENT
XY

DIAG ATTACHMENT 11(X)


OUTPUT SIDESHIFT LE
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

DIAG ATTACHMENT 12(X)


OUTPUT SIDESHIFT RI
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

DIAG ATTACHMENT
NOT USED

13(X)

DIAG ATTACHMENT
NOT USED

DIAG ATTACHMENT
NOT USED

DIAG ATTACHMENT
NOT USED

16(X)

DIAG ATTACHMENT 17(X)


OUTPUT SPREAD LE OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

DIAG ATTACHMENT 18(X)


OUTPUT SPREADER LE IN
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

DIAG ATTACHMENT 19(X)


OUTPUT SPREAD RI OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

DIAG ATTACHMENT 20(X)


OUTPUT SPREADER RI IN
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

DIAG ATTACHMENT 21(X)


PRESENT OUTPUT SIGNAL

14(X)

15(X)

BUZZER AUTO 20-40

XY

015043

PISTOL

8.4.10 OLS
OLS, menu overview
Not used.
Maintenance Manual DCT 8090

UDCT01.02GB

8:22

8 Control system EXTRA

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

Maintenance Manual DCT 8090

8 Control system EXTRA

8:23

8.4.11.7 I/O
I/O, menu overview
Not used.

8.4.11.8 RMI
RMI, menu overview
Not used.

Maintenance Manual DCT 8090

UDCT01.02GB

8:24

8 Control system Settings

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

Maintenance Manual DCT 8090

9:1

9 Frame, body, cab and accessories

Contents 9 Frame, body, cab and accessories


9
Frame, body, cab and accessories ...................................................................9:3
9.1
Controls and instruments .................................................................................9:4
9.2
Safety and emergency equipment ...................................................................9:9
9.3
Seats..............................................................................................................9:10
9.4
Heating, ventilation and air conditioning ........................................................9:13
9.4.1
Fresh air filter ............................................................................................9:25
9.4.8
Condenser.................................................................................................9:25
9.4.9
Moisture filter.............................................................................................9:26
9.5
Wiper/washer system.....................................................................................9:27
9.6
Lighting system ..............................................................................................9:28
9.7
Signalling system ...........................................................................................9:30
9.8
Entertainment and communication ................................................................9:32
9.9
Glass/windows/mirrors...................................................................................9:33
9.9.3
Roof window..............................................................................................9:33
9.9.5
Rearview mirror .........................................................................................9:33
9.10
Cab structure and suspension .......................................................................9:34
9.10.2
Doors.........................................................................................................9:34
9.10.3
Cab undercarriage ....................................................................................9:35
9.11
Cab interior ....................................................................................................9:36
9.12
Frame.............................................................................................................9:37
9.13
Body structure................................................................................................9:38
9.14
Central lubrication ..........................................................................................9:39
9.15
Paint/coatings ................................................................................................9:41

Maintenance Manual DCT 8090

UDCT01.02GB

9:2

UDCT01.02GB

Maintenance Manual DCT 8090

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

9:3

9 Frame, body, cab and


accessories
Frame, body, cab and accessories,
description
The machine consists of frame, body and cab.
The frame (chassis) is the machine's structural part and is made of
high-strength steel.
The body consists of fenders, engine hood, tanks and other parts
mounted on the frame.
The cab is built separately and isolated from the frame using
heavy-duty rubber dampers. Driver's seat, steering wheel, and control
lever for hydraulics can be adjusted for optimal individual operating
position. Effective insulation gives a minimum of vibrations and a low
sound level. The machine is equipped with heating and ventilation, air
condition is available as an option.

Maintenance Manual DCT 8090

UDCT01.02GB

9:4

9 Frame, body, cab and accessories Controls and instruments

9.1 Controls and instruments


Controls and instruments, overview
Overview

Overview

11

10

15

12

13

12

015102

14
1.

Left instrument panel

2.

Gear and multi-function lever (S162)

3.

Steering wheel panel

4.

Steering wheel

5.

Switch direction indicators (S161)

6.

Panel for hydraulic functions

7.

Control breaker for hydraulics (S250)

8.

Switch for parking brake (S107)

9.

Control lever (S815)

10. Driver's seat


11. Accelerator pedal (B690)
12. Brake pedals
13. Declutch pedal (S220-1)
14. Electronic box with fuses and relays
15. Hour meter (P708)

UDCT01.02GB

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Controls and instruments

Left-hand dashboard panel

9:5

Left-hand dashboard panel


16. Switch for fan (S118)
17. Switch for heat (S117)

24..28

29 30 31 18. Switch for air distribution (S139)


19. Switch for work lights cab roof (S105-1)

19..23

20. Switch working lights carriage and attachment (S105-2)

18
16
Left instrument panel

Extra working lights attachment and carriage


010907

17

21. Switch for work lights mast (S105-3)


Extra working lights mast
22. Switch for rotating beacon (S110)
23. Switch for hazard lights (S109)
24. Switch for headlights (S100)
25. Spare
26. Spare
27. Spare
28. Spare
29. Spare
30. Spare
31. Socket 12 VDC

Maintenance Manual DCT 8090

UDCT01.02GB

9:6

9 Frame, body, cab and accessories Controls and instruments

Steering wheel panel

32

33

35

34

Steering wheel panel

36

32. Warning lamp for low battery charge


33. Warning lamp for low brake pressure
34. Indicator for active error codes
35. Warning lamp for bypass of hydraulic functions
36. Not used

37..41

37. Warning lamp for high coolant temperature

49

38. Warning lamp for low oil pressure engine

42..46

39. Indicator light for preheating

47 48

40. Warning lamp for low coolant level engine


41. Warning lamp for high oil temperature transmission
42. Warning lamp for low fuel level
43. Warning lamp for high temperature hydraulic oil

50

51

52

53

44. Indicator light for high beam


45. Indicator light for travel direction
46. Indicator light for parking brake
47. Indicator light for locked twistlock (secured load)
48. Indicator light for contact (attachment / load)
49. Indicator light for unlocked twistlock (load released)
50. Panel for warning and indicator lights
51. Display for control and monitoring system

64
63
62

54

52. Indicator for control and monitoring system

55

53. Ignition key lock


54. Switch for defroster

61
Steering wheel panel

60

59 58 57

008132

56

55. Switch for windshield wiper roof, interval


56. Switch for windshield wiper roof, continuous
57. Switch for interior lighting
58. Switch for windshield wiper rear, interval
59. Switch for windshield wiper rear, continuous
60. Function keys for control and monitoring system
61. Driving direction indicator, Forward Neutral Reverse
62. Shifting program A, automatic shifting
63. Shifting program 1, locked to gear position one
64. Shifting program 2, locked to gear position two

UDCT01.02GB

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Controls and instruments

Panel for hydraulic functions

9:7

Panel for hydraulic functions

68

65. Lift/lower (R8071)


66. Tilt (R8072)

70
67. Side shift (R8073)
72

68. Opening the twistlock (S1002)

74
74
73

69. Switch for horn (S149)


70. Switch for twistlock, automatic/manual locking (S1003)
71. Switch for spreading 20'-40' (attachment) (S1012)
72. Switch for stopping spreading at 30' (attachment) (S1004)
73. Switch for automatic spreading 20'-40' (S1012-2)
74. Switch for by-pass of hydraulic functions (S1005)

014179

Key for bypass of hydraulic functions

69

Panel for hydraulic functions and control lever

65
66

68

67
7

69
70
71
72

74

74

014178

73

Panel for hydraulic functions and linear control levers

Maintenance Manual DCT 8090

UDCT01.02GB

9:8

9 Frame, body, cab and accessories Controls and instruments

Operating menus, overview

11

12

13

14

1.

Operating menu engine and transmission

8.

Operating menu service

2.

Operating menu engine

9.

Operating menu heating and air conditioning

3.

Operating menu for oil temperature

10. Operating menu code lock

4.

Operating menu electrical system

11. Operating menu statistics, operating hours

5.

Operating menu container counter

12. Operating menu statistics, fuel consumption

6.

Operating menu service interval

13. Operating menu statistics, driving distance

7.

Operating menu statistics

14. Operating menu statistics, lift statistics

Event menus overview

014668

10

Event menus overview


Side lift attachment with twistlock locking

014669

UDCT01.02GB

1.

Event menu contact twistlock

2.

Event menu twistlocks

3.

Event menu open door

4.

Event menu automatic spreading

Maintenance Manual DCT 8090

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

9:9

9.2 Safety and emergency equipment


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

6,7,10
2

4
3

1
9

5
1.

Back-up alarm

2.

Revolving beacon.

3.

Horn.

4.

Electrically powered loud horn

5.

Fire extinguisher

7.

Buzzer in cab to indicate alarm or forgotten action,


e.g., if the operator leaves the cab without first
applying the parking brake.

8.

External rear view mirrors.

Used to provide increased visibility for operating.

9.

If the machine is supplied with a fire extinguisher, it


should be of the type ABE in accordance with EN 3
part 1, 2, 4 and 5. With such a fire extinguisher, it
is possible to extinguish fires in both solid organic
materials and fluids. Adapted fire extinguishing
equipment can be ordered from Cargotec.
6.

014175

11

Blinking brake lights when reversing.

10. Control breaker for hydraulics (servo circuits).


Breaks all transmission of power and control signals
to the hydraulics.
11. Buzzer automatic spreading (H9003)

Seat belt.

