UDRS01 - 01GBMaintenance DRS Last

00 General Information/
Scheduled Maintenance
01 Power Unit
Maintenance
Manual
UDRS01.01GB
DRS 4527-4531
02 Power Transmission
03 Hydraulic System
04 Electric System
05 Cabin
06 Working Devices
07 Frame and Shields
08 Equipment
General Information/Scheduled Maintenance
00
General Information/Scheduled Maintenace

00.1 General Information ..........................................................................
00.1.1 About the Documentation .......................................................
00.1.2 Warranty Agreement ...............................................................
00.1.3 To the Maintenance Personnel ...............................................
3
3
3
4
00.2 Instructions for Initiating into Maintenance Work ......................... 5

00.2.1 General Instructions ............................................................... 5
00.2.2 Maintenance and Repair Personnel ....................................... 5
00.3 Regulations for Safe Maintenance Work ........................................
00.3.1 General Safety View Points ....................................................
00.3.2 Concerning the Maintenance and Repair Personnel ..............
00.3.3 Preparing for Hazardous Situations ........................................
6
6
7
8
00.4 Preparing of the Machine for Maintenance ..................................... 9

00.4.1 Maintenance Enviroment ........................................................ 9
00.5 Maintenance Reports ...................................................................... 10
00.6 Lubrication Oil Recommendations ................................................ 11
00.7 Running-In ....................................................................................... 13
00.7.1 Initial Maintenance ................................................................ 14
00.8 Scheduled Maintenance ................................................................. 15
00.8.1 Scheduled Maintenance for Engine Scania DI12 ................. 15
00.9 Scheduled Maintenance .................................................................
00.9.1 Scheduled Mainteanance for Engine Cummins QSM11 ......
00.9.2 Scheduled Maintenance for Gear Box and Power Unit .......
00.9.3 Scheduled Maintenance for Steering ...................................
00.9.4 Scheduled Maintenance for Hydraulics ...............................
00.9.5 Scheduled Maintenance for Boom ........................................
00.9.6 Scheduled Maintenance for Spreader ..................................
00.9.7 Scheduled Maintenance for Others ......................................
00.9.8 Unit Conversation .................................................................
00.9.9 General Tightening Torques .................................................
Maintenance Manual DRS 4527-4531
16
16
17
17
17
18
18
19
20
24
UDRS01.01GB
UDRS01.01GB
00.1 General Information

The maintenance manual contains the actual information
required during maintenance work. This information acquaints the maintenance and repair personnel with correct and safe methods of maintenance and repair work.
The professional support of our maintenance organization and the maintenance instructions make possible the
safe, reliable and efficient operation for the machine during its operation life.
00.1.1 About the Documentation

The following documentation is supplied with the machine:
Operator's manual DRS 4527-4531 (in cab with
machine)
Maintenance manual DRS 4527-4531
Spare parts catalogue with machine card
All documentation can be ordered from Kalmar Industries.
00.1.1.1 Ordering of documentation
Documenation is ordered from Kalmar Industries:
Kalmar Industries AB, SE-341 81 Ljungby, Sweden.
Always indicate publication number when ordering.
00.1.2 Warranty Agreement

Warning!
Negligence of scheduled maintenace measures mentioned in this manual will release Kalmar Industries
from all warranty liabilities. Warranty information is
at the end of this manual.
UDRS01.01GB
00.1.3 To the Maintenance Personnel

Carefully familiarize yourself with the planned maintenance program, maintenance points and instructions and
follow them during your maintenance work, to secure the
high level of the safety in operation and reliability. Use
oils, greases and liquids, defined later in this manual.
Only original Kalmar parts shall be used. A strict compliance with cleanness especially by maintenance of hydraulic and fuel devices by scheduled maintenance is the
best way to be ensure, that the machine operates as
planned. Take care according the instructions on your
working place for the oils, greases and liquids, changed
during the maintenance.
Warning!
Never pour oils, greases and liquids changed during
the maintenance down the drain or in to the earth!
Bear the responsibility for the environment! Only
trained personnel is allowed to maintain the machine.
Do not maintain the machine, if you are not sure about the
safety instructions and orders. Ask if needed for guidance
of safety maintenance in your working place the personnel responsible for occupational instruction and guidance
or get in contact with the service organization of the manufacturer.
UDRS01.01GB
00.2
Instructions for Initiating into

Maintenance Work
The service and repair personnel must be clear about the

machine operation, the working principles, and the designed functions of the machine systems. The service
section is meant as an introduction to enable correct and
safe service and repair work. Therefore it is important that
the instructions in the manual are studied carefully prior
to work.
00.2.1 General Instructions

To the commissioning of a new machine and the first
scheduled services should be paid a special attention.
The manufacturer has drawn up a special service schedule particularly for this machine. The manufacturer has
contributed significantly to develop a service program to
maintain the proper safety level of the machine. Data for
correct maintenace measures have been collected as result of an extensive research work. In addition to this,
feedback from different operating conditions has been
considererd very carefully.
By careful following of the maintenance schedule specified by the manufacturer, a rational and economic maintenance of the machine is enabled. The manufacturer has
invested in the profitable training maintenances of a high
level performance. Qualified and experienced trainers
are always available, if problems arise at the client.
00.2.2 Maintenance and Repair Personnel

The machine may be serviced and repaired by qualified
and trained personnel only. The employer is responsible
for selecting of the person suited to the service and repair
duties. The employer is responsible for training of the
service and repair personnel into the proper workmanship
considering the safety at work.
The service person refers to a person, who performs the
scheduled services and eventual repairs at the machine.
The service person must attend to maintain his qualifications, e.g. by periodically repeated training. The employer
is responsible for maintaining of the qualifications of the
service and repair personnel. The machine must not be
serviced or repaired by personnel who has lost skills. If
necessary, the employer must retrain the person selected
for the service and repair work at the machine.
UDRS01.01GB
00.3
Regulations for Safe Maintenance

Work
The person performing the service shall be physically

suited for this kind of work. As far as health and power of
seeing are concerned, the person shall fulfil the requirements necessary for the work. The employer is responsible for selecting the person suited for the duty as well as
for initiating into the correct and safe service work at the
machine.
00.3.1 General Safety View Points

The service and repair personnel of the Reach Stacker is
responsible for that the machine doesn't cause damage
to other persons in connection with the service or repair
work.
1. Thoroughly acquaint yourself with the machiner's
structure and the manuals. Observe the instructions
and warnings.
2. Try to determine the hazards, and avoid them. Report
any faults that you have noticed to your superior or to
the person in charge of repairs.
3. Wear required protective clothing.
4. Always observe sufficient caution and care when
climbing into or coming down from the machine. Always move along the paths designated as walkways.
Keep the walkways clean. Remove all safety risks,
such as snow and ice, and other foreign matter. Wipe
away all oil leakages at once to prevent slipping.
5. Keep the machine clean, especially the adjusting and
control devices.
6. Do not allow any unauthorized persons to operate the
machine entrusted in your use. The operator of the
machine is responsible for any damage caused by the
machine.
7. Acquaint yourself in advance with the use of emergency exits.
8. Do not stand under a hanging container or load.
9. If problems arise, remember to stay calm. Think first,
and then act accordingly.
UDRS01.01GB
00.3.2 Concerning the Maintenance and Repair

Personnel
1. Before starting off, make sure that nobody is standing
in front or behind the machine.
2. Avoid sudden stops and starts.
3. Always perform the maintenance and repair work according to the instructions given.
4. By observing a danger spot, immediately report to the
person responsible for safety.
5. The machine must not be handed over for operation,
until the observed faults and damages have been repaired.
6. Observe the signs and instructions indicating free
height. You should know the exact total height of your
machine before driving into places with rstriced free
height. Be especiallycareful with temporary structures,
hanging overhead power lines, etc.
7. You may perform the service and repair work only in
compliance with your actual qualification.
8. Don't try to guess! Maybe you make a wrong guess,
causing a possible danger to yourself and the other
personnel.
9. If necessary, consult a person being aware of how to
proceed.
10.When servicing pressurised systems, proceed very
carefully. Non-discharged energy sources always are
hazardous.
11.Follow unconditionally the instructions given.
12.If it is necessary to remove protective guards during
the service, place warning signs and take other measures to protect other persons from danger.
13.When changing driving direction, stop the machine
completely with the service brake before moving the
direction selector lever.
14.Watch out for the edges of driveways where the surface may be yelding and cause the danger of overturning.
15.Remember that the machine is not intended for carrying persons.
16.Always stop the engines whenever you leave the machine even for a short while. Lower any load to the
ground.
UDRS01.01GB
17.Always remember to engage the parking brake before

leaving the cabin.
18.Make a detailed report on any collisions, including the
damage caused. This could prevent accidents from
being repeated.
19.Observe the weight of your carrier, and its total weight
loaded. Do not drive on surfaces with insufficient load
capacity.
20.Follow the periodic maintenance schedule. This ensures that the controls and the whole carrier operate
reliably and safely.
21.The engine must always be stopped when service or
inspections are being carried out.
22.The use of open flame is absolutely forbidden when
checking fuel or battery electrolyte levels.
23.The radiator is pressurized when the coolant is hot open the radiator cap slowly and cautiously.
24.Do not open the main switch when the engines are
running.
25.Only a person that is well acquainted with the carrier's
control and the cabin equipment is allowed to be in the
cabin during service and repairs.
26.Driving is forbidden without fastened seatbelts.
27.Never park the machine on a inclined plane.
00.3.3 Preparing for Hazardous Situations

00.3.3.1 Maintenance Reports
Inform your superior or the person responsible for repairs
of faults observed at the service. The machine must not
be operated until the faults and damages have been repaired.
See to it that your service reports are perfectly recorded.
Record the objects to be repaired individually, and note
the repair measures precisely. In addition to this, try to
find out, why the object has been damaged.
00.3.3.2 Tools
Use only proper tools at the service and repair work.
UDRS01.01GB
00.3.3.3 Reporting of Dangers

Always inform in writing your superior or the person responsible for safety of dangers observed in the service
environment or in machines serviced.
The reports recorded must be filed carefully. It is essential
that the reports are available to be analyzed if necessary.
00.4
Preparing of the Machine for

Maintenance
The service and repair work should be performed in the

premises intended for this use. State the extent of the
service work. Prepare yourself for the service or repair
work by reading the service and repair manuals. Prepare
yourself for the work by tools and materials needed. See
to it that the tools to be used are proper and in good condition. See to it that the warning signs for eventual hazardous situations have been placed in position.
Prior to the service work: Check the reparations made in
the operation of the machine since the last service. Check
the previous service report. Try to find out the expected
safety level on the basis of the information collected;
which points shall be particularly considered at the next
service.
00.4.1 Maintenance Enviroment