Maintenance Manual DCT 8090

UDCT01.02GB

9:10

9 Frame, body, cab and accessories Seats

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.

The seat has the following equipment:

mechanical height adjustment

angle of seat

armrest right

two-point seat belt

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.

Adjustable arm rest, right

3.

Adjustable tilt, backrest

4.

Display of weight adjustment

5.

Adjustable seat height

6.

Adjustable seat angle

7.

Longitudinal adjustment

UDCT01.02GB

014151

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Seats

9:11

Seat, description (product alternative BE-GE


9200)

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 seat has the following equipment:

5
8

006825

6
7

mechanical height adjustment

armrest right

two-point seat belt

seat heating

head restraint

armrest left

The seat features a sensor that senses compression of the seat. 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.

Controls
1.

Adjustable lower back (lumbar) support

2.

Adjustable arm rest, right

3.

Adjustable arm rest, left

4.

Adjustable tilt, backrest

5.

Adjustable suspension position

6.

Adjustable seat angle

7.

Adjustable seat height

8.

Longitudinal adjustment

Maintenance Manual DCT 8090

UDCT01.02GB

9:12

9 Frame, body, cab and accessories Seats

Seat, description (product alternative BE-GE 9200


air suspension)

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

The seat has the following equipment:

5
8

006826

6
7

Controls BE-GE 9200


1.

Adjustable lower back (lumbar) support

2.

Adjustable arm rest, right

3.

Adjustable arm rest, left

4.

Adjustable tilt, backrest

5.

Adjustable suspension position

6.

Adjustable seat angle

7.

Adjustable seat height

8.

Longitudinal adjustment

UDCT01.02GB

air suspension (with external compressor)

armrest right

three-point seat belt

seat heating

armrest left

head restraint

The seat features a sensor that senses compression of the seat. 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.

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Heating, ventilation and air conditioning

9:13

9.4 Heating, ventilation and air


conditioning
Heating and ventilation unit, function description
(product alternative EHC)
The heating and ventilation unit (EHC) handles heating and
ventilation. (The heating and ventilation unit cannot add cooling.)
The temperature in the cab is thermostat-controlled by Control unit
cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 C. The
system is operated with controls on the instrument panel.
The heating and ventilation system used heat from the engine's
cooling system via a heater to warm the outdoor air. Outdoor air is
forced by the fan through the heater and on through channels in the
cab's interior, and is then directed at, e.g., the windshield (defroster)
or the feet.

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

The heating and ventilation unit can:

add fresh air to the cab

clean the air from impurities

warm the air when it is cold

defrost the windows (defroster function)

Maintenance Manual DCT 8090

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.

Switch fan (S118)

10. Control unit engine (D794)

2.

Switch temperature (S117)

11. Water valve (Y673)

3.

Switch air distribution (S139)

12. Heat exchanger

4.

Sensor cab temperature (B775-1)

13. Actuator recirculation (M612)

5.

Sensor temperature outlet fan (B775-2)

14. Fan motor heat (M657)

6.

Sensor outdoor temperature (B774)

15. Damper motor (Y672)

7.

Control unit cab (D790-1)

16. Switch defroster on Control unit KIT (D790-2)

8.

Engine

17. Operating menu on Control unit KID (D795)

9.

Sensor engine temperature

UDCT01.02GB

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Heating, ventilation and air conditioning

9:15

Air conditioning, function description (product


alternative ECC)

Air conditioning is available as an option to the heating unit, this


combination is called (ECC) and handles heating, ventilation, cooling,
and dehumidification.

001839

The temperature in the cab is thermostat-controlled by Control unit


cab (D790-1). The cab temperature is controlled compared to set
temperature. The temperature can be set between 16 and 28 C. The
system is operated with controls on the instrument panel.

Defroster nozzles

For cooling, the compressor that compresses the refrigerant is


activated. Refrigerant is evaporated in the evaporator in the cab.
When the refrigerant is evaporated, cold is then generated in the
evaporator. The outdoor air is cooled when it is forced through the
evaporator by the cab fan. Then the air can be directed in the same
way as for the heating system.
The air conditioning adds the following functions to the heating and
ventilation unit:

dehumidification of the air when it is humid

cooling of the air when it is warm

As an option for the air conditioning there is automatic shut-off


of cooling when the door is open. This means that cooling is turned
off when a door is open. Cooling is activated again when the door
is closed. The air conditioning has a delay of 45 seconds between
cut-off and cut-in.

Maintenance Manual DCT 8090

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.

Switch temperature (S117)

15. Damper motor (Y672)

2.

Switch fan (S118)

16. Control unit frame (D797-1)

3.

Switch air distribution (S139)

17. Magnetic clutch (M645)

4.

Sensor cab temperature (B775-1)

18. Compressor

5.

Sensor temperature outlet fan (B775-2)

19. Condenser

6.

Sensor outdoor temperature (B774)

20. Moisture filter

7.

Control unit cab (D790-1)

21. Pressure switch (S246)

8.

Engine

22. Expansion valve

9.

Water valve (Y673)

23. Sensor temperature in refrigerant circuit (B775-3)

10. Sensor engine temperature

24. Heat exchanger for cooling

11. Heat exchanger

25. Switch defroster on Control unit KIT (D790-2)

12. Control unit engine (D794)

26. Operating menu on Control unit KID (D795)

13. Actuator recirculation (M612)


14. Fan motor heat (M657)

UDCT01.02GB

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Heating, ventilation and air conditioning

9:17

Heating, ventilation and air conditioning,


component location
1

16
15
13

5
6
7

12

005221

11
9, 14

10
1.

Operating menu on Control unit KID (D795)

10. Cab fan (M657)

2.

Switch defroster on Control unit KIT (D790-2)

11. Fresh air and recirculation damper (M612)

3.

Sensor outdoor temperature (B774)

12. Fresh air filter

4.

Control unit cab (D790-1)

13. Heat exchanger (cold and heat)

5.

Sensor cab temperature (B775-1) (inside of the left


control panel, behind a grating)

14. Sensor temperature refrigerant (B775-3)

6.

Switch air distribution (S139)

7.

Switch temperature (S117)

8.

Switch fan (S118)

9.

Expansion valve

(located the copper pipe inside the expansion valve)


15. Air distributor (Y672)
16. Sensor temperature outlet fan (B775-2) (in air
distributor)

Maintenance Manual DCT 8090

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

Compressor Yuchai YC6A240-30

5.

Pressure switch (S246)

Compressor Cummins QSB6.7

6.

Moisture filter

2.

Magnetic clutch compressor (M645)

7.

Sight glass

3.

Water valve (Y673)

UDCT01.02GB

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Heating, ventilation and air conditioning

9:19

General recommendations for work on the air


conditioning unit

CAUTION
Authorisation is required to perform repairs on the
climate control unit.

WARNING
If there is a rupture of a cooling hose or leakage on the
plant turn off the unit immediately.
It is dangerous to allow refrigerants to come in contact
with skin or eyes.
Never release refrigerant in a closed rum; the gas can
cause asphyxiation in, for example, pits.
Never weld on or near a closed cooling system.
Empty refrigerant during repairs on the air conditioning.
Work may only be performed on the refrigerant circuit
by an accredited company.

WARNING
Electric fans can injure hands.
Risk of personal injury.
Avoid placing hands near the cooling fans when the
engine is running.

Air conditioning, checking/performance test

NOTE
The air conditioning does not work at temperatures below approx.
0 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 compressor turns on and off without error.

Check that the drain for the cooling element's condensation water
is not clogged.

Maintenance Manual DCT 8090

UDCT01.02GB

9:20

9 Frame, body, cab and accessories Heating, ventilation and air conditioning

Check that there is no refrigerant leakage. In case of leakage, oil


and gas often form a dusty, dirty spot.

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.

After running for 10 minutes, check that there are no bubbles


visible in the receiver dryer's sight glass. (Bubbles should occur
only when the compressor starts and stops).

Place a thermometer by the air vent closest to the evaporator. After


5-10 minutes, the temperature should be under 10 C. (Deviations
in the measurement result can occur if the performance test is
conducted when the ambient temperature is below approx. 18 C).
If bubbles occur, subsequent filling should be done by an expert.

013669

Check the temperatures on the hoses and similar items


as follows:
1

Check that the hoses and components on the pressure side have
roughly the same temperature by feeling them with your hand.

NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) can be very hot. Risk of burn injuries.

UDCT01.02GB

All hoses and components on the pressure side (from the


compressor to the expansion valve) should be warm.

All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.

Check the expansion valve. Frost or cold temperatures on


the intake side indicate that it is defective or clogged and that
circulation is limited or stopped on the pressure side.

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.)

Maintenance Manual DCT 8090

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.

Refrigerant amount, checking


Using the sight glass an estimation of the correct amount of refrigerant
can be checked. Normally it should not be possible to see bubbles
when the air conditioning system is operating. Bubbles may appear if
the plant contains the wrong amount of refrigerant, in connection with
the compressor stopping and starting, and if the condenser is defective
or at very high ambient temperature.
It is easiest to confirm bubbles if you observe the sight glass at the
same time as the compressor starts. Then bubbles are usually seen
from a few seconds after the compressor has started, until the system
starts to work normally.

NOTE
Reliable checking of refrigerant quantity through the sight glass can
only be performed when the ambient temperature is above approx.
15 C.

Sight glass inspection


1

Machine in service position, see section B Safety.

Start the engine and let it idle.

Switch on the air conditioning with max. cooling and fan.

Maintenance Manual DCT 8090

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

Bubbles in the glass means that the quantity of refrigerant is


incorrect or that the condenser is defective, clogged by, e.g., dust,
or that the ambient temperature is very high.

Action in the event of leakage in the system


1

Turn off the air conditioning.

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.

Rectify faults, seal leaks by replacing gaskets, hoses, etc.

Fill with the correct quantity of R134a refrigerant according to the


following points when all defects have been repaired.

The following work requires special filling equipment.

Connect the suction pressure gauge's blue hose to the service


valve on the compressor's suction side marked with S, SUC or
SUCTION.

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 hoses to the fluid reservoir.

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

Maintenance Manual DCT 8090

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.

Compressor cooling oil


22 At delivery, the compressor is filled with cooling oil. Under normal
conditions the oil should not be changed or refilled. In the event
of suspected incorrect oil quantity, see the instruction: "When
replacing the compressor."
In case of refrigerant loss there may also be oil loss, since
approx. 25% of the oil volume is absorbed by the refrigerant.
Recommended oil types that may be used are shown in the
section F Technical data.

Maintenance Manual DCT 8090

UDCT01.02GB

9:24

9 Frame, body, cab and accessories Heating, ventilation and air conditioning

When replacing the compressor


23 The compressor is filled with cooling oil when delivered. When
changing cooling compressor, change the oil as follows:

UDCT01.02GB

Drain the defective compressor of oil and measure the


quantity.

Then drain the new compressor of oil and refill with the same
amount that was drained from the defective compressor. For
oil volume in the system, see section F Technical data.

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Fresh air filter

9:25

9.4.1 Fresh air filter


Fresh air filter, changing
The fresh air filter is located at the front of the cab.
1 Machine in service position, see section B Safety.
2

Remove the cover and change the fresh air filter.

9.4.8 Condenser
Condenser, cleaning

1.

Machine in service position, see section B Safety.

Blow clean the condenser's cooler with compressed air.

014732

Condenser

Maintenance Manual DCT 8090

UDCT01.02GB

9:26

9 Frame, body, cab and accessories Moisture filter

9.4.9 Moisture filter


Moisture filter, checking

Machine in service position, see section B Safety.

Start the engine and let it idle.

Check the colour of the indicator on the moisture filter.


Blue indication = moisture filter ok.
Grey or pink indication = change moisture filter (see Moisture filter,
changing, page 9:26).

Indicator moisture filter

Moisture filter, changing

WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1

Machine in service position, see section B Safety.

Drain the air conditioning of refrigerant R134a, with the intended


draining equipment.

IMPORTANT
Working on the air conditioning requires special
authorisation.
3

Disconnect hoses and cabling from the moisture filter.

Disconnect the moisture filter pressure switch from the moisture


filter.

Change the moisture filter.

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

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Wiper/washer system

9:27

9.5 Wiper/washer system


Wiper/washer system, description
On the cab there are wipers for the front windshield, rear window,
and roof window. The function is to clean the windows and maintain
good visibility from the cab.

The wiper arm is attached to the wiper motor's shaft over a splined
taper. The shaft is made of hardened steel and the wiper arm's
bracket is made of a mild die cast material.

A
A

Wiper motor front

Wiper motor roof

Wiper motor rear

Washer motor and reservoir

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.

Maintenance Manual DCT 8090

UDCT01.02GB

9:28

9 Frame, body, cab and accessories Lighting system

9.6 Lighting system


Lighting system, function description
The function of the lighting is to increase safety during operation and
load handling.
The lights are turned off automatically after 5 minutes of idling so that
the lights do not drain the batteries. Extra work lights are turned off after
2 minutes. The lighting is activated automatically when the operator
sits in the set, selects a gear, or if the accelerator pedal is depressed.

NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.

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.

Switch work lights cab roof (S105-1)

17. Make-contact brake lights (S216)

2.

Switch work lighting attachment (S105-2)

18. Control unit frame (D797-1)

3.

Switch working lights mast (S105-3)

19. Direction indicator (H422, H423, H426 & H427)

4.

Switch headlights (S100)

20. Running lights (H416-1, H416-2, H417-1 & H417-2)

5.

Switch revolving beacon (S110)

21. Driving lights low beams (E400L & E400R)

6.

Break-contact door (S266-LE & S266-RI)

22. Driving lights high beams (E402L-1 & E402R-1)

7.

Control unit cab (D790-1)

23. Tail lights (H412L & H412R)

8.

Multi-function lever (S162)

24. Brake lights (H411L & H411R)

9.

Lever direction indicator (S161)

25. Working lights mast (E404L-1 & E404R-1)

10. Switch interior lighting on Control unit KIT (D790-2)

26. Extra work lights mast (E404L-4 & E404R-4)

11. Control unit KIT (D790-2)

27. Control unit attachment (D791)

12. Relay work lights cab roof (K3017-1 and K3017-2)

28. Work lights Twistlock attachment (E404L-3 &


E404R-3)

13. Work lights cab roof (E406L-1 E406R-1, E406L-2


and E406R-2)
14. Back-up lights (E405L & E405R)

29.

Extra work lights Twistlock attachment (E404L-5


& E404R-5)

15. Revolving beacon (H428)


16. Interior lights (E434-1)

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15 M

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Lighting system

9:29

Lighting system, component location


The function of the lighting is to increase safety during operation and
load handling.

NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.
The following lighting is available:

3,8,10
12
24
23

19, 20, 21

17

18

16

15

11, 13, 14

1.

Working lights mast (E404L-1 & E404R-1)

2.

Extra work lights mast (E404L-4 & E404R-4)

14. Direction indicators rear (H426 & H427)

3.

Relay working lights cab roof (K3017-1 & K3017-2)

15. Break-contact door (S266-LE & S266-RI)

4.

Multi-function lever (S162)

16. Switches, see Controls and instruments, overview,


page 9:4

5.

Control unit KIT (D790-2)

17. Control unit frame (D797-1)

6.

Interior lights (E434-1)

18. Make-contact brake lights (S216)

7.

Work lights cab roof (E406L-1 & E406R-1)

19. Direction indicators front (H422 & H423)

8.

Extra work lights cab roof (E406L-2 & E406R-2)

20. Running lights front (H416-1 & H417-1)

9.

Revolving beacon (H428)

21. Driving lights low beams (E400L & E400R)

Brake lights (H411L & H411R)

Driving lights high beams (E402L-1 & E402R-1)

10. Control unit cab (D790-1)


11. Running lights rear (H416-2 & H417-2)

22. Control unit attachment (D791-1)

12. Back-up lights (E405L & E405R), white

23. Work lights twistlock attachment (E404L & E404R)

13. Tail lights (H412L & H412R) red

24. Extra work lights carriage (E404L-5 & E404R-5)

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22

9:30

9 Frame, body, cab and accessories Signalling system

9.7 Signalling system


Signal system, function description
The function of the signals is to increase safety during operation and
load handling. This can take place with light and sound. The machine
has the following signal systems:

NOTE
It is important to use the correct bulb type for each area. See section
F Technical data.

4
6

17

15
16
D6
18

D790-1 5
9
D797-1
10

D790-2

D791-1

11

1.

Switch revolving beacon (S110)

15. Relay loud horn (K3016)

2.

Switch hazard lights (Hazard) (S109)

16. Loud horn (H850-1)

3.

Switch parking brake (S107)

17. Make-contact operator in seat (S230)

4.

Switch horn (S149-3)

18. Buzzer cab (H853)

5.

Control unit cab (D790-1)

19. Control unit KID (D795)

6.

Multi-function lever (S162)

20. Control unit attachment (D791-1)

7.

Lever direction indicator (S161)

21. Buzzer automatic spreading (H9003)

8.

Control unit KIT (D790-2)

9.

Control unit frame (D797-1)

NOTE

10. Direction indicator (H422, H423, H426 & H427)


12. Back-up alarm (H965)
13. Horn (H850)

On machines with side lift attachment, the sound


signal can also be activated with button open
twistlock (S1002) on the hydraulic functions panel
or open twistlock on the joystick, providing that the
function for open twistlocks at contact is not active.

14. Revolving beacon (H428)

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20

21

12

11. Back-up lights (E405L & E405R)

19

D795

009767

13

14 M

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Signalling system

9:31

Signalling system, component location


The following communication systems are available.

19 18

17

16

15

14

13

3 4 5

12 10,1 1 9 8

1.

Control unit KID (D795)

11. Control unit cab (D790-1)

2.

Buzzer cab (H853)

12. Make-contact operator in seat (S230)

3.

Control unit KIT (D790-2)

13. Horn (H850)

4.

Multi-function lever (S162)

5.

Lever direction indicator (S161)

14. Switches, see Controls and instruments, overview,


page 9:4

6.

Revolving beacon (H428)

15. Loud horn (H850-1)

7.

Back-up alarm (H965)

16. Control unit frame (D797-1)

8.

Back-up lights (E405L & E405R)

17. Direction indicators front (H422 & H423)

9.

Direction indicators rear (H426 & H427)

18. Control unit attachment (D791-1)

10. Relay loud horn (K3016)

19. Buzzer automatic spreading (H9003)

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9:32

9 Frame, body, cab and accessories Entertainment and communication

9.8 Entertainment and


communication
Entertainment and communication, general

For information and description of equipment, see supplier's


documentation for each product.