1. Provide for placing the service environment to premises, where the machines can be serviced safely and
without exposing the regular work to danger.
2. See to it that the environment cannot be contaminated
by the machine being serviced.
3. Always keep the service environment clean and trim.
4. See to it that there is no danger in the service environment, which possibly could endanger the personnel.
5. Be aware of the correct action in case of possible accidents. Keep yourself informed about the location of
the electrical main switches of the service environment, as well as of the fire extinguishing equipment.
6. Keep yourself informed about the safety regulations
regarding the service environment.
UDRS01.01GB
10
00.5
Maintenance Reports
When performing the service, report the work systematically in accordance with the service schedule drawn up
by the manufacturer. Note carefully damages observed
and repair measures. The service schedule drawn up by
the manufacturer is presented in section 'First service
and scheduled service' of this main group.
Define and record the safety level of the machine in the
service report after every service. If, by your estimation,
the machine doesn't correspond to the designed safety
level, inform of this your superior responsible for the safety. After every service, file the service reports.
UDRS01.01GB
00.6
11
Lubrication Oil Recommendations
Required oils, greases and fluids

Item
Class
Filling
API/ASTM/
capacity / l
SAE
Type
Engine Cummins QSM11

Diesel motor oil
All Seasons, but not Artic condi- SAE 15W-40
tions
API CH4
or ACEA
E5
Engine
Scania DSI 12
<-40 ... +30C
-25 ... +30C
-20 ... +45C >
-15 ... +30C
-10 ... +30C
-5 ... +45C >
0 ... +45C >
Diesel motor oil
API CE or 33
CF
CCMC-D5
ACEA E3
Hydraulic oil tank

Cabin transfer hydraulic
-30+25C
-10+35C
-10+35C
-20+30C
0+30C
+10+50C
Hydraulic oil
Drive axle PRC7534

Rockwell
Differential
Planetary gear
-40C...>
-26C...>
-12C...>
SAE 5W-30
SAE 10W-30
SAE 15W-40
SAE 20W-30
SAE 30
SAE 40
SAE 50
36
600
2,8
1)
NESTE MJ 46,
BP Tracton 9, TEXACO TDH
Esso Torque Fluid 62
ISO-VG 46
ISO 68
ISO-100
60
2X12,5
Hypoid oil SAE 75W/90 EP
GL-5
-"-"-
Gearbox
Clark 36000
-25 ... +45C
Transmission oil SAE 5W30

UTTO transmission oil 4)
Rotation transmission
GL-5
Lubricating points of
chassis and lifting device
EP Multi-purpose grease
example ESSO Unirex EP 2
NLGI 2
Lubricating slide planes of boom EP Multi-purpose grease

and spreader
ore ESSO Moly Grease 2
NLGI 2
Central lubrication,
optional 2)
EP Multi-purpose grease, Class

If the temperature is continuously under
-10C, EP Multi-purpose grease
Fuel tank
Cooling system3)
Windscreen washer
High-quality diesel fuel

Glycol 50% / water 50%
Windscreen washer liquid
NLGI 2
5,5
2kg
NLGI 0
500
60
10
UDRS01.01GB
12
Required oils, greases and fluids

Item
Type
Class
Filling
API/ASTM/
capacity / l
SAE
1. In colder weather, a hydraulic oil heater should be used.

2. Refer to the 'Central oiler' section 08 of the manual.
3. Add DCA4 additive to coolant for Cummins engine, 1,2 units / US gallon. Check the amount of additive with the
test serie CC-2602.
4. UTTO-transmission lubricant must be qualified by on of the following specifications in order of preferance:
Caterpillar TO-4
John Deere J20 C, D
Allison C-4
Dexron oils must not be used.
UDRS01.01GB
00.7
13
Running-In
Long life of the machine can be ensured bu avoiding

great loads and high engine speeds during the first 300
operating hours. During this time, all finely machined surfaces reach their final smoothness and hardness.
The engine should not, however be lugged at low speeds
or allowed to idle long.
Especially observe during the running-in period that the
engine and transmission oil pressures and temperatures
are normal. Oil change during running-in should also be
done sooner than normally. Also refer to the engine's
manual for running-in instructions.
During running-in you should also pay special attention to
the tightness of screws and nuts, and tighten them as
necessary.
Running-in of an overhauled engine follows the same
principles as above, but the running-in period is somewhat shorter.
UDRS01.01GB
14
00.7.1 Initial Maintenance

Special attention should be paid to taking a new vehicle
into operation and to its first maintenaces. Maintenance
charges are small compared with cost of repairs caused
by neglect.
Warning!
In addition the proceeding stated in this maintenance
volume a new machine must be subjected to all the
maintenance and checks mentioned in the book.
In addition to the instructions in the maintenance chart,
the following service should be carried out during the first
50...150 hours.
Maintenance of a new machine during first 150 hours
Maintenance itemUDRS01.01GB
Interval/working hours
50
100
150
1.
Replace hydraulic system filters
2.
Change engine oil
Replace engine oil filter
4.
Change transmission oil
5.
Replace transmission filter
6.
Change differential and planetary gear oil
7.
Change brake oil
Warning!
Please consult also the engine instruction manual for
running-in directions. Apply these directions after replacements of major components, too.
After the initial maintenace do follow scheduled maintenance program, where service intervals are based upon
operating hours.
UDRS01.01GB
00.8
15
In the scheduled maintenance of the reach stacker the

maintenance instructions of this groupshall be followed,
though the instructions in the maintenance of the components may differ from them.
00.8.1 Scheduled Maintenance for Engine

Scania DI12
Interval in operating hours
Maintenance item
Daily
ENGINE, see also engine manual

1. Check the engine oil level
2. Check the coolant level
3. Clean the air pre-filter and replace the air filter when
400
h
1000
h
2500
h
6000 h
or at
least
every
two
years
At least
every
fifth
years
the clogging indicators show fully red

4. Check cooling fan
5. Check the possible oil- and the fuel leakages
6. Clean water separator, if needed
7. Change engine lubricating oil
8. Cleaning oil cleaner
9. Replace engine oil filter
x
x
10. Clean the air pre-filter
11. Check engine intake system
12. Checking electrolyte level in batteries, if needed
add only battery water

13. Check state of charge and cleanliness in batteries
14. Check engine screws and tighten to spec. torque
15. Check hoses and replace if necessary
16. Replace the air filter and clean the air pre-filter, also
when the clogging indicators show fully red

17. Replace engine fuel filter
18. Clean and replace the fuel pre-filter (optional)
19. Check the condition and tightness of the fan belt
x
x
x
20. Clean crankcase breather
21. Wash up engine
22. Checking/adjusting valve clearances
23. Checking/adjusting injectors DI12
24. Checking/adjusting PDE injector rocker arms

DI12 PDE
25. Cleaning cooling system and changing cooland fluid
UDRS01.01GB
16
00.9
In the scheduled maintenance of the reach stacker the

maintenance instructions of this group shall be followed,
though the instructions in the maintenance of the components may differ from them.
00.9.1 Scheduled Mainteanance for Engine

Cummins QSM11
Maintenance item

Dai-ly
1.Check the engine belt
2.Check the engine oil level
3.Check coolant level
4.Check cooling fan
5.Clean water separator
6.Check air cleaner service indicator; replace filter if indicator

shows red
250 h
7.Change engine oil *)
8.Replace engine oil filter *)
9.Replace engine fuel filter
10.Check additive content of coolant (SCA)
11.Replace coolant filter
12.Check engine intake system
13.Check crankcase breather
14.Check engine wiring harness
500 h
1500 h
15.Adjust valves and atomizer
16.Clean crankcase breather
17.Steam wash engine
18.Check turbocharger nuts and tighten to spec. torque
19.Check engine screws and tighten to spec. torque
20.Check hoses and replace as necessary
21.Check state of charge and cleanliness in batteries
22.Service exhaust catalysis CRT**) (optional)
6000 h or at
least every two
years
23.Flush cooling system and Change coolant
24.Clean and adjust electronic controlled fuel system ***)
25.Check water pump
26.Check fan hub
27.Check turbocharger
28.Check idley pulley mouting
29.Check vibration damper
*) Change interval 125 operating hours, if engine lubricating oil does not comply with API CF-4 specific.
**) See instructions: CRT-service manual, part C appendixes
***) Adjust requires special equipment and must be done a Cummins Authorized Repair Location
UDRS01.01GB
17
00.9.2 Scheduled Maintenance for Gear Box

and Power Unit
Maintenance item
Transmission
250
Dai-ly
h
1.Check transmission oil level
2.Check possible oil leaks
3.Replace transmission oil filters
500
h
1000
h
2000
h
At least
once a
year
4.Change transmission oil
5.Clean screen filter
6.Check transmission oil pressure
Drive Axle
1.Check oil level in differential and planetary gear (common oil
space)
2.Adjust parking brake according to instructions
3.Check and tighten screw connections
4.Check and tighten wheel nuts
5.Check tyre pressure
6.Change differential and planetary gear oil
7.Check parking brake friction surfaces for wear, replace as necessary (wet disk brakes on drive axle needs no maintenance)
6.Change brake oil
00.9.3 Scheduled Maintenance for Steering

Maintenance item
Steering Axle
Dai-ly
250
h
1.Check steering lingake joints
2.Check and tighten wheel nuts
3.Check tyre pressure
4.Check and tighten screw connections
500
h
1000
h
2000
h
At least
once a
year
5.Lubricate wheel bearings
00.9.4 Scheduled Maintenance for Hydraulics

Maintenance item
HYDRAULICS
Dai-ly
1.Check hydraulic hoses and connections for possible leaks
2.Check hydraulic oil level. Sight glass attached to hydraulic

tank is used for checking. Oil level should be in the midway of
the gauge when spreader is lowered to its standard position and
boom telescopic extension is fully retracted.
250
h
500
h
At
least
1000 2000 4000 once a
h
h
h
year
UDRS01.01GB
18
3.Replace brake hydraulics filter
4.Replace hydraulic oil filter
5.Replace filter element of hydraulic system breather
6.Measure hydraulic system pressure
7.Change hydraulic oil and clean tank of

possible impurities
x
x
8.Change brake oil and clean tank of

possible impurities
9.Check the pressure of possible pressure accumulators in system
10.Change cabin transfer hydraulic oil
1)
1) Every two years
00.9.5 Scheduled Maintenance for Boom

Maintenance item
BOOM
Dai
ly
1. Lubricate the slide pieces in boom front end 1)
2. Lubricate bearings of the boom 1)
3. Lubricate sliding surfaces of inner boom
50
h
250
h
500
h
1000
h
At least
once a
year
4. Lubricate boom support rollers
5. Check sliding pads
1) Daily lubrication, if there is not central lubrication.
00.9.6 Scheduled Maintenance for Spreader

Maintenance item
SPREADER
Dai
ly
50
h
1. Lubricate bearings of longit. tilting cylinders 2)
2. Lubricate bearings of lengthening cylinders 2)
3. Lubricate rocker bearings of turning device 2)
4. Lubricate bearing of turning device 2)
250
h
5. Lubricate slide planes
6. Lubricate bearings of bearer
7. Lubricate gear rim
1000
h
At least
once a
year
8. Lubricate twistlocks
9. Lubricate bearings of twistlock turning cylinder

10. Check rotation transmission oil level
x
x
11. Change oil to rotation transmission
12. Check sliding pads
13. Inspection of twistlocks 3)
2) Central lubrication point (optional equipment)

3) First time 5000 operating hours or 2 years whichever occurs first.
UDRS01.01GB
500
h
19
00.9.7 Scheduled Maintenance for Others

Maintenance item
OTHERS
Dai-ly
1.Fill lubricant tank of central lubricational system, (optional equipment)
2.Check instrument panel, indication lights and signal horn
250
h
3.Check operation of central lubricator dispencers and condition of

pipes
4.Check operation of electric devices
5.Check by driving all machine function
500
h
1000
h
7.Measure braking system pressures
8.Check screw connections and tighten them as necessary to specified torques
9.Wash the whole machine throughly clean
10.Check the operation of the overload control system and adjust it

if necessary
6.Check brake system for possible oil leaks
11.Clean fuel tank of possible impurities
2000
h
At least
once a
year
UDRS01.01GB
20
00.9.8 Unit Conversation

Convert to SI-units
Old unit
Coefficient
Si-units
1 kp.......
1 kpm.......
1 kpm/s.......
1 kp/mm2.......
1 mm vp.......
9,80665
(9,81)
(10)
..
..
..
..
..
N
Nm = J = Ws
W = J/s = Nm/s
N/mm2 = MPa
Pa
98,1
1 kp/cm2.......
0,980665
(0,98)
(1,0)
.. kPa
1 mmHg.......
133,322
.. Pa
1 atm.......
101,325
.. kPa
1 bar.......
100
.. kPa
1 hv.......
0,7355
(0,75)
.. kW
1 hp.......
0,7457
.. kW
1 cal.......
1 kcal/kg.......
4,1868
(4,19)
(4,2)
.. J = Nm = Ws
.. kJ/kg
1 kWh.......
3,6
.. MJ
1 km/h.......
0,278
.. m/s
1 mpk/h(solmu) ....
0,514
.. m/s
1 m3/h.......
0,000278
.. m3/s
1 l/min.......
0,00167
.. m3/s
1 kcal.......
1 kcal/h.......
1,163
(1,16)
(1,2)
.. Wh
.. W
Note!Calorie (cal) from Ws

1 kWh = 860 kcal = 3,6 MJ
UDRS01.01GB
21
Convert to old units

Si-units
Coefficient
Old unit
N.......
Nm = J = Ws.......
W = J/s = Nm/s ....
N/mm2 = MPa ....
Pa.......
0,101972
(0,102)
(0,1)
..
..
..
..
..
1 Pa.......
0,0010
.. bar
0,0075
.. mm Hg
0,00987
.. atm
0,010
.. bar
0,0102
.. kp/cm2
0,000102
.. kp/mm2
1 bar.......
1,02
(1,0)
.. kp/cm2
1 MJ.......
0,278
(0,3)
.. kWh
1 kJ/kg.......
1 J = Nm =Ws.......
0,239
(0,24)
(0,25)
.. kcal/kg
.. cal
1 Wh.......
1 W.......
0,859845
(0,86)
.. kcal
.. kcal/h
1 kW.......
1,36
.. hv
1,34
.. hp
1 m/s.......
3,6
1,94
.. km/h
.. mpk/h (knot)
1 m3/s.......
0,0036
0.060
.. m3/h
.. l/min
1 kPa.......
1 kp
1 kpm
1 kpm/s
1 kp/mm
1 mm vp
Note!All the above presented conversion coefficients are approximations of

some degree.
Length
1 in = 25,4 mm
1 mm = 0,039 in
1 ft = 0,3048 m = 304,8 mm
1 cm = 10 mm = 0,39 in
1 yd = 0,9144 m = 914,4 mm
1 dm = 10 cm = 3,9 in
UDRS01.01GB
22
Length
1 naut. mile = 1852 m
1 m = 10 dm = 3,28 ft
1 stat. mile = 1609 m
1 km = 1000 m = 1090 yd
Area
1 sq in = 645,2 mm2
1 mm2 = 0,0015 sq in
1 sq ft = 0,09290 m2
1 cm2= 100 mm2 = 0,15 sq in
1 sq yd = 0,8361 m2
1 dm2 = 100 cm2 = 15 sq in
1 sq mile = 2,590 km2
1 m2 = 100 dm2 = 1,19 sq yd = 10,76 sq ft

1 km2 = 1000000 m2
= 0,38 sq mile
Volume
1 US fl oz = 29570 mm3
1 cu in = 0,01639 dm3
1 cu ft = 0,02832 m3
1 cu yd = 0,7646 m3
1 US qt = 0,9464 dm3
1 US gal = 3,785 dm3
Mass
1 oz = 28,35 g
1 g = 0,0353 oz
1 lb = 0,4536 kg
1 kg = 1000 g = 35,3 oz
1 short ton = 0,9072 t
1 kg = 2,205 lb
1 long ton = 1,016 t
Force
1 ozf = 0,2780 N
1 N = 3,597 ozf
1 lbf = 4,448 N
1 N = 0,2248 lbf
1 kp = 9,807 N
1 N = 0,1020 kp
UDRS01.01GB
23
Pressure
1 ft H2O = 2,989 kPa
1 bar = 100 kPa = 100000 Pa
1 in Hg = 3,386 kPa
1 kPa = 7,5 mmHg
1 in H2O = 0,2941 kPa
1 kPa = 0,33 ft H2O
1 psi = 1 lbf/sq in = 6,895 kPa
1 kPa = 0,29 in Hg
1 kPa = 4,01 in H2O
1 kPa = 0,15 psi
1 kPa = 0,15 lbf/sq in
Energy
1 Btu = 1055 Nm = 1055 J
1 Nm = 1 J = 1 Ws
1 ft-lbf = 1,356 Nm
1 kJ = 1000 Nm = 0,95 Btu
1 kcal = 4187 Nm
1 Nm = 0,74 ft-lbf
1 Wh = 3600 Nm
1 kJ = 0,24 kcal
1 Ws = 1 Nm
1 kJ = 0,00028 Wh
1 kpm = 9,807 Nm
1 Nm = 0,102 kpm
Power
1 Btu/hr = 0,2931 W
1 W = 3,412 Btu/hr
1 ft-lbf/s = 1,356 W
1 W = 0,7376 ft-lbf/s
1 hp = 0,746 kW = 746 W
1 kW = 1000 W = 1,341 hp
1 hv = 0,736 kW = 736 W
1 kW = 1000 W = 1,359 hv
Temperature
C = 5/9 X (F-32)
F = 9/5 X C+32
K = C + 273,15
UDRS01.01GB
24
00.9.9 General Tightening Torques

General tightening torques for screw connections, metric ISO-standard thread
Screw size
Tightening torque Nm
Strength class, surface treatment, material
5.8
Zne
8.8
oiled
8.8
Zne
10.9
oiled
12.9
oiled
M4
1,77
M5
3,53
6,35
5,66
8,94
10,7
M6
6,04
10,9
9,69
15,3
18,3
M8
14,5
26,1
23,2
36,8
44,1
M10
28,6
51,5
45,8
72,4
89,9
M12
49,7
89,4
79,6
125
151
M14
79,0
142
127
200
239
M16
121
218
194
307
368
M18
169
304
271
428
513
M20
236
426
379
598
718
M22
319
573
510
806
967
M24
409
735
655
1030
1240
M27
591
1060
943
1490
1790
M30
807
1450
1290
2040
2450
M33
1090
1950
1740
2750
3290
M36
1410
2520
2243
3550
4260
M39
1800
3240
2880
4560
5460
M42
2250
4020
3580
5660
6790
- 1 Nm = 0,102 kpm
- Zne = electrogalvanized
If the screw shank is reduced in diameter (thinned) or the thread terminates in a clear end groove, the values
listed in the table must not be used. Tightening torques for these cases must be calculated separately.
UDRS01.01GB
Power Unit
01
Power Unit
01.1 Power Unit - Scania ........................................................................................ 3
01.2 Power Unit - Cummins .................................................................................. 4
01.2.1 Tightening Connection between Engine and Transmission ................. 5
01.3 Engine - Scania .............................................................................................. 6
01.4 Engine - Cummins .......................................................................................... 8
01.4.1 Maintenance Points for Fuel Tank and Coolant Expansion Tan .......... 9
01.5 Transmission CLARK 15.5 36431 ...............................................................
01.5.1 Checking Transmission Oil Level ......................................................
01.5.2 Changing Transmission Oil ................................................................
01.5.3 Transmission CLARK 15.5 36431 .....................................................
01.5.4 Cross Section of Transmission ..........................................................
01.5.5 Oil Pump ............................................................................................
11
11
11
12
13
14
01.6 Instructions for Checking Transmission Operation .................................

01.6.1 Electric Inspections ............................................................................
01.6.2 Hydraulic Inspections .........................................................................
01.6.3 Pressure Measuring ...........................................................................
01.6.4 Selector Valve ....................................................................................
01.6.5 Measuring Points ...............................................................................
01.6.6 Troubleshooting .................................................................................
01.6.7 Tightening Torques of Transmission Bolts and Screws .....................
15
15
15
15
16
17
18
19
01.7 Stall Use: Testing of Engine and Transmission ........................................ 20

01.7.1 Testing ............................................................................................... 20
UDRS01.01GB
UDRS01.01GB
Power Unit
Power Unit
01.1 Power Unit - Scania

4
11
10
Y3
Y2
Y1
Y4
Y5
8
Figure 1. Power Unit
1
Engine
Transmission and the torque converter
Transmission pump
Engine oil dipstick
Engine oil filling
Oil cleaner
Oil filter
Fuel filter
Transmission oil filling
10
Transmission oil dipstick
11
Transmission oil filters
Weight of power unit 1930 kg (4250 lb)
UDRS01.01GB
Power Unit
01.2
Power Unit - Cummins