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Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Glass/windows/mirrors

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

The rear-view mirrors are of the type convex mirror. There is an


interior rear view mirror on all machines.
The machine has tinted windows in tempered glass.

Side windows

Windscreen (front window)

Roof window

Rear window

Side windows, front

001512

The following panes may be of laminated glass:

Side windows front, position E

Windshield (front window), position B

9.9.3 Roof window


Roof window, description
Roof windows are a safety feature and are therefore always made
of polycarbonate plastic.

Roof window, checking


Check that the roof window is not damaged or cracked. If the roof
window is defective, change it immediately.

WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!

9.9.5 Rearview mirror


Rearview mirror, description
The rear-view mirrors are of the type convex mirror. There is an interior
rear view mirror on all machines.

Maintenance Manual DCT 8090

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9 Frame, body, cab and accessories Cab structure and suspension

9.10 Cab structure and suspension


Design and suspension, description
The cab has a flat floor with a bracket for the operator's seat. It is
suspended in the cab substructure via heavy-duty rubber insulators
located on the cab's underside. This is to minimise vibrations from
the frame to the cab. There is an insulator at four points, one in each
corner. Each insulator bracket has a rubber bushing and a bolt.

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

opening window (emergency exit door

There are switches in the doors that detect whether the door is open.
The switch is used to illuminate the interior lighting and indicate an
open door.
The signal can be 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

Machine in service position, see section B Safety.

Visually inspect the door's mounting points.


Lubricate the hinges of the doors if necessary.
Check the door's locking mechanism with regard to function and
wear.

006914

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Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Cab undercarriage

9:35

9.10.3 Cab undercarriage


Cab undercarriage, checking
Machine in service position, see section B Safety.

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

The cab's mounting points with dampers.

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9 Frame, body, cab and accessories Cab interior

9.11 Cab interior


Cab interior, description
The cab is designed for best operator comfort. On the dashboard
panels there are grouped switches, controls, warning and indicator
lights to give the operator a good working environment.
Recycled material is used for all parts.

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Instrument panels

Interior plastic parts

Interior textile/fabric parts

Insulation

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Frame

9:37

9.12 Frame
Frame, description
The function of the frame is to be the structural support for the
machine's components:

1.

The rear section of the frame with counterweights

4.

Bracket front fenders

2.

Engine compartment with engine and transmission


mounts

5.

Cab mounts (4 points)

6.

Steering axle mounts

3.

The rear section of the frame with drive axle mounts

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9:38

9 Frame, body, cab and accessories Body structure

9.13 Body structure


Body, description
The body's function is a part of the frame. There are fenders to deflect
dirt, footsteps and handrail to facilitate access on the frame, engine
hood to deflect dirt and objects from the engine compartment and a
counterweight to balance the machine's lifting capacity.

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1.

Counterweight

2.

Hood engine compartment

3.

Fenders

Maintenance Manual DCT 8090

014667

9 Frame, body, cab and accessories Central lubrication

9:39

9.14 Central lubrication


Central lubrication, description

Central lubrication lubricates the machine's lubrication points


automatically during operation according to preset intervals and
replaces the lubrication in preventive maintenance. The machine
has two separate central lubrication systems, one for the machine
and one for the attachment.
The central lubrication is built up of the following components:

Pump unit, with lubricant reservoir.

Distribution block, that distributes and portions the grease


between the different grease points.
The distribution block lubricates one point at a time. If a point
cannot be lubricated properly, e.g. in the event of a line blockage,
the following points will not be lubricated. The grease is forced
out through the safety valve on the pump unit.

Lines, between main unit and distribution block as well as


distribution block and grease nipples.

Grease nipples, at grease points.

On the pump unit it is possible to adjust the lubrication interval's


frequency and duration.
Example illustration, components, central lubrication
1.

Pump unit

2.

Safety valve

3.

Distribution block

The central lubrication is supplied with voltage when the parking


brake is released.

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.

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9:40

9 Frame, body, cab and accessories Central lubrication

Central lubrication, checking


1

Check that no grease has been forced out through the safety
valve (position 2).
If grease is pushed out through the safety valve, this means that
there is a system blockage. Locate the blocked line by feeling the
connections at the distribution block. A blocked hose remains
pressurised and the connection becomes firm.

NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2

Turn the start key to position I.

Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in switch manual
operation (position 5).
If the indicator pins do not move even when the pump is running,
troubleshoot the pump unit.

NOTE
The system can be lubricated manually through the grease
nipple on the distribution block.
Overview of central lubrication. Example figure.
1.

Lubricant nipple, filling point, lubricating grease 4

2.

Safety valve

3.

Lubricant nipple, manual lubrication of the


system

4.

Indicator pin

5.

Switch, manual operation

UDCT01.02GB

Fill grease in the pump unit through the filler nipple, see section
F Technical data.

Maintenance Manual DCT 8090

9 Frame, body, cab and accessories Paint/coatings

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.

Maintenance Manual DCT 8090

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Maintenance Manual DCT 8090

10:1

10 Common hydraulics

Contents 10 Common hydraulics


10 Common hydraulics .........................................................................................10:3
10.2
Safety valves..................................................................................................10:4
10.3
Tanks and accumulators ................................................................................10:5
10.4
Pumps............................................................................................................10:6
10.6
Temperature control, cleaning and hydraulic oil...........................................10:10
10.6.6
Breather filter hydraulic oil tank ...............................................................10:12
10.6.7
Hydraulic oil filter .....................................................................................10:12
10.6.8
Hydraulic oil.............................................................................................10:13
10.6.9
Fine filter hydraulic oil..............................................................................10:15

Maintenance Manual DCT 8090

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10:2

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Maintenance Manual DCT 8090

10 Common hydraulics Common hydraulics

10:3

10 Common hydraulics
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps 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.

Feed pressure control valve attachment

5.

Servo pressure

2.

Brake pressure

6.

Accumulator charging pressure

3.

Precharging accumulators

7.

Pump pressure brakes and steering

4.

Steering pressure

8.

Pump pressure load handling

Maintenance Manual DCT 8090

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10:4

10 Common hydraulics Safety valves

10.2 Safety valves


Safety valves, component location

NOTE

The valves shall be closed during operation and are opened to


depressurise the machine.

014683

1.

Accumulator drain valve with opening knob and


lock ring.

2.

Relief valve attachment (figure shows open


valve).

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Maintenance Manual DCT 8090

10 Common hydraulics Tanks and accumulators

10:5

10.3 Tanks and accumulators


Tanks and accumulators, component location
Tank

Tank

1.

Cap for hydraulic oil filter

2.

Filler plug hydraulic oil

3.

Sight glass hydraulic oil

4.

Breather filter hydraulic oil tank

5.

Drain plugs hydraulic oil

008086

Accumulator

Accumulator

1.

Brake system accumulators

2.

Accumulator lift

014672

Maintenance Manual DCT 8090

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10:6

10 Common hydraulics Pumps

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.

Hydraulic oil pump for load handling (position 1) supplies Control


valve lift, lower, tilt and attachment.

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.

Hydraulic oil pump for load handling

2.

Hydraulic oil pump for brake pressure, steering

Hydraulic oil pump brakes and steering, check

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.

Machine in service position, see section B Safety.

Depressurise the hydraulic system, see section B Safety.

Connect a pressure gauge (0-25 MPa) to the measuring outlet for


pump pressure brakes and steering on the main valve.

Start the engine and let it idle.

000475

014649

Operation menu hydraulic oil temperature

Measuring outlet, pump pressure brakes and steering


[PM]

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Maintenance Manual DCT 8090

10 Common hydraulics Pumps

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

Check that the pressure rises to the specified feed pressure on


the pressure plate.
7

Depressurise the hydraulic system, see section B Safety.

Remove the pressure gauge and fit the protective cap on the
pressure check connection.

Close the accumulator drain valve.

015023

Close the accumulator drain valve.

Pressure plate, pump pressure brakes and steering

NOTE

014619

Check that the accumulator drain valve is completely closed


and tighten the lock ring.

Close the accumulator drain valve.

Maintenance Manual DCT 8090

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10:8

10 Common hydraulics Pumps

Hydraulic oil pump load handling, check

Operate and warm up the machine so that the oil in the hydraulic
system reaches operating temperature, at least 50 C.

Machine in service position, see section B Safety.

Depressurise the hydraulic system, see section B Safety.

Connect a pressure gauge (0-25 MPa) to the measuring outlet for


pump pressure load handling on the main valve.

Close the accumulator drain valve and relief valve attachment.

Start the engine and let it idle.

000475

014650

Operation menu hydraulic oil temperature

014619

Measuring outlet, pump pressure load handling [P2]

Close the accumulator drain valve.

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Maintenance Manual DCT 8090

10 Common hydraulics Pumps

10:9

Check that the feed pressure corresponds with the pressure plate.

Turn off the engine.

Depressurise the hydraulic system, see section B Safety.

015024

10 Remove the pressure gauge and fit the protective cap on the
pressure check connection.

Pressure plate, feed pressure load handling


11 Close the accumulator drain valve.

NOTE

014619

Check that the accumulator drain valve is completely closed


and tighten the lock ring.

Close the accumulator drain valve.