2
Figure 2. Power Unit

1. Engine
2. Transmission and the torque converter
Weight of power unit 1930 kg (4250 lb)
UDRS01.01GB
Power Unit
01.2.1 Tightening Connection between Engine

and Transmission
45 Nm
(33 lbf.ft)
1
71...77 Nm (52,5...57 lbf.ft)
CUMMINS L10, M11: 185 Nm (136,5 lbf.ft)
SCANIA DS11: 190 Nm (140,5 lbf.ft)
Figure 3. A = Engine
B = Transmission
If the tension discs connecting transmission and engine;

point 1; shall be changed, check by mounting that the
new discs are suitable. They must be closed against the
surfaces of engine and transmission. If not, remove with
grindstone the sharp edge of the disc opening.
Engine flywheel housings face of joint (C) SAE
J617 No. 3.
UDRS01.01GB
Power Unit
01.3
Engine - Scania
Scania DI12 turbocharged and recooled direct injection

engine, low emissions.
Principal dimensions and data
Power
243 kW (330 hv) / 2100 rpm
Max. torque
1458 Nm / 1300 rpm
Number of cylinders
Cylinder numbering from the front

end
1-2-3-4-5-6
Engine displacement
11.7 dm3
Cylinder bore
127 mm
Stroke
154 mm
Aspiration
turbocharged
Cooling
by liquid
Direction of rotation of the crankshaft clockwise

viewed from engine front end
Dry weight
UDRS01.01GB
995kg
Power Unit
17
1, 2
14
19
11
15
13
12
10
7 4 5 6
16
18
Figure 4. Engine
1
Type plate
Engine serial number, stanped in engine block
Oil cooler
Dipstick
Oil cleaner
Oil filter
Draining, engine oil
Cooland pump
Charger air cooler
10
Turbocharger
11
Hydraulic pump
12
Control unit A96
13
Starter motor
14
Fuel filter
15
Automatic belt tensioner
16
Draining, coolant
17
Oil filling
18
Fuel hand pump
19
Compressor
For complete details and instructions on the engine, see

the Operators Manual.
UDRS01.01GB
Power Unit
01.4
Engine - Cummins
Cummins QSM11 turbocharged and recooled low emission diesel engine, which fullfills emission and regulations
step III.
Figure 5. Cummins QSM11 Engine

Principal dimensions and data
Power
246 kW (330 hv) / 2100 rpm
Max.torque
1458 Nm / 1300 rpm
Number of cylinders
Cylinder numbering from the front

end
1-2-3-4-5-6
Engine displacement
10.8 dm3
Cylinder bore
125 mm
Stroke
147 mm
Aspiration
turbocharged
Cooling
by liquid
Direction of rotation of the crankshaft clockwise

viewed from engine front end
Dry weight
940 kg
For complete details and instructions on the engine, see

the Operators Manual.
UDRS01.01GB
Power Unit
01.4.1 Maintenance Points for Fuel Tank and

Coolant Expansion Tan
4
Figure 6. Maintenance Points for Fuel Tank and
Coolant Expansion Tank
A
Checking hose
Filling cap of coolant system
Coolant expansion tank
Fuel tank
Filling of fuel system
Draining plug
Sensor of fuel level
UDRS01.01GB
10
Power Unit
01.4.1.1 Air Cleaner
4
2
Figure 7. Air Cleaner

1
Main filter element
Safety element
Prefilter
Air cleaner maintenance indicator
Indicator reset
The air filter element must be replaced immediately when
the indicator (4) shows red. After replacing the filter element, reset the indicator using the button (5).
Clean the pre-filter (3) frequently enough, daily in dusty conditions.
UDRS01.01GB
Power Unit
11
01.5 Transmission CLARK 15.5 36431

The Clark transmission incorporates two main components: the torque converter and gearbox. The assembly
is mounted as one unit to the flywheel housing of the engine.
01.5.1 Checking Transmission Oil Level

Oil level is checked daily with the engine running at idle
speed and the oil temperature at normal level 82 to 93C
(180 to 200 F).
If the oil temperature is below 82C (180 F), it must be
warmed up. Run the engine at 20 to 30 r/s (1200-1800 r/
min) with the highest speed range selected (lever in extreme position away from driver) while applying brakes
(STALL). The oil level must be on the highest level plug.
Warning!
Do not use the converter transmission in stall-use
continuously more than 30 seconds that the torque
converter does not become too warm. Keep between
the stall-uses a pause of about 1 minute.
01.5.2 Changing Transmission Oil

Drain out the used oil when its temperature is 65 to 95C
(150 to 203 F). The drain plug is under the transmission.
Remove the oil sump screen, clean it thoroughly, and reinstall. Remove the oil filter, remove the cartridge, clean
the housing, install a new cartridge and reinstall the filter.
Fill the gearbox with clean oil up to the lower mark level.
Check the oil level with the dipstick located to the right of
the cabin (beside oil filling cap). Run the engine at idling
speed to fill the torque converter and the pipelines with
oil. Add oil up to the upper plug while the engine is running. Final inspection of oil level is done when the oil is at
normal operating temperature 82-93C (180-200 F).
For oil quality, filling capacity, see Lubrication Oil Recommendations and changing interval, see Scheduled maintenance.
UDRS01.01GB
12
Power Unit
01.5.3 Transmission CLARK 15.5 36431

630 rpm Min. 40 l/min (10 USgal/min)
2300 rpm Max. 140 l/min (37 USgal/min)
Converter inlet
Breather
Main pressure
measuring point
Oil fill
Converter
out
Oil dipstick
Oil cooler
From oil cooler

Lube pressure
Fwd. clutch
Control valve
4th clutch
pressure port
Oil filters (2 pcs)

From filter
This line: 117 l/min

(31 USgal/min)
Measuring point for converter
output pressure
Measuring point for converter
output temperature
1st speed clutch

pressure port
3rd speed clutch

pressure port
Oil sump intake screen
Oil drain plug
Figure 8. Transmission CLARK 15.5 36431
UDRS01.01GB
Power Unit
13
01.5.4 Cross Section of Transmission
1 st
2 nd
3 rd
4 th
Figure 9. Cross Section of Transmission
UDRS01.01GB
14
Power Unit
01.5.5 Oil Pump
Torque converter
safety valve
Main pressure
measuring point
Pressure regulating valve
Figure 10. Oil Pump
UDRS01.01GB
Power Unit
01.6
15
Instructions for Checking

Transmission Operation
01.6.1 Electric Inspections

Check the functioning of conductors, sensors, connectors
and solenoid valves in the electric system of the transmission control.
01.6.2 Hydraulic Inspections

Check the transmission oil level before checking the oil
pressures and volume flows of the transmission and
torque converter.
01.6.3 Pressure Measuring

When checking pressures keep the engine speed at 33 r/
s (2000 RPM), and make sure that the speed range selector is in the neutral position.
Clutch Pressures: Normally 17 to 19 bar (240-280 PSI)
Allowed deviation in all clutch pressures in the same conditions is 0,34 bar (4 PSI).
Torque Converter Outlet Pressure:
Min 1,7 bar (25 PSI) / 2000 RPM
Max 4,9 bar (70 PSI) / unloaded at max . speed
Converter Outlet Lines Flow: 90 l/min (24 USgal/min)
For measuring points, see the illustration in this chapter.
UDRS01.01GB
16
Power Unit
01.6.4 Selector Valve
12/24 Volt
Figure 11. Selector Valve
UDRS01.01GB
Power Unit
17
01.6.5 Measuring Points
Figure 12. Measuring Points

Pressure measurement
Measuring point
Clutch pressure, forwards
FC
Clutch pressure, 2nd
2C
Clutch pressure, reverse
RC
Pilot pressure, forwards
FP
Pilot pressure, reverse
RP
Pilot pressure, 3rd gear
3P
Pilot pressure, 2nd gear
2P
Pilot pressure, 1st gear
1P
Clutch pressure, 1st gear
See section 01.5.3 Transmission

CLARK 15.5 36431
Clutch pressure, 3rd gear

CLARK 15.5 36431
Clutch pressure, 4th gear

CLARK 15.5 36431
UDRS01.01GB
18
Power Unit
01.6.6 Troubleshooting
Fault
Cause
Remedy
Low clutch pressure
Low oil level

Clutch pressure regulating valve spool stuck
open
Faulty feed pump
Broken or worn clutch
axle or piston sealing
rings
Clutch piston bleed
valve
stuck open
Fill to proper level

Clean valve spool and
housing
Replace pump
Replace sealing rings
Clean bleed valves
thoroughly
Low output of converter feed pump
Low oil level

Intake screen dirty
Air leak in pump feed
hose, connections, or
broken hose
Damaged oil pump
Add oil
Clean intake screen
Tighten all connections
and replace hose as
necessary
Replace pump
Overheating
Worn oil seeling rings
Inspect and repair converter

Replace pump
Add oil
Check and tighten oil
sleeve connections
Worn oil pump

Low oil level
Air leak in pump intake
sleeve
UDRS01.01GB
Noisy converter
Worn coupling gears

Replace
Worn oil pump
Replace
Worn or damaged bear- Complete overhaul to
ings
determine damaged
bearing
Lack of power
Low Stall speed of

engine
Cf. "overheating"
Adjust engine correctly

See "Overheating" for
repair instructions
Power Unit
19
01.6.7 Tightening Torques of Transmission

Bolts and Screws
Grade 5
Thread size
Nm (kpm) (lbf.ft)
Fined thread
Coarse thread
3/8"
35-39 (3,6-4,0) (26-29)
31-34 (3,2-3,5) (23-25)
7/16"
56-61 (5,7-6,2) (41-45)
50-56 (5,1-5,7) (37-41)
1/2"
87-95 (8,9-9,7) (64-70)
77-85 (7,9-8,7) (57-63)
9/16"
123-136 (12,6-13,9) (91100)
111-122 (11,3-12,4) (82-90)
Grade 8
Thread size
Nm (kpm) (lbf.ft)
Fined thread
Coarse thread
50-55 (5,1-5,7) (37-41)
45-49 (4,6-5,0) (34-36)
7/16"
79-87 (8,1-8,9) (58-64)
71-77 (7,2-7,9) (52-57)
1/2"
122-134 (12,4-13,7) (90-99) 109-120 (11,1-12,2) (80-88)
9/16"
174-191 (17,7-19,4) (128141)
3/8"
156-172 (15,9-17,6) (115127)
UDRS01.01GB
20
Power Unit
01.7
Stall Use: Testing of Engine and

Transmission
With help of STALL use the engine and transmission condition will be tested.
Check the STALL running speed of this machine in the
user's manual chapter Technical Information. Compare
this value with running speed value in STALL use.
If the STALL- running speed is lower than the given engine STALL-running speed, the engine function has to be
adjusted and / or repaired.
If the measured STALL-running speed is higher than the
given engine STALL-running speed, the transmission
function has to be adjusted and/or repaired.
01.7.1 Testing
Select the driving direction forwards and engage the highest gear. Keep the brake pedal engaged and rev the engine speed up to the highest running speed. Compare the
highest running speed with the given STALL- speed of
the machine.
Warning!
Do not use the converter transmission in stall-use
continuously more than 30 seconds so that the
torque converter does not become too warm. Keep
between the stall-uses a pause of about 1 minute.
UDRS01.01GB
Power Transmission
02 Power Transmission
02.1 Power Train Components - Scania .................................................. 3
02.1.1 Main Components of the Power Train .................................... 3
02.2 Power Train Components - Cummins ............................................. 4
02.2.1 Main Components of the Power Train .................................... 4
02.3 Drive Shaft ......................................................................................... 5
02.3.1 Change Differential Gear Unit Oil ........................................... 5
02.3.2 Change Planetary Gear Units Oil ........................................... 5
02.3.3 Construction of the Wheel Hub ............................................... 7
02.3.4 Torque Chart: Wheel Hub and Brake Housing ....................... 8
02.3.5 Brake Housing Cover .............................................................. 9
02.3.6 Friction Discs for Brake ......................................................... 10
02.3.7 Housing Pressure Measuring for Coolant Fluid .................... 10
02.3.8 Tightening of the Wheel Hub ................................................ 11
02.3.9 Instruction for Pinion Shaft Bearings .................................... 12
02.3.10 Rolling Resistance of Differential Bearings ......................... 15
02.4 Steering Axle ...................................................................................
02.4.1 Installation of Steering Axles ................................................
02.4.2 Tightening and Lubrication of Wheel Bearings .....................
02.4.3 Turning Resistance Control of the Steering Pivot Bearings ..
17
19
20
22
02.5 Wheels ..............................................................................................

02.5.1 Tyre Pressure .......................................................................
02.5.2 Torque of Wheel Nuts ...........................................................
02.5.3 Checking of the Rims ............................................................
23
23
24
25
UDRS01.01GB
UDRS01.01GB
Power Transmission
Power Transmission
02.1 Power Train Components - Scania

02.1.1 Main Components of the Power Train
1
2
3
Figure 1. Main Components of the Power Train

1. Engine
3. Prop shaft and the spring-loaded disc brake as a parking brake
4. Drive axle with differential, drive shafts and planetary
gears in the both axle ends
5. Transmission pump
UDRS01.01GB
Power Transmission
02.2
Power Train Components Cummins
02.2.1 Main Components of the Power Train
2
3
Figure 2. Main Components of the Power Train

1. Engine
3. Prop shaft and the sring-loaded disc brake as a parking brake
4. Drive axle with differential, drive shaft and planetary
gears in the both axle ends
5. Transmission pump
UDRS01.01GB
Power Transmission
02.3
Drive Shaft
The casing of the drive shaft assembly mounted rigidly to

the machine frame is of sturdy steel casting construction.
On the ends of the drive shaft are planetary gear unit and
the hubs. On the hubs are mounted wet disc brakes, free
of maintenance.
In a new and/or renovated machine the oil for the differential or planetary gear unit must be changed first time after 150 operating hours and after it regularly at 1000
operating hour intervals, yet at least twice a year.
02.3.1 Change Differential Gear Unit Oil

It is better to drain direct after driving because the warm
oil runs faster out of the differential. Open the drainage
plug on the bottom of the differential case to drain the oil
out (see figure).
Filling is done through the filler plug and in such a way
that the oil starts to flow back from the filler opening (see
figure). Oil quality and volumes are defined in the maintenance group 00 "Recommended lubricants and fluids".
02.3.2 Change Planetary Gear Units Oil

The oil change interval of the planetary gear units and the
oil grade to be used are the same as in the differential
gear assembly. Before the drain plug of the planetary
gear unit is opened, the wheel must be turned so that the
drain/filling plug will be in the bottom position. Before oil
filling turn the wheel so that the drain/filling plug is in upper position. Fill oil until it starts to flow out of the opened
oil level opening (see figure).
UDRS01.01GB
Power Transmission
2250 Nm
B
1
Differential gear unit
Oil level and fill plug
Drain plug
Planetary gear unit
Drain/fill plug
Oil level plug
Adhere to cleaness when changing the oil. Remember to

check the tightness of threaded plugs after filling.
UDRS01.01GB
Power Transmission
02.3.3 Construction of the Wheel Hub

Wheel (rim)
Wheel nut
and stud
Planetary
wheel hub
Ring gear
Piston return
spring hub
O- ring
Roll pin
Ring gear hub
Piston return spring

Brake housing
Return spring quide
Plug
Brake housing cover

Connector
Plug
Piston
Planetary gear
Lockwire
Hub bearing
Capscrew
Hub seals
Cover
Bearing
Sleeve
Hub nut
Adjusting disc
Sun gear
Seal wear
Locking ring
Sealing of the hub
Hub bearing lock

disc and screw
O- ring
Plug
Screw
O- ring
Piston seals
Stationary disc
Seals
Friction disc
Housing to stationary disc spacer
Cover screw
Figure 3. Construction of the Wheel Hub
UDRS01.01GB
Power Transmission
02.3.4 Torque Chart: Wheel Hub and Brake

Housing
5
7
Figure 4. Wheel Hub and Brake Housing
UDRS01.01GB
No:
Description
Size
Cover-to-planetary spider capscrew
Torque
Lbf.ft
Nm
7/16" - 14
1/2" - 13
60-75
85-115
82-102
116-156
Piston return spring plug
61-75
81-102
Cover and spindle-to-axle housing capscrew - internal mount
5/8" - 11
3/4" - 10
7/8" - 9
7/8" - 14
1" - 12
1-1/4" - 12
180-230
310-400
500-650
500-650
725-950
1700-2200
244-312
450-542
678-881
678-881
938-1288
2305-2983
Cover and spindle-to-axle housing capscrew - external mount
M16 x 2.00
M20 x 2.50
199-258
369-479
270-350
500-650
Planetary spider-to-wheel hub capscrew
3/8" - 16
1/2" - 13
3/4" - 10
35-50
85-115
310-400
48-68
116-156
450-542
Bearing adjusting nut lock plate screw
3/8" - 16
7/16" - 14
35-50
60-75
48-68
81-102
Cover-to-brake housing capscrew
9/16" - 12
M16 x 2.00
M20 x 2.50
125-165
199-258
369-479
169-224
270-350
500-650
Power Transmission
02.3.5 Brake Housing Cover
3
4
9
11
12
10
Figure 5. Braking House Cover

No:
Description
Torque
Lbf.ft
Nm
Hydraulic bleeder
15-20
20-27
Plug
10 min.
14 min.
Housing cover plug
20 min.
27 min.
Coolant fill/level plug

- Sump cooling only
35 min.
47 min.
Plug
10 min.
14 min.
Hydraulic fluid inlet fitting

- Tapered seat
25-31
34-47
Hydraulic fluid inlet fitting

- O-ring
25-35
34-47
Magnetic drain plugsg

- Cooling system
20 min.
27 min.
Coolant input port plugs
60-75
81-102
10
Hydraulic fluid inlet
25-35
34-47
11
Plug
10 min.
14 min.
12
Coolant output port plugs
60-75
81-102
Note! Removing air from the brake housing takes about

ten times more time than by usual brakes. This is due to
the big capacity of the housing.
UDRS01.01GB
10
Power Transmission
02.3.6 Friction Discs for Brake

1
Figure 6. 1 = Stationary disc 2 = Friction disc

Checking the wear of the brake friction discs:
Friction disc diameter
Minimum thickness
13"
3,81 mm
17"
4,31 mm
22"
5,08 mm
02.3.7 Housing Pressure Measuring for Coolant

Fluid
Figure 7. Pressure Level in the Coolant Output is 1 "0.5

Bar
UDRS01.01GB
Power Transmission
11
02.3.8 Tightening of the Wheel Hub
Figure 8. 1 = Adjusting nut
2 = Locking plate
Adjust the wheel hub bearings as follows:

1. Tighten the axle nut to 1355-1630 Nm (1000-1200
lbf.ft) pretorque, so that the bearings are without clearance in the wheel hub.
2. Turn the hub 5-10 turnings in both directions.
3. Open the axle nut half turn and turn the hub 3-5 turnings in both directions.
4. Tighten the axle nut to 745-815 Nm (550-600 lbf.ft)
torque with new bearings and 500-550 Nm (370-407
lbf.ft) with used bearings.
5. Turn the hub 5-6 turnings and check the torque value.
Tighten if needed.
6. Lock the axle nut with the locking plate.
7. If you cannot tighten the locking plate so tighten the
axle nut, until the mounting of the locking plate is possible.
UDRS01.01GB
12
Power Transmission
02.3.9 Instruction for Pinion Shaft Bearings
Figure 9. A = Spacers
B = Stamped number
Disassemble the bearings of the pinion shaft. Measure

the thickness of the spacers located between the faces,
and check the pinion shaft end for the number stamped to
it. If the number is an integer, the value is defined as thousandths of an inch, and if the number is a decimal, the value is defined as hundredths of a millimetre.
Example: +3 or -3 =.003" and +.03 or -.03 =.03 mm.
Calculate the nominal spacer thickness according to the
following examples. Take the value of the number
stamped on the pinion shaft and add it to the old spacer
thickness. The sum is the thickness of the new spacer
when installing the bearings of a new pinion shaft.
Calcuting examples of the thickness of spacer between
pinion shaft bearings
Example 1:
UDRS01.01GB
Thickness of old space
0,76 mm (0.030")
Number stamped on old pinion shaft -2
-0,05 mm (0.002")
Nominal spacer thickness
0,71 mm (0.028")
Number stamped on new pinion shaft +5
+0,13 mm (0.005")
Thickness of new spacer
0,84 mm (0.033")
Power Transmission
13
Example 2
Thickness of old space
0,76 mm (0.030")
Number stamped on old pinion shaft 2
-0,05 mm (0.002")
Nominal spacer thickness
0,81 mm (0.032")
Number stamped on new pinion shaft +5
+0,13 mm (0.005")
Thickness of new spacer
0,94 mm (0.037")
02.3.9.1 Rolling Resistance of Pinton Shaft Bearings
Figure 10. F = Force
A = Sleeve
The rolling resistance is 0.56-5.08 Nm (0.41-3.75 lbf.ft)

with new bearings.
The rolling resistance with used bearings is 1,13-3,39 Nm
(0.83-2.50 lbf.ft).
UDRS01.01GB
14
Power Transmission
02.3.9.2 Torque Value of the Nut on Drive Pinion
Figure 11. 1 = Flange bar

Torque values:
UDRS01.01GB
Thread size
Torque value
7/8" - 20
271 - 373 Nm
1" - 20
407 - 542 Nm
1 1/4" - 12
949- 1220 Nm
1 1/4" - 18
949 - 1220 Nm
1 1/2" - 12
1085 - 1491 Nm
1 1/2" - 18
1085 - 1491 Nm
1 3/4" - 12
1220 - 1627 Nm
2" - 12
1627 - 2034 Nm
Power Transmission
15
02.3.10 Rolling Resistance of Differential

Bearings
Figure 12. 1 = Adjusting Ring

Use the adjusting ring to set the rolling resistance of the
differential bearings to 1.7-3.9 Nm (1.3-3.0 lbf.ft).
Adjust the backlash between the pinion and the crown
wheel to 0.20-0.46 mm (0.008"-0.018") with a used
wheel pair, and to 0.30 mm (0.012") with a new wheel
pair.
UDRS01.01GB
16
UDRS01.01GB
Power Transmission
Power Transmission
17
02.4 Steering Axle