Maintenance Manual DCT 8090

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10:10

10 Common hydraulics Temperature control, cleaning and hydraulic oil

10.6 Temperature control, cleaning


and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
The hydraulic system's oil is cooled and cleaned by means of it
circulating through coolers and filters for the wheel brakes. The cooler
has a temperature-controlled electric fan that counteracts overheating.
Temperature control consists of hydraulic oil tank, hydraulic oil pump,
valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine
filter, hydraulic oil temperature sensor and bypass valve.
Hydraulic oil pump brakes and steering pumps oil (from the tank)
through the brake system's cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases the air flow through the cooler when the temperature
needs to be reduced. When the oil is cold, a bypass valve opens
and leads the oil directly to the tank so that resistance through the
cooler and filter does not become too great. The bypass valve closes
when the oil gets hot and then instead leads the oil through the cooler
and filter. The temperature sensor controls activation of the fan and
temperature display in the display.
Return oil from brakes, steering and load handling is filtered through
the hydraulic oil filter in the hydraulic oil tank.

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.

Hydraulic oil pump brakes and steering

9.

2.

Valve block, accumulator charging valve and priority


valve (part of the main valve)

10. Control unit KID (D795)

3.

Hydraulic oil filter brakes and steering

4.

Valve block brake system

5.

Wheel brake

6.

Hydraulic oil filter

7.

Hydraulic oil cooler

15. Control valve lift, tilt and attachment (part of the main
valve)

8.

Sensor hydraulic oil temperature (B776)

16. Hydraulic oil filter load handling

UDCT01.02GB

Control unit frame (D797-1)

11. Cooling fan


12. Thermal bypass valve
13. Hydraulic oil tank
14. Hydraulic oil pump load handling

Maintenance Manual DCT 8090

10 Common hydraulics Temperature control, cleaning and hydraulic oil

10:11

Temperature control, cleaning and hydraulic oil,


component location

1
2
10

9
3

014673

1.

Breather filter hydraulic oil tank

6.

Thermal bypass valve

2.

Hydraulic oil filter

7.

Sensor hydraulic oil temperature (B776)

3.

Fine filter, hydraulic oil

8.

Main valve

4.

Cooling fan

9.

Hydraulic oil pump brakes and steering

5.

Cooler hydraulic oil

10. Hydraulic oil tank

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10:12

10 Common hydraulics Breather filter hydraulic oil tank

10.6.6 Breather filter hydraulic oil tank


Breather filter hydraulic oil tank, changing

Turn off the engine and turn off the main electric power.

Clean the area around the filter housing.

Remove the filter housing.


Press down and turn approx. 1/8 turn clockwise.

Replace the filter insert.


Handle the filter cartridge as environmentally hazardous waste.

008084

1.

Cover plate for hydraulic oil filter

2.

Filling point hydraulic oil

3.

Sight glass hydraulic oil

4.

Breather filter hydraulic oil tank

Fit the filter housing.


Press down and turn approx. 1/8 turn anticlockwise.

Reset the filter indicator by pressing down the button in the middle
on the glass centred on the filter cartridge.

10.6.7 Hydraulic oil filter


Hydraulic oil filter, changing

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

IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1

Turn off the engine and turn off the main electric power.

2
On machines with raised cab: Remove the footstep over the
covers and clean the covers and the area around them.

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Maintenance Manual DCT 8090

10 Common hydraulics Hydraulic oil

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.

Clean the filter holder's parts. Be especially thorough with the


magnetic rod.

Fit the new filters and assemble the filter units.

Install the filter units and cover plates. Tighten the bolts crosswise.

008084

10:13

1.

Cover plate for hydraulic oil filter

2.

Filling point hydraulic oil

3.

Sight glass hydraulic oil

4.

Breather filter hydraulic oil tank

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

10.6.8 Hydraulic oil


Hydraulic oil, level check

NOTE
The oil level is checked with the mast lowered and the attachment in
the 20-foot position.
1

Machine in service position, section B Safety.

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.

Maintenance Manual DCT 8090

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10:14

10 Common hydraulics Hydraulic oil

Hydraulic oil, changing

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

IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.

Machine in service position, see section B Safety.

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.

Fit the drain plug when the oil has drained.

008084

NOTE
1.

Cover plate for hydraulic oil filter

2.

Filling point hydraulic oil

3.

Sight glass hydraulic oil

4.

Breather filter hydraulic oil tank

Make sure that the drain plug's washer seal is also removed.
5

If the hydraulic oil filters are to be changed, change them before


filling the tank with oil, see Hydraulic oil filter, changing, page
10:12.

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.

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Maintenance Manual DCT 8090

10 Common hydraulics Fine filter hydraulic oil

10:15

10.6.9 Fine filter hydraulic oil


Fine filter hydraulic oil, changing

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

IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1

Machine in service position, see section B Safety.

Remove the cover.

Take out a drainage receptacle.

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.

Maintenance Manual DCT 8090

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10:16

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Maintenance Manual DCT 8090

11:1

11 Common electrics

Contents 11 Common electrics


11
Common electrics ............................................................................................11:3
11.2
Electrical protection........................................................................................ 11:3
11.2.2
Fuses ........................................................................................................ 11:4
11.3
Batteries......................................................................................................... 11:7
11.3.1
Start battery............................................................................................... 11:7
11.4
Alternator ....................................................................................................... 11:9
11.5
Distribution of electricity ............................................................................... 11:10
11.5.1
Voltage feed ............................................................................................ 11:10
11.5.2
Electrical distribution box......................................................................... 11:15
11.5.3
Control units ............................................................................................ 11:16
11.6
Communication ............................................................................................ 11:18
11.6.1
CAN bus .................................................................................................. 11:18
11.6.2
Redundant CAN-bus ............................................................................... 11:18
11.6.3
CAN-bus drivetrain .................................................................................. 11:18

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Maintenance Manual DCT 8090

11 Common electrics Common electrics

11:3

11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN-bus.

11.2 Electrical protection


Electrical protection, component location
1

1.

Control switch

2.

Circuit fuses, electrical distribution box cab

3.

Main fuses, electrical distribution box frame

4.

Circuit fuses, electrical distribution box frame

5.

Battery disconnector

014691

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11 Common electrics Fuses

11.2.2 Fuses
Fuses, description
Main fuses

Main fuses

1
2

IMPORTANT

3
4

Risk of cable damage and fire in cable harnesses!


Always use fuses with the correct ampere rating.

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.

Battery voltage (30) to cab, engine, and


transmission, (50 A)

3.

Electric power feed relay K3009-1, power to


emergency stop switch voltage (15E), (50 A)

4.

Ignition voltage (15) to control units on frame,


engine, cab and transmission, (50 A)

Terminal blocks on frame and carriage

Terminal blocks on frame and carriage

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.

Terminal blocks on frame and carriage

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Maintenance Manual DCT 8090

11 Common electrics Fuses

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.

F58-5 15 SUPPLY POWER CAB

F58-4 30
MAIN POWER
CAB

A1
B2

10A KCU (KALMAR CAB UNIT)


5A KCU,START UP (KALMAR CAB UNIT)

C3

10A SERVICE

D4

10A OPT CUSTOMER

E5

10A OPT RADIO

F6

25A OPT SEAT HEATER, TURNABLE SEAT

G7

15A OPT WORK LIGHT

H8

15A OPT AIRCUSHIONED SEAT

A1

25A KCU (KALMAR CAB UNIT)

B2

10A KIT (KALMAR INFORMATION TERMINAL)

C3

15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)

D4
E5
F6

X2044980 1

5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)


10A SERVICE
5A OPT MAP READING LIGHT

G7

10A OPT CONVERTER 12V

H8

10A OPT COMPRESSOR HORN

014689

F58-4 15
SUPPLY POWER
CAB

Circuit fuses electrical distribution box cab

A
B
014198

C
D
Fuses on frame
A

30-fuse (battery voltage), 51-3

30-fuses (battery voltage), 58-1

15-fuses (ignition voltage), 58-2

15E-fuses (control breaker voltage), 58-3

Fuses in cab
15-fuses (ignition voltage) and 30-fuses (battery
voltage), 58-4

15-fuses (ignition voltage), 58-5

014688

Circuit fuses electrical distribution box frame

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11 Common electrics Fuses

Fuses, changing

IMPORTANT
Risk of cable damage and fire in cable harnesses!
Always use fuses with the correct ampere rating.

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Turn off the system voltage (battery disconnector).

Remove the cover from the fuse holder.

Check that the fuses are intact. Change when needed.

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11 Common electrics Batteries

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 the engine off, the battery voltage should be 2325 V.

Operating menu for electrical system

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.

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11 Common electrics Start battery

Battery cables, checking

DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no
machine parts wear or chafe against the battery cables.
Change damaged battery cables.
The following battery cables should be checked for clamping, risk of
rubbing and damage to the battery cables. Rectify incorrect clamping
and risks of rubbing. Change battery cables that show signs of damage.

Diesel-powered machines

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Plus-cable between battery and battery disconnector.

Plus-cable between battery disconnector and starter motor.

Plus-cable between starter motor and alternator.

Plus-cable between battery disconnector and main fuses.

Plus-cable between starter motor and preheating relay.

Plus-cable between preheating relay and preheating coil.

Ground cable between battery and frame.

Ground cable between engine and frame.