The steering axle is one swing axle pivoted longitudinally
on the machine frame with two pivot-axles (1). The overload control gauge (2) is mounted to the Pivot-axle to
measure the shear force acting on the axle, (optional).
Turning of the wheels is performed by one steering cylinder (3) with one piston rod passing through. Strong stub
axles (4) are mounted with sliding bearings (5) to the axles. Disk brakes (11) for steering axle, (optional).
UDRS01.01GB
18
Power Transmission
C
C
1.2
3
B
A
5
6.7
4
1
8
10
6
5
A-A
B-B
Figure 13. Steering Axle
UDRS01.01GB
Pivot-axle
Overload control gauge (optional)
Cylinder
Axle spindle
Sliding bearing
Sliding ring
Bearing
Axle
Cone bearing
10
Retainer screw
C-C
Power Transmission
19
02.4.1 Installation of Steering Axles

Install the pivot axles and bearing housings into place.
Secure axle retainer screw (1) with a screw locking.
Set the axles into place.
Tighten the fixing screws (2) of the bearing housings to a
tightness of 380 Nm (280 lbf.ft).
Make sure that the axles are in place and that they are
free from backlash tighten up fixing screw (3).
Finally, open the fixing screw (3) 1/4 turns and lock with a
nut (4).
380 Nm
280 ft- lbf
4
3
A -- A
Figure 14. Installation of Steering Axles
UDRS01.01GB
20
Power Transmission
02.4.2 Tightening and Lubrication of Wheel

Bearings
Tightening and lubrication of the wheel hub have to be
performed according to the maintenance table intervals.
D
A
E
B
C
Figure 15. Wheel Hub of the Steering Axle

A
Adjusting nut
Locking plate
Protecting cover
Grease nipple
Locking nut
Measure the continuous rolling resistance, nominal value

is 30-50 Nm ( 22 - 37 lbs / ft ). If the measured rolling resistance differs from the nominal value, remove the protecting cover of the wheel hub and change the tightness
of the bearing adjusting nut, until the continuous bearing
rolling resistance corresponds with the above-mentioned value.
Check by mounting the locking plate between adjustment
and locking nuts, that the shoulder in the axle keyway
prevents the rotation of the locking plate on the axle. Lubricate both sides of the locking plate with grease.
Tighten the locking nut of the bearings to 1000 Nm ( 740
lbs / ft )
UDRS01.01GB
Power Transmission
21
Warning!
After tightening check that the continuous rolling resistance of wheel hub is not more than 50 Nm ( 37 lbs
/ ft ).
Turn the edge of the locking plate over the edge of adjusting nut and locking nut and remount the bearing protecting cover.
Lubricate the wheel bearing pumping through the grease
nipple (D) new recommended grease.
02.4.2.1 Lubrication Points of the Steering Axle
In machine without an optional central lubrication the lubrication points have to be lubricated manually according
to the lubrication table intervals in this manual.
Pump through the grease nipples shown in the figure below enough grease to the lubrication points.
2
3
6
Figure 16. Lubrication Points of the Steering Axle
UDRS01.01GB
22
Power Transmission
02.4.3 Turning Resistance Control of the

Steering Pivot Bearings
The turning resistance of the pivot bearings is
defined by axial torque of the pivot axle cone
bearings. This torque may reduse during the operating hours of the machine, and at worst
cause damages in stub axle. Check the pivot
bearings turning resistance approximately every
2000 operating hours and adjust if needed the
pivot axial torque.
150- 170 Nm
A
A
150- 170 Nm
194 Nm
The axial torque of the pivot axle pivot is correct,

when the starting turning resistance of the pivot
bearings (A) is 150-170 Nm by turning the wheel
hub by the rim (B). The pivot axle pivot must be
released from the lever (C) between cylinder
and stub axle when measuring the turning resistance.
Adjustment of the Turning Resistance
The turning resistance will be adjusted by axial
tightening of the stub axle pivot: install a shim/
shims (D) into the bearing house of the stub axle
pivot, mount the covering of the bearing house
and tighten the fixing nuts to 194 Nm. The starting turning resistance of the stub axle must be
150-170 Nm measured like before. If the resistance is lower than this value adjust the turning
resistance again.
Figure 17.Turning Resistance of the Stubaxle Pivot
UDRS01.01GB
Power Transmission
02.5
23
Wheels
The wheels on the drive- and steering axle are identical

and interchangeable. The drive axle is fitted with double
wheels.
Warning!
It is absolutely necessary that always before tyre
work pressure is removed or reduced to 1 bar
(15PSI).
02.5.1 Tyre Pressure

Driving with underinflated tyres, with lower pressure than
defined in this group, may cause the tyre cords to break,
and the tyre may slip on the rim, causing valve failure.
Over-inflation subjects the tyres to harmful effects of impacts.
Tyre size
Tyre pressure
18.00-25PR40
10 bar
18.00-33PR36
10 bar
Figure 18. Tyre Pressure Mark
UDRS01.01GB
24
Power Transmission
02.5.2 Torque of Wheel Nuts

Before taking the machine into the service, check the
tightness of all wheel nuts with the wheels lifted up.
Check the driving wheels during running-in after 2, 4 and
8 operating hours. If You change one wheel, check the
tightness of the nuts according to the running-in regulations.
305Nm
400Nm
Figure 19. Checking interval for tyre pressure and torque

of the nuts is 250 operating hours.
UDRS01.01GB
Power Transmission
25
02.5.3 Checking of the Rims
Figure 20. Checking of the Rims

During the long operation time the rims can catch fine
cracks and breaks. They can be caused by following reasons:
Some tyres has been empty or the tyre pressure has
been too low while machine has been loaded.
The tyre pressure differs from the base value.
Genuine spare tyres has not been used after the first
installation. The material and strength of non genuine
spare tyres may not meet the requirements of heavy
machines.
Deformation of the rim caused by external hits.
Measures to be taken
We recommend annual checks for cracks for example using magnetic particle test (SFS 3286 or DIN 54131).
This can take place during tyre work, one rim after another. The rims which has been checked can easily be recognized, if You mark them with colour, which is changed
every year.
Warning!
It is absolutely necessary that always before tyre
work pressure is removed or reduced to 1 bar
(15PSI).
UDRS01.01GB
26
Power Transmission
Check Procedure
1. Deflate the tyre, see figure The wheel
2. Dismount the wheel from the machine
3. Dismount the tyre from the rim.
4. Disassemble the loose parts from the rim, see figure
Rim of the wheel. (loose parts are No. 1 + 3 + 6 + 9).
5. Clean the areas shown ---- down to bare metal (rim
part No. 4 + 8), see figure Rim of the wheel and figure
Gutterband and Backband.
6. The cleaned areas of the rim must be magnetic particle tested.
7. If cracks or crack indications appear, grind smoothly
maximum 0,5mm in depth. Then carry through a crack
detection test, using the penetrant method (use solvent based penetrant).
8. If no cracks appear after point 6: Approve the wheel.
9. If no cracks appear after point 7: Approve the wheel.
10.If cracks appear after point 7: Reject the wheel.
11.Approved wheel have to be protected against rust
(painted) .
12.Reassemble the tyre and the loose parts, see figure
Rim of the wheel. Make sure that all loose rim parts are
in the correct place.
13.Reinflate the tyre & remount the wheel
14.Records: When the wheel has been checked, mark
the wheel and record the result.
Warning!
Because of the material and manufacturing method
of a rim, it is not advisable to repair a rim by welding.
To avoid uneven load, check the tyre pressure regularly.
UDRS01.01GB
Power Transmission
27
Figure 21. Rim of the Wheel

1,9
Flange
Lockring driver
Locking
Gutterband
Wheel Driver
Beadseatband
Centerband
Backband
Figure 22. Gutterband and Backband
UDRS01.01GB
28
UDRS01.01GB
Power Transmission
Hydraulic System
03 Hydraulic System
03.1 Operating Principle of Hydraulic System ....................................... 2
03.1.1 Letter and Number Signals in the Hydraulic Diagrams ........... 2
03.1.2 Pumps ..................................................................................... 2
03.1.3 Boom Movement Hydraulic ..................................................... 4
03.1.4 Steering Hydraulics ................................................................. 5
03.1.5 Top-lift Hydraulic ..................................................................... 6
03.1.6 Pre-control Pressure ............................................................... 7
03.1.7 Filtering of Hydraulic Oil .......................................................... 7
03.1.8 Cooling of Hydraulic Oil .......................................................... 7
03.1.9 Clean Hydraulics ..................................................................... 8
03.1.10 Measures to Prevent Pollution of the Hydraulic System ..... 10
03.1.11 Fault Finding for Leakage ................................................... 12
03.1.12 Dismantling Hydraulic Cylinders ......................................... 13
03.2 Hydraulic Brake System .................................................................
03.2.1 General .................................................................................
03.2.2 Brake Hydraulics ...................................................................
03.2.3 Adjusting and Measuring Points for Brake System ...............
03.2.4 Adjusting of Brake Pressure .................................................
03.2.5 Adjusting the Brake Pedal ....................................................
03.2.6 Adjusting the Parking Brake .................................................
15
15
15
17
18
20
21
03.3 Maintenance of Diaphragm Accumulators ...................................

03.3.1 Structure of a Diaphragm Accumulator and Filling Device ...
03.3.2 Checking of the Pressure Accumulators ...............................
03.3.3 Filling Pressure Accumulators with Nitrogen Gas .................
22
22
23
25
03.4 Steering Hydraulic System .............................................................