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11 Common electrics Alternator

11:9

11.4 Alternator
Alternator, component location
The alternator is fitted on the engine. See section 1 Engine.

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11 Common electrics Distribution of electricity

11.5 Distribution of electricity


Distribution of electricity, description
This section describes distribution of electric power and communication
between control units. Electric power distribution describes the
foundation of the electrical system and the network of control units.

11.5.1 Voltage feed


Start-up of electrical system, description
When the machine is not used, the machine's electrical system is in
a powerless mode, that is, neither power electronics nor control units
are supplied with voltage. At machine start, voltage feed is activated
and the redundant CAN-bus is initiated. Start is handled by control
unit cab (D790-1).
The first pre-requisite for the machine to be able to perform any action
is to first establish the redundant voltage feed for control units and
then establish CAN-bus communication to administer control signals
for functions.
Control units establish communication when:

Start-up

Operators door is opened

Interior lighting is lit

Flashing hazard lights are activated

Start key in position I

Start-up

D791
The following takes place at start-up:

Startup signal
D790-2

Start-up signal to Control unit cab (D790-1).

2.

Control unit cab (D790-1) initiates connection of redundant


voltage feed. See Redundant voltage feed of control units,
description, page 11:12.

3.

Control unit cab (D790-1) activates ignition voltage (15).

D795

D797-1

014674

D790-1

1.

Start-up signal is sent

D791

See Ignition voltage (15), description, page 11:12.

D790-1

D790-2

D795

4.

Control unit cab (D790-1) establishes redundant CAN-bus.

D797-1
Redundant CAN-bus communication

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014675

See Redundant CAN-bus, description, page 11:18.


5.

Control unit cab (D790-1) activates CAN-bus drivetrain. See


CAN-bus drivetrain, description, page 11:18.

6.

Control unit cab (D790-1) activates control breaker voltage (15E).


See Emergency stop switch voltage (15E), description, page
11:13.

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11 Common electrics Voltage feed

11:11

System down in powerless mode


The system goes down in powerless mode when:

Start key in position 0 and no activity signal has been sent.

Start key in position 1 and automatic engine shut-down has been


activated.

The following takes place when the system goes down in powerless
mode.
1.

Cab control unit (D790-1) cuts off emergency stop switch voltage
(15E).
See Emergency stop switch voltage (15E), description, page 11:13.

2.

Control unit cab (D790-1) cuts off ignition voltage (15).


See Ignition voltage (15), description, page 11:12.

3.

Redundant voltage feed to control units is cut off.

4.

Cab control unit (D790-1) disconnects the redundant CAN bus.


See Redundant CAN-bus, description, page 11:18.

5.

Cab control unit (D790-1) disconnects the redundant voltage feed.


See Redundant voltage feed of control units, description, page
11:12.

6.

Control unit cab (D790-1) awaits start-up signal. Other electronics


are powerless.

11.5.1.1 Battery voltage (30)


Battery voltage (30), description
The battery voltage feeds voltage:

Control system at start. See Start-up of electrical system,


description, page 11:10.

Starter motor

Main relays (15-voltage)

Control switch relays (15E-voltage)

Engine

Transmission

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11 Common electrics Voltage feed

11.5.1.2 Redundant voltage feed of control units


Redundant voltage feed of control units, description
The redundant voltage feed only feeds the control units' control logic
and buses, and is controlled completely by Control unit cab (D790-1).
The control units' outputs remain without power and are supplied with
voltage first when ignition voltage is activated.

A
D791
Startup signal
D790-1

D790-2

The redundant voltage feed for each control unit is independent of


other control units. If a control unit is not working the voltage feed to
other control units is not affected.

D795

When all control units have redundant voltage feed and bus
communication, the system is ready to receive, process signals.

D797-1

When redundant voltage feed is activated the following takes place.

1.

Start-up signal is sent to Control unit cab (D790-1), see A in


illustration.

2.

A hold circuit is activated in Control unit cab (D790-1) which


activates the control unit's control logic.

3.

Control unit cab (D790-1) activates redundant voltage feed to the


other control units, see B in illustration.

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

Start-up signal is sent

All control units are supplied with voltage

014676

D790-1

11.5.1.3 Ignition voltage (15)


Ignition voltage (15), description
The ignition voltage feeds the power electronics.
The ignition voltage is activated by:

Startup
2

D790-1

Start key in position I

Flashing hazard lights (Hazard) activated

When ignition voltage is activated the following takes place.

D1 D2

1.

Battery disconnector in position 1. Voltage feed to Control unit


cab (D790-1), ignition, switch flashing hazard lights, door switch
and interior lighting.

2.

Switch for start-up signal gives pulse to Control unit cab (D790-1).

D795
3
K1

D790-2

CAN bus communication is established (not drive-train).


3.

Start key in position I or flashing hazard lights activated.

D797-1

4.

Control unit cab (D790-1) feeds voltage to power relay ignition


(K315-1) and relay ignition key lock (K315-2) in electronic box
frame.

D793

5.

Ignition voltage supplies control units, relays, solenoid valves and


other electronics.

D3
D4

D794

014677

K4

Drivetrains CAN bus establishes communication.

Power feed ignition circuit


D1. Diagnostic menu CAN/POWER 5
D2. Diagnostic menu CAN/POWER 7
D3. Diagnostic menu CAN/POWER 10
D4. Diagnostic menu CAN/POWER 12

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11 Common electrics Voltage feed

11:13

11.5.1.4 Emergency stop switch voltage (15E)


Emergency stop switch voltage (15E), description
The emergency stop switch voltage supplies functions which require
a control switch, e.g. working hydraulics.

S250
D1

The control switch is activated with Switch control switch.

1
2

D790-1
D5

Condition for activating emergency stop switch voltage is that Switch,


control switch, is not pressed in.

D2

D4
K3009-1

D3

K3009-2

Ignition voltage (15)

Switch, control switch not activated.

When emergency stop switch voltage is activated the following takes


place.

D791

D4
Y6010

1.

Ignition voltage is connected to Control unit cab (D790-1).

2.

Control unit cab (D790-1) activates Power relay K3009-1 in


electrical distribution box frame and emergency stop switch
voltage (15E) feeds the circuit until relay K3009-2 in electrical
distribution box frame.

3.

15E-feed sends a voltage signal to Control unit cab (D790-1) and


verifies that Power relay control breaker (K3009-1) is active but
that Power relay control breaker (K3009-2) is inactive.

4.

Control unit cab (D790-1) activates power relay control breaker


(K3009-2) in the electrical distribution box and the emergency
stop switch voltage supplies voltage to the control units (not
drivetrain).

5.

When Switch control switch (S250) is pushed down, the


emergency stop switch voltage (15E) is cut off to Control unit
cab (D790-1) and power is guided to relay K3002 and K3007, as
well as Power relay control switch K3009-1 and K3009-2. Power
supply to the control units is cut off and the functions cease.

K3002
5

D797-1

Start key in position I

Y6011

This verifies that the control breaker is working.

D4
Y6004
K3007

Y6005
014678

Power feed, control breaker circuit


D1. Diagnostic menu CAN/POWER 7

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.

D2. Diagnostic menu CAN/POWER 6


D3. Diagnostic menu CAN/POWER 15
D4. Diagnostic menu CAN/POWER 6
D5. Diagnostic menu CAN/POWER 6

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11 Common electrics Voltage feed

11.5.1.5 Voltage converter


Voltage converter, description

The voltage converter is located under a protective casing to the left


behind the driver's seat.
The voltage converter converts 24 Volt to 12 Volt. 12 V voltage
is available for accessories through connector X067 in the cab's
electrical distribution box. (15 and 30 voltage, ground and 12V.)
12 V voltage is also available in sockets on the instrument panel,
see section 9 Frame, body, cab and accessories group 9.1 Controls
and instruments.

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11 Common electrics Electrical distribution box

11:15

11.5.2 Electrical distribution box


Electrical distribution box, component location
4

3
14

2
6

15
7

16
17

8
9
10
11
12
13

014679

18
1.

Circuit fuses battery voltage (30) F58-3

10. Relay ignition K315-2

2.

Circuit fuses ignition voltage (15) F58-2

11. Power relay ignition K315-1

3.

Circuit fuses emergency stop switch voltage (15E)


F58-3

12. Power relay control switch K3009-1

4.

Diagnostic socket engine, (Engine alternative Yuchai


YC6A240-30)

14. Diagnostic socket machine

5.

Diagnostic socket transmission

15. Circuit fuses cab battery voltage (30) and ignition


voltage (15) F58-4

6.

Main fuses

7.

Circuit fuse control unit transmission (0.5 A) (F51-3)

8.

Relay tilt in/out K3002

9.

Relay lift/lower K3007

13. Power relay control switch K3009-2

16. Diagnostic socket drivetrain


17. Circuit fuses cab ignition voltage (15) F58-5
18. Voltage converter

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11 Common electrics Control units

11.5.3 Control units


Control units, general
Control units are appointed responsibility for parts of functions.
Therefore a certain function cannot be associated to a special control
unit, instead the function occurs in cooperation between control units,
sensors, valves, etc.
Control unit cab and control units on the frame and attachment have
indicator lamps that can be used to check basic information on the
status of other control units.
Indicator lamps have the following significations:
Indicator lamps control unit cab

Table Indicator lamps control unit cab


Light 1

Green light when there is battery voltage to unit. The


light is physically controlled by voltage feed to the
control unit.

Light 2

Flashes green when redundant voltage feed control


unit and redundant CAN-bus communication is active.
No power in system.

4
3
006767

2
1

Green light when power electronics and 15-voltage


are supplied with voltage.

Indicator lamps control unit cab


Light 3

Long yellow single flashing light at communication with


Control unit KID (D795), which is a prerequisite for
trouble-shooting.
Short yellow single flashing light at communication
with Control unit engine (D794) and Control unit
transmission (D793).
Double flashing yellow light (short and long flashes)
at communication with display and engine or
transmission.

Light 4
Indicator lamps control units on frame and attachment

Red light at active error.

Table Indicator lamps control units on frame and attachment

1
2

Light 1

Green light when there is battery voltage to unit. The


light is physically controlled by voltage feed to the
control unit.

Light 2

Flashes green when any redundant voltage feed left,


redundant voltage feed right or 15-voltage is not found.

3
006766

Green light when redundant voltage feed, left,


redundant voltage feed, right and 15-voltage are
supplied with voltage.

Indicator lamps control units on frame and attachment.


Light 3

Yellow single flashing light at communication with


Control unit KID (D795) or Control unit cab (D790-1).
Yellow double flashing light during communication with
Control unit KID (D795) and Control unit KIT (D790-2).

Light 4

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Red light at active error.

Maintenance Manual DCT 8090

11 Common electrics Control units

11:17

Control units, position


1

1.

Control unit, frame (D797-1)

5.

Control unit, transmission (D793)

2.

Control unit KID (D795)

6.

Control unit engine Yuchai (D794)

3.

Control unit KIT (D790-2)

7.

Control unit engine Cummins (D794)

4.

Control unit cab (D790-1)

8.

Control unit attachment (D791-1)

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11:18

11 Common electrics Communication

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

The network consists of control units and segments. Segment is the


CAN-bus between control units.

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.

11.6.1 CAN bus


CAN-bus, description
The CAN-bus consists of two twisted cables (twisted pair).

11.6.2 Redundant CAN-bus


Redundant CAN-bus, description
CAN R

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

Redundant CAN-bus means that each control unit has two


connections for communication. The CAN-bus is connected in series
between the control units. This means that the CAN-bus can handle
loss of a segment. If several segments fail, then one or some control
units lose contact with the network and work independently, often with
limited capacity to perform their task.
Signals can be checked with diagnostic menu.

11.6.3 CAN-bus drivetrain


CAN-bus drivetrain, description
Communication with Control unit engine (D794) and Control unit
transmission (D793) are separate from the redundant CAN-bus.

D790-1

D794

D793

003171

Signals can be checked with diagnostic menu.

Principle illustration CAN-bus drivetrain

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Maintenance Manual DCT 8090

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.

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D:2

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Maintenance Manual DCT 8090

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.

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E:2

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Maintenance Manual DCT 8090

F:1

F Technical data

Contents F Technical data


Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Specifications for lifting capacity and dimensions............................................F:6
Oils and lubricants, recommendation...............................................................F:8
Tightening torques, recommendations...........................................................F:10
Tightening torque, connections for air conditioning unit.................................F:11
Tightening torque, ORFS connections ...........................................................F:12
Unit explanations ...........................................................................................F:13
Conversion SI-units........................................................................................F:14
Conversion table, length ................................................................................F:15
Conversion table, area...................................................................................F:15
Conversion table, volume ..............................................................................F:15
Conversion table, weight................................................................................F:15
Conversion table, pressure ............................................................................F:16

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F:2

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Maintenance Manual DCT 8090

F Technical data Technical data

F:3

F Technical data
Data
Machine weights and dimensions vary with equipment installed on the
machine and are described in detail in the product specification and
spec. sheet for the relevant machine.

1. Motor

Yuchai YC6A240-30

Power acc. to ISO 3046 (net power)

164 kW at 2200 rpm

164 kW at 2200 rpm

Torque ISO 3046

800 Nm at 1500 rpm

949 Nm at 1500 rpm

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

24 V (2x12 V / 135 Ah)

2. Transmission

Dana HR32000
3 3

No. of gears, forward - reverse

3. Driveline/Axle
Drive axle, type

Kessler D81
Kessler D91

4. Brakes
Footbrake system - wheels affected
Parking brake system - wheels affected

Wet Disc Brake drive wheel


Spring brake - drive wheel

5. Steering
Hydraulic servo

Steering system

6. Wheels
12.00x24

Dimension, front and rear

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

Maintenance Manual DCT 8090

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F:4

F Technical data Technical data

9.6 Frame, body, cab and accessories, lighting system


Light

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

D1S Xenon tubes. Insert and


ballast replaced complete.

70

PK22s (H3)

Headlights (high and low beams)

Work light, Xenon


Revolving beacon

Volumes
Any deviation from this table must be supported with written approval
from Cargotec.

1.2 Engine, fuel system

Yuchai YC6A240-30

Fuel tank, volume

Cummings QSB6.7
380 L

Fuel quality

Diesel according to:


EN590,
ASTM D 975 No 1D,
ASTM D 975 No 2D.

1.7 Engine, cooling system


Coolant volume
Coolant filling

32 L

29 L

Volvo Penta Coolant VCS,


ready-mixed.

ES Compleat, Premix

See Oils and lubricants, recommendation, page F:8.

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

See Oils and lubricants, recommendation, page F:8.


24 L

Maintenance Manual DCT 8090

20 L

F Technical data Technical data

2.6 Transmission, lubrication


system
Oil type

F:5

HR32000
See Oils and lubricants, recommendation, page F:8.
32 L

Oil volume

3.3 Driveline/Axle, drive axle

Kessler D81

Oil grade

See Oils and lubricants, recommendation, page F:8.

Kessler D91

Oil volume, differential

42 L

54 L

Oil volume, hub reduction

2x4 l

2x4 l

7 Load handling
Oil grade

See Oils and lubricants, recommendation, page F:8.

9 Frame, body, cab and accessories


R134a

Refrigerant air conditioning


Volume refrigerant
Lubricant air conditioning

Se sign for air conditioning


ZEXEL PAG-oil ZXL100
5 L

Windshield wiper fluid, volume

10 Common hydraulics
Oil grade

See Oils and lubricants, recommendation, page F:8.

Hydraulic oil tank, volume

320 L

Hydraulic oil system, volume

450 L

Maintenance Manual DCT 8090

UDCT01.02GB

F:6

F Technical data Technical data

Specifications for lifting capacity and


dimensions

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

Number of containers, 8'6" container

Number of containers, 9'6" container

Dimensions
6900

6900

Truck width (W [mm])

4050

4100

Height, base machine, Spirit Delta (H6 [mm])

3940

4000

Seat height (H8 [mm])

2800

2860

Distance drive axle - the attachment's front


section (L2 [mm])

1185

1185

Axle distance (L3 [mm])

4550

4550

3270 2250

3270 2200

Turning radius, outer (R1 [mm])

6750

7000

Slewing radius, inner (R2 [mm])

1150

1500

Truck length (L [mm])

Track (front - rear) (T [mm])

UDCT01.02GB

Maintenance Manual DCT 8090

F Technical data Technical data

F:7

DCT80
E5

DCT90
E6

E7

E8

E5

E6

250

300

Minimum track width for 90 stacking, 20'


container (A1 [mm])

10600

10850

Minimum track width for 90 stacking, 40'


container (A2 [mm])

14200

14350

Ground clearance, min [mm]

E7

E8

Standard Duplex mast


15220

16220

18720

21220

15280

16280

18780

21280

Mast height, min. (H3 [mm])

8540

9040

10290

11540

8600

9100

10350

11600

Mast height, max (H5 [mm])

15040

16040

18540

21040

15100

16100

18600

21100

Lift height (H4 [mm])

3 3

3 3

2220

2280

600

600

Mast tilting, forward back ( [mm])

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

Axle load pressure front, (without load) [kg x


103]

22,7

23,3

24,8

26,3

22.9

23,5

25,0

26,5

Axle load pressure front, (with classed load)


[kg x 103]

34,9

35,5

37,0

38,5

36,7

37,3

38,8

40,3

Axle load pressure rear, (without load) [kg]

12800

13500

Axle load pressure rear, (with classified load)


[kg]

8600

8700

Maintenance Manual DCT 8090

UDCT01.02GB

F:8

F Technical data Technical data

Oils and lubricants, recommendation


Cargotec's stated service intervals in the maintenance manual are
conditional on oil selection according to the following table. The
table states recommended viscosity for different oil types and grades
depending on outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
Oil type, quality

-20

-10

+10

+20

+30

+40

-4

+14

+32

+50

+68

+86

+104

1.8 Engine, lubrication system


Yuchai YC6A240-30

SAE 15W-40 (engine oil)

API CH-4 or ACEA E5

SAE 15W-30 (engine oil)


SAE 10W-30 (engine oil)
SAE 5W-30 (engine oil)

SAE 15W-40 (engine oil)

Cummings QSB6.7
API CH-4 or ACEA E5

SAE 5W-30 (engine oil)

2.6 Transmission, lubrication system


GM Allison C-4

SAE 50

John Deere J20 C, D

SAE 40

Caterpillar TO-4

SAE 30

MIL-PRF-2104G

SAE 20
SAE 10W

NOTE

SAE 0W-20

Engine oil or GL-5 oil may not be used.