03.4.1 Steering System ...................................................................
03.4.2 Steering Device ....................................................................
03.4.3 Oil Flow in Load Sensing Steering System ...........................
03.4.4 Fault Diagnosis .....................................................................
27
27
28
29
30
03.5 Hydraulic Components for Basic Machine ................................... 31

03.5.1 Hydraulic Oil Tank Maintenance Points ................................ 32
03.5.2 Pumps ................................................................................... 34
03.6 Hydraulic Components for the Cabin Transfer ............................
03.6.1 Pressure Adjusting for the Load Control Valve .....................
03.6.2 Pressure Relief Valve (Rv) Adjusting ....................................
03.6.3 Oil Changing to the Cabin Transfer Hydraulic ......................
36
37
37
39
03.7 Hydraulic Components for the Spreader ...................................... 40

03.7.1 Adjusting the Spreader Lengthening .................................... 41
UDRS01.01GB
Hydraulic System
03.1
Operating Principle of Hydraulic

System
This chapter describes the operating principle of the hydraulic system in RS2002 Reach Stacker . Item numbers
in the text refer to the hydraulic diagrams. In operating
principle the numbers of components are marked with parenthesis, for example valve (30).
Electronic solenoid valves, which control actuators or
functions, are shown in the diagrams with the letter Y, for
example Y57. The diagrams are attached to section C of
the manual.
03.1.1 Letter and Number Signals in the

Hydraulic Diagrams
03.1.1.1 Pumps
In a diagram, the maximum volume flow produced by a
pump is marked above the picture symbol of the pump,
e.g. 206 l/min.
03.1.1.2 Pipes and Hoses
Pipes and hoses related to valves and/or actuators are
marked, for example, with letters P and T. P1 is a pressure line, T1 is a return line, TP is a drain line, and LS is
an LS signal line. Letters A, B, show connection items for
valves and actuators, to which pipes or hoses are connected.
03.1.1.3 Valves
Pressure adjustment valves are marked in the diagrams
with letters PM and a number. Adjustment values of pressure adjustment valves with a PS marking are described
in table form in that diagram, where said valve is defined.
For example, from PS 4 valve you adjust the pressure to
a numerical value, which is shown in the table as a nominal pressure value of PM 4 measurement point.
Adjustment values of pressure adjustment valves with a
fixed pressure setpoint are shown in the diagram as a numerical value next to the picture symbol of the adjustment
valve.
03.1.2 Pumps
Pumps for work movements and steering are adjustabledisplacement pumps ( 16.1, 16.2, 17.1), connected with
transmission power converter. Running speed is same as
by diesel engine.
UDRS01.01GB
Hydraulic System
Pump for top lift movements and extra speed by boom lifting (17.2) is a vane pump. Brake pump (17.3) is a gear
pump. Inner pumps (17.1 and 16.1) are used for boom lift
and telescope movements. Middlemost (17.2) pump is
used for top lift movements and extra speed by boom lifting with light load.
Outer (16.2) pump is used for steering, boom and telescope movements. Brake pump (17.3) acts as a charging
pump for pressure batteries and as a pump for wet brake
cooling.
Pressure reduction valve PS22 (4) in pressure-battery
charging valve is connected to the brake pump pressure
connection, and the pressure reduction valve acts as the
pump's relief valve.
16.1
17.1
16.2
17.2
17.3
Figure 1. Pumps
16.1
Lift and boom in/out
16.2
Steering, lift and boom in/out
17.1
17.2
Spreader and fast lifting
17.3
Brakes
UDRS01.01GB
Hydraulic System
03.1.3 Boom Movement Hydraulic

03.1.3.1 General
Boom lifting and telescope are controlled by proportional
valves controlling the load sensing main valve units. The
pump pressure is determined by drive pressure (load).
Movement speed in lifting and on telescope are adjusted
after start-up phase by changing the pump's output angle
and by altering the diesel engine's running speed. Simultaneous movement on boom lifting and telescope e.g.
vertical lifting movement can be performed by operating
two functions of the boom control manual controller simultaneously (cross movement lever of boom control).
03.1.3.2 Boom Lifting / Lowering
Boom lifting is performed by means of the single acting
cylinders, because piston arm sides of hoist cylinders
(2.1 and 2.2) are connected to the tank line. Boom lifting
is controlled with proportional valve Y58. Pumps output is
controlled simultaneously for both hoist cylinders. The lifting speed will be adjusted in the beginning stepless by
valve control, by changing pumps' output angles. During
lifting, oil from arm side of hoist cylinders (2.1 and 2.2) is
drained directly through the tank line to the tank. In lifting
lock valves (6.1 and 6.2) do not affect lifting, instead they
let the oil flow unhindered to lifting cylinders (2.1 and 2.2).
Extra speed by boom lifting is acted, when the pressure
of the lifting cylinders is under 90 bar (19.2) B6. Then toplift-pumps' output is controlled by solenoid valve Y87 (26)
direct to hoist cylinder, while free circulation valve Y56
(32) is closed.
Boom lowering is controlled with proportional valve Y57 ,
which let the oil from hoist cylinders (2.1 and 2.2) through
main valve (30) to the tank, and at the same time adjust
lowering speed steplessly. Boom hoist cylinders are
equipped with lock valves (6.1 and 6.2 ), which are
opened with a hydraulic control command. Boom is lowered because of load and boom weight, so pump output
is not needed for the lowering movement. Lowering
speed is slowed by limit electric adjusting value. When
the boom is lowered, there is formed underpressure at
arm sides of hoist cylinders (2.1 and 2.2), which sucks oil
directly from the tankline to the cylinder arm side.
Pressure at piston side of the lifting cylinder is measured
by pressure transmitter (19.2) B6, and on the basis of
pressure data it sends, electronic control reduces flow of
return oil from lifting cylinders (2.1 and (2.2) on heavy
loads through valve (30) to the tank. It tries, as much as
possible, to electronically adjust lowering speed to be
equal on all loads.
UDRS01.01GB
Hydraulic System
03.1.3.3 Boom Extend / Retract

Boom extend is controlled by proportional valves Y51,
which are used to guide the volume flow produced by the
pumps to the piston side of the boom's telescope cylinder
(3) through valve (30) A1-port. Oil is drained from the arm
side through B1-gate of valve to tank. Lifting speed is adjusted steplessly with valve controls, by changing the
pumps' output angles.
Boom retract is controlled with proportional valve Y52,
which is used to guide oil's volume flow to the piston rodder side of the boom's telescope cylinder (3) through
valve (30) B1-port. At the same time telescope's lock
valve (7) is opened, and oil is drained from the piston side
to the tank through the main valve (30) through valve (30)
B1-port to tank. Adjustment of movement speed is done
steplessly with the joystick.
03.1.4 Steering Hydraulics

When machine steering is used, the volume flow produced by the pump (16.2) goes to the priority valves (27).
In the priority valve the volume flow is divided into two, primarily for use of the steering device (23) and mini steering control valve (36) and secondarily for use of lifting and
telescoping valve (30).
Steering speed is determined by turning speed of the
steering wheel, by higher speed the priority valve (27) directs stronger flow to the steering cylinders (1).
System is load-sensitive. The load (steering cylinder's
pressure) transmits an LS signal to the pump's adjuster,
which adjusts pump output as necessary. The LS signal
is also transmitted to a priority valve (27), which guides oil
flow to be used by steering. Steering speed and pressure
are determined by adjusting pump output according to the
LS signal received by the steering device. When turning
speed is increased, the priority valve guides a bigger volume flow through the steering device to the steering cylinders ( 1 ).
Steering circuit is equipped with relief valves which protect it from outside shocks. The relief valves are located
in a relief valve block in connection with the steering device (23). Maximum pressure going to steering device
(23) mini steering control valve (36) is limited with LS-signal's pressure reduction valve adjustment of the priority
valve (27).
UDRS01.01GB
Hydraulic System
03.1.5 Top-lift Hydraulic

03.1.5.1 General
Top-lift movements are performed by solenoid valves,
some of them are mounted on the top of the boom and
some on the top-lift.
Pressure to the boom upper end is directed through one
extra pressure line from the top-lift pump (17.2) by closing
the free circulation from valve Y56 (32), which is switched
on always, when one of the top-lift movements is in function. Return oil into the tank is flowing through one extra
tank line. In this line is mounted one 5 bar non-return
valve to prevent the draining of the lenghtening cylinders
and to keep the back edge of the top-lift allways lower
than the front edge.
03.1.5.2 Longitudinal Tilting
In normal function the longitudinal tilting of top-lift is in so
called reducing position (Y63 switched on), the top-lift is
positioned because of the earth gravity in horizontal position and the movements for-/backwards are reduced with
throttles (12.3 and 12.4). With a reversible locking switch
the current can be switched off in solenoid Y63, the toplift is locked in respect to the boom. It is used specially by
turning the top-lift/container in longitudinal position,
where free movements can be harmful. In this situation
the top-lift will be tilted by means of one special longitudinal tilting switches, which are controlling solenoidvalve
Y65a/b. The tilting speed can be adjusted by throttle
valves (12.1 and 12.2). Shock valves 175 bar (21.1 and
21.2) are mounted in the cylinders.
03.1.5.3 Rotation Motor
Regulating valve Y59 (9) is a proportional valve, which
makes the stepless adjustment of the rotation speed possible. Rotation circuit is equipped with a 200 bar shock
valve (8), which limits the rotation moment to given maximum value and specifies on the other hand the maximum
retarding by stopping to prevent the overloading of the rotation devices. Rotation engine is one slow hydraulic engine, which is mounted in the gear reducer. Between
engine and transmission is one plate-compressor brake.
The brake will be opened automatically by throttle check
valve (13.1) and closed, when the rotation movement is
stopped.
UDRS01.01GB
Hydraulic System
03.1.5.4 Use of the Twistlocks

Control by solenoid valve Y71a/b and closed / open-position of the twistlocks is secured by non-return valves
(32.1 and 32.2).
03.1.5.5 Side Shift
Control by solenoid valve Y62a/b. Motion speed is adjusted by fixed throttles (38.1 and 38.2) and the circuit is
equipped with shock valves (8.1).
03.1.5.6 Adjustment of Gripping Length
Control by solenoid valves (Y73a/b and Y74a/b). By lenghtening the gripping length the return line will be opened
by non-return valves (33.1 and 33.2).
03.1.5.7 Pile Slope, Optional
Control by solenoid valves (Y73a/b and Y74a/b). By lenghtening the gripping length the return line will be opened
by non-return valves (33.1 and 33.2).
03.1.6 Pre-control Pressure

Pre-control pressure is taken from pressure line of pumps
and pressure is reduced with a pressure reduction valve
(31). This pressure is used as the pre-control pressure of
the direction valve (30) and mini steering control valve
(36).
03.1.7 Filtering of Hydraulic Oil

Filtering is performed by full flow return filters (15). Absolute filtering value is 10 m. Filters are equipped with 1
bar electrical pressure-difference sensor and signal light
in the cabin and with one 1,5 bar by-pass valve. The sensor is in function only in temperatures over 20C to prevent the malfunction signals because of the viscosity
changes in low temperatures.
The main pump can be optionally equipped with a pressure filter (53) with 10 m filtering value and a visual indicator.
03.1.8 Cooling of Hydraulic Oil

Oil cooler (18) is equipped with electrical fan controlled by
thermostat ( 50C). The cooler is ptotected against pressure shocks with shock valve of 5 bar.
UDRS01.01GB
Hydraulic System
03.1.9 Clean Hydraulics

Hydraulic systems are extremely sensitive to impurities a hydraulic system is just as sensitive as a diesel engine's
fuel system, with its pumps, filters and lines.
It is therefore extremely important that hydraulic systems
are kept clean and free from impurities. A clean system
means that there are no impurities in the system, whether
it be in the hydraulic fluid, component parts of the system
or hydraulic lines and hoses.
By impurity, we refer to everything and anything that is
not intended to be in the system:
solid particles such as dust, grit, threads of cotton
waste, flakes of rubber from hoses or seals, etc.
liquids
gasses
03.1.9.1 Possible Sources of Impurity
Existing impurities
- Casting sand, welding cinder, dust, water, etc., from
components, hydraulic lines and hoses.
Generated impurities
- Scaling. When particles that come between two
moving surfaces attach themselves to one of the
surfaces and thereafter act as a cutting surface to
the opposite surface where it cuts or grinds off material. The newly formed particles then harden and
cause even more wear and tear as they circulate in
the system.
- Erosion
- Cutting or "cold welding"
- Cavitation, insufficient flow to pump
- Corrosion that generates particles
- Fatigue/wear and tear that generates particles
Accidentally added impurities
- During repair operations
UDRS01.01GB
Hydraulic System
- As a result of topping up with impure hydraulic fluid