3.3 Driveline/Axle, drive axle

SAE 80W-140

API GL-5

SAE 75W-90

10 Common hydraulics
ISO VG 68

DIN 51524 Part 3 HVLP

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

Maintenance Manual DCT 8090

F Technical data Technical data

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.

Electrical connector grease


Electrical connector grease 923836.0552.

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.

Maintenance Manual DCT 8090

UDCT01.02GB

F:10

F Technical data Technical data

Tightening torques, recommendations


The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tightening
torque should be reduced by approx. 5%.
For soft materials (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque varies depending on surface
treatment. Certain combinations of bolts and nuts require lubrication
according to the following table.

State

Nut

Screw

Lubrication

untreated

untreated

oil

bright galvanised

untreated or 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

Maintenance Manual DCT 8090

F Technical data Technical data

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

Tightening torque, connections for air


conditioning unit
O-ring coupling cooling coils
Hose diameter

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.

Maintenance Manual DCT 8090

UDCT01.02GB

F:12

F Technical data Technical data

Tightening torque, ORFS connections


Pipe and hose coupling

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

Maintenance Manual DCT 8090

F Technical data Technical data

F:13

Goods coupling
UNF-UN

Metric-ISO

BSSP

Thread (inch)

Tightening torque
(Nm)

Thread
(mm)

Tightening torque
(Nm)

Thread (inch)

Tightening torque (Nm)

7/16-20

21

10x1

20

1/8-28

20

1/2-20

27

12x1.5

35

1/4-19

35

9/16-18

40

14x1.5

45

3/8-19

70

3/4-16

78

16x1.5

55

1/2-14

100

7/8-14

110

18x1.5

68

3/4-14

190

1"1/16-12

180

20x1.5

80

1"-11

300

1"3/16-12

230

22x1.5

98

1"1/4-11

330

1"5/16-12

285

26x1.5

170

1"1/2-11

400

1"5/8-12

320

27x2

180

1"7/8-12

400

33x2

310

42x2

330

48x2

400

Unit explanations
Unit

Abbreviation

Newton metre

Nm

Kilopond metre

kpm

Kilopascal

kPa

Megapascal

MPa

Kilowatt

kW

Kilojoule

kJ

British thermal unit

Btu

Calorie

ca

Inch

in

Feet

ft

Yard

yd

Mile

mile

Centimetre

cm

Meter

Kilometre

km

Maintenance Manual DCT 8090

UDCT01.02GB

F:14

F Technical data Technical data

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)

Speed and acceleration

Horsepower/torque
Bhp x 5252 rpm= TQ (lb ft)

TQ x rpm 5252 = bhp

Temperature
C = (F 32)/1.8

F = (C x 1.8) + 32

Flow factor
l/min (dm3 /min)

UDCT01.02GB

x 0.264

= US gal/min x 3.785

Maintenance Manual DCT 8090

= litre/min

F Technical data Technical data

F:15

Conversion table, length


Unit

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

Conversion table, area


Unit

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

1 ha = 100 a 1 mile2 = 259 ha = 2.59 km2

Conversion table, volume


Unit

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

1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)

Conversion table, weight


Unit

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

1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Maintenance Manual DCT 8090

UDCT01.02GB

F:16

F Technical data Technical data

Conversion table, pressure


Unit

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

kg/cm2 = 735,56 Dry (mmHg) = 0.96784 atm

UDCT01.02GB

Maintenance Manual DCT 8090

G:1

G Terminology and index

Contents G Terminology and index


Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:5

Maintenance Manual DCT 8090

UDCT01.02GB

G:2

UDCT01.02GB

Maintenance Manual DCT 8090

G Terminology and index Terminology and index

G:3

G Terminology and index


Terminology
Explanations
Term

Description

Accumulator

Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.

Attachment

Part of the machine that grabs the load when lifting.

Anti-corrosion agent

Prevents oxidation, in simple terms, rustproofing.

Working hydraulics

All load handling functions, i.e. lift and lower, tilt, side shift, spreader and levelling.

Axle distance

Distance between drive axle and steering axle.

Bar

Unit for measuring pressure.

Battery disconnector

Cuts off current from battery.

Daily inspection

The actions that should be performed daily to ensure the machines functionality.

Decitonne

Tenth of a tonne, measure of the machines lift capacity.

Display

"Window" showing digital information on steering wheel panel in cab.

Operating hours

Number of hours machine has been in operation, shown on hour meter in cab.

Drive axle

Driving axle that receives the torque from the drivetrain.

Drivetrain

Parts in machine involved in power transmission; engine, torque converter, transmission,


propeller shaft and drive axle with differential and hub reduction.

ECC

Electric Climate Control. Climate control unit with thermostat-controlled cooling,


dehumidification, and heating.

EHC

Electric Heat Control. Heating system with thermostat-controlled heating.

Electrolyte level

Fluid level in battery cells.

Expansion tank

Tank for coolant.

Fixed displacement

Non-adjustable volume (capacity) of a pump.

Hanging load

Lifted load.

FMI

Fault Message Identifier.

Main fuse

Located by battery. Cuts the power to all systems in the whole machine.

Hydraulic oil

Oil for hydraulic system. See specifications in operator's manual.

Hydraulic oil pump

Pump in hydraulic system.

Hydraulic system

System that uses oil pressure to transmit power to different functions.

Indicator

Manual "sensor", e.g., shows that a filter is clogged and needs to be replaced.

Refrigerant

Fluid/gas in air conditioning. May only be handled by authorised trained person.

Low-emission engine

Engine with low emissions of hazardous substances. Manufactured according to


regulations.

LC

Load centre.

Lift capacity

Indicates machine's maximum lift capacity.

Lifting point

Attaching point for lift device when lifting an object.

Trolley

Lifts the load, located on the mast.

Solenoid valve

An electro-magnetically controlled valve. See also proportional valve.

Control valve

Valves that can be used to control something, e.g., release pressure and thus lower
a boom or a fork.

Machine model

Machine type. Indicated, for example: DCT 8090. See also type designation.

Maintenance Manual DCT 8090

UDCT01.02GB

G:4

G Terminology and index Terminology

Term

Description

Environmental waste

Used oils, filters, etc., must be handled according to governing national laws and
regulations.

Torque converter

Hydraulic, variable clutch.

Hub reduction

Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drivetrain.

Pilot oil pressure

A low control pressure to, for example, a valve.

Planetary gear

Type of transmission with gears in constant mesh.

Product alternatives

One of several alternatives is selected for a machine, e.g., engine alternative.

Proportional valve

An electro-magnetically controlled valve. If a current is applied, the valve is activated


in proportion to the current's amplitude. In everyday language, a stepless valve, as
opposed to an Off/On valve. On, e.g., the transmission's valve housing.

Frame beam

Supporting beams in the frame.

Recirculation

Circulates again and again.

Serial number

Unique machine designation. Available on machine plate.

Service position

How machine should be safely positioned before service may be started.

Servo

A small user movement results in a big machine movement, e.g. power steering.

Servo pressure

A low control pressure to control a higher pressure, for example, to a valve.

Side lift

Attachment. See attachment.

Side shift

Parallel sideways movement of attachment.

Levelling

Attachment is tilted, for example, if load stands on uneven ground.

Spirit Delta

Enclosed type of cab.

SPN

Suspect Parameter Number.

Spreading

Widening of attachment.

Mast

Carrier of trolley, attachment and load.

Dust reservoir

The air filter collects the coarsest particles in a dust reservoir, emptied automatically
during operation.

Steering axle

Wheel axle with steering.

Buzzer

Audible alarm to catch the operators attention.

Option

Optional equipment for machine.

Tilting

Load is tilted forward or backward.

Transmission oil

Oil for transmission and torque converter. See specifications in operator's manual.

Securing machine for transport

Actions before transporting machine.

Twistlocks

Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container for lifting.

Type designation

Indicates type of machine and capacity. See also machine model.

Maintenance

Periodic maintenance actions so that machine functions safely and for long life.

Wet brakes

Brake discs in oil-bath.

Valve slide

Moving part in the valve. Decides the oil's path.

UDCT01.02GB

Maintenance Manual DCT 8090

G Terminology and index Index

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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. . 8:17
. . 1:17
. . 9:32
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B:21
8:8, D:1
. . 1:25
. . 8:22
. . 8:22

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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
. . . 1:21

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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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General safety information . . . . . . . . . . . . . . B:3


Glass/windows/mirrors . . . . . . . . . . . . . . . 9:33

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

Maintenance Manual DCT 8090

UDCT01.02GB

G:6

G Terminology and index Terminology

Other functions . . . . . . . . . . . . . . . . . . . 7:31

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

Radiator and expansion tank . . . . .


Reading instructions . . . . . . . .
Rearview mirror . . . . . . . . . .
Redundant CAN-bus . . . . . . . .
Redundant voltage feed of control units
Rim . . . . . . . . . . . . . . . .
RMI . . . . . . . . . . . . . . . .
Roof window . . . . . . . . . . . .

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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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Maintenance Manual DCT 8090

. 4:8
. 6:5
. 6:4
. 9:27

G Terminology and index Index

Maintenance Manual DCT 8090

G:7

UDCT01.02GB

last page

Cargotec improves the efficiency of cargo flows by offering solutions for


the loading and unloading of goods on land and at sea wherever cargo
is on the move. Cargotecs main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields.
Cargotecs global network offers extensive services that ensure the
continuous, reliable and sustainable performance of equipment.

Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 00
fax +46 372 263 90
www.cargotec.com

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