Penetrative impurities
- Penetration via breather air to the hydraulic tank
- Penetration via the piston rod's lubricating film
- Penetration through poorly sealed inspection hatches
- Condensation
- Penetration via rod seals
03.1.9.2 Solid Particles
It is possible to see a particle of 40 in size with the naked eye, but not one of 10 .. (1 = 1/1000 mm).
By comparison, a strand of human hair is approx. 70
thick. The smallest particles are less than 25 in size and
are not visible to the naked eye.
It is not, therefore, possible to judge, with the naked eye,
whether or not hydraulic fluid is sufficiently clean! A particle count using special machinery or magnification equipment must be made to establish the degree of impurity.
Solid impurities in hydraulic systems cause many different types of problem. Large quantities of impurity dramatically reduce the operative life span of the system.
Hydraulic components break down as a result of internal
wear. Particle accumulation can cause the check valves
and servo valves to jam, which may lead to movement
problems. Some movement might not work, or movement
could be slow or in the wrong direction.
03.1.9.3 Gasses
The most common gas that occurs as an impurity in a hydraulic system is air. Unlike fluids, gasses can be compressed. If air is allowed to enter a hydraulic system, this
compression will be experienced as a "sponginess" of operation, making hydraulic movements difficult to control.
Air in the hydraulic fluid can also cause corrosion damage, particularly when localized, sudden reductions in
pressure, known as cavitation, occur.
03.1.9.4 Liquids
The most common liquid impurity that occurs in a hydraulic system is water, for example, through condensation.
UDRS01.01GB
10
Hydraulic System
This can cause rust to form, resulting in flakes or particles

of rust entering the system. This most commonly occurs
in the tank and those parts that are above the level of the
hydraulic fluid. Such parts can be inside single action cylinders where the complete length of the hydraulic piston
stroke, is seldom or never used. One simple preventive
measure for such parts is to regularly run all hydraulic
functions to their end positions so that the whole of the
cylinders are lubricated.
03.1.10 Measures to Prevent Pollution of the

Hydraulic System
03.1.10.1 When Changing Attachments
Many machines have attachments that can be changed,
which also means that hydraulic lines and hoses must be
loosened and switched over. This entails a major risk of
impurities penetrating into the system.
Always clean the connection point extremely thoroughly before disconnecting
If possible, use quick release connectors fitted with a
non-return valve. This will then reduce the risk of impurities entering the system and fluid being spilt
Clean the connectors extremely thoroughly before
making the connection. Make sure that no impurities
are forced into the connectors themselves.
03.1.10.2 When the System is Operating
All protruding hydraulic components, such as hydraulic
piston rods, are at considerable risk from both mechanical damage and impurities. Due to the fact that the level
of hydraulic fluid in the tank varies, the tank will "breath"
through the breather filter and if the level becomes too
low, the hydraulic pump will fill the system with air.
Be extremely careful with hydraulic piston rods so as
to avoid physical damage to them
Regularly empty condensation water from the hydraulic tank
Make sure that the fluid level in the hydraulic tank is always right level
Make sure that all filters in the system function correctly. Regularly replace filter elements, in accordance
with the machine's lubrication chart
UDRS01.01GB
Hydraulic System
11
Regularly check the wiper and rod seals and replace

them as required
03.1.10.3 Storage and Topping up of Hydraulic Fluid
Be particularly careful when topping up hydraulic fluid
- carelessness is one of the major causes of impurities
entering the system
Store drums, cans and funnels in as clean conditions
as possible, for example, under a tarpaulin and not directly on the floor.
Handle drums, cans and funnels with care and clean
them as necessary
Store drums of hydraulic fluid horizontally so that
bungs and taps are below the fluid level, which will reduce the risk of impurities and humid air entering the
drum.
Always top-up hydraulic fluid through a clean strainer,
preferably through a filter, using a top-up pump.
Never use the very last of the fluid in the drum. This
could contain water and other impurities, depending
on the number of times that the drum has been
opened.
Hydraulic oil provided by oil companies in closed containers is not clean enough to be used in the hydraulic
system as is. The oil must be cleaned/filtered before it
can be added to the machine's hydraulic oil tank.
03.1.10.4 Repairs and Service
As soon as a hydraulic system is opened, there is always
a great risk of impurities entering the system
Thoroughly clean the around the area of the system on
which work is to be carried out
Isolate the area where work is to be carried out with
the help of, for example, clean protective plastic sheeting
Do not open sensitive components out in the field, replace the complete component instead
Immediately insert protective plugs in all open connections
UDRS01.01GB
12
Hydraulic System
Make sure that exchange components are thoroughly

clean
Carry out the repair as soon as possible
After dismounting, clean all parts
If a serious breakdown has occurred, for example, if a
pump or hydraulic motor has seized, metal particles
may have been spread and polluted the entire system.
In such cases, it is extremely important to carefully filter or replace the hydraulic fluid. Under all such circumstances, the system's filters must always be replaced
Never fit components where the protective plugs have
fallen out - impurities may have entered the system.
Warning!
If there is the slightest doubt about the purity of the
hydraulic fluid - send a fluid sample to the manufacturer of the fluid.
03.1.11 Fault Finding for Leakage

All fault finding should take place with the minimum hydraulic pressure required to actually discover the leakage. High pressure will tighten all seals and make it
more difficult to discover any leakage.
Check extremely carefully where the leakage comes
from before taking any action. It may be possible to
stop the leakage without the necessity of costly dismantling.
Check for external leakage
- welds on cylinder ends
- welds on coupling connections
- Leakage between the cylinder pipe and the cylinder
head, could be due to a faulty O ring or damage to
the O ring's sealing surface. Both problems can be
corrected with the cylinder in place.
- Leakage between the cylinder head and the piston
rod, could be due to a damaged piston rod or damaged/worn piston rod seal.
Check for internal leakage
UDRS01.01GB
Hydraulic System
13
- Leakage between the hydraulic piston seal and the

cylinder pipe, due to worn piston seal. Put the cylinder under pressure and check to see if the piston
sinks back.
Warning!
Do not check for leaks with your hand, as even a
small leak could be strong enough to penetrate the
hand. Use a face mask that covers your entire face,
as well as protective clothing and footwear that provide protection against high-pressure liquid sprays.
Always wear these when working near pressurised
hydraulic hoses, pipes, or components.
03.1.12 Dismantling Hydraulic Cylinders

Before dismantling, always check that the piston rod is
free from any remains of paint. Also check to ensure that
there are no burrs or impact damage by the connections
or couplings. Make sure that the chamfer up to the
chrome surface of the piston rod is free from burrs and
any remains of paint.
Loosen the cylinder from its mounting and loosen the
hydraulic connections
Immediately plug the cylinder connections and hoses/
lines.
When the cylinder is opened - observe the highest
possible level of cleanliness! Study the Technical
Handbook to see how respective cylinders are designed and constructed.
03.1.12.1 Check Surfaces
Check the surfaces of seals. Always think about how
the seals function and the type of sealing surfaces that
they have. See the following descriptions:
- O ring grooves internal and external
- piston rod seals in the cylinder head
- sealing groove on the piston
- cylinder pipe surface
- piston rod surface. The piston rod has a chromium
plated surface of 20-50 in thickness. Very minor
damage to this plated surface will not necessarily directly result in leakage
UDRS01.01GB
14
Hydraulic System
- All sliding surfaces (dynamic surfaces). These are

always the most difficult to ensure a tight seal, for
example, cylinder pipe and piston rod.
Warning!
When fitting the cylinder head: Fit the head absolutely straight, preferably by hand. Do not, under any circumstances, hit it with a mallet or hammer. If the
cylinder head is fitted askew the lip of the piston rod
seal can be damaged and any sealing function will be
lost. This applies to all types of piston rod seals.
UDRS01.01GB
Hydraulic System
03.2
15
Hydraulic Brake System
03.2.1 General
The hydraulic brake system consist of hydraulic pump,
charge valve of brake pressure accumulators, brake
pressure accumulators, pedal valve and wet disc brake of
drive axle.
The parking brake is spring-loaded dry disc brake unit on
the cardan shaft, which can be switched on by the operating switch in the cabin.
The system is completely hydraulic and controlled by
charge valve, pressure accumulators and brake pedal
valve. The hydraulic pump fills through the charge valve
the pressure accumulators. When they are filled, the
charge valve leads the pressure of the pump to the hydraulic system.
The pressure accumulators are selected, so that they
make it possible to brake several times, before pressure
in the accumulators falls below the specified pressure limit and the charge valve switches the pump to fill the system. The brake pedal valve controls the hydraulic brake
cylinders in the axle. By adjusting the movement of the
brake pedal the hydraulic pressure to the brake cylinders
can be adjusted.
03.2.2 Brake Hydraulics

Brake hydraulics gets volume flow from the brake pump
(9). The pump gives volume flow to both charging of pressure accumulators of brakes and to cooling of the brakes.
From the pump the oil goes first through a pressure filter
(5) to charge valve of the accumulators, from where it
goes to brake cooling and is distributed evenly to each
brake. From the brakes the cooling oil returns back to the
tank. A thermo bypass valve (18) prevents generation of
excessive cooling pressure inside the brakes, when the
oil is cold.
If pressure in the pressure accumulators has fallen below
about 128bar, accumulators' charge valve charges the
pressure accumulators (8), and when pressure of accumulators is 160bar, the valve switch the pump (9) to free
circulation.
Integrated to the charge valve of accumulators in the
brakes is handbrake valve Y12, which releases handbrake cylinder (2) when it is energized. Then pressure of
the hydraulic oil can squeeze in the spring of handbrake
cylinder (2) and release the handbrake. When Y12 is de-
UDRS01.01GB
16
Hydraulic System
energized, the spring force pushes hydraulic oil from the

cylinder to the tank, and at the same time spring force
causes braking force on the handbrake.
Brake pedal valve (11) gets pressurized hydraulic oil from
pressure accumulators (8) Pressure accumulators are
so-called diaphragm-type accumulators, with volume of
2,8 litres. Pre-filling pressure is nitrogen gas (service
manual instruction).
Installed into the parking brake circuit is one accumulator
(8.1), and installed into the driving brake circuit are three
corresponding accumulators (8.2,8.3,8.4), which are separated from each other with counter valves.
Pressure switch S13 in charge valve (4) is switched on, if
pressure in the accumulator circuit is low (115 bar).
Pressure switch (7) S23 for brake lights is switched on, if
pressure is below 2,5bar.
UDRS01.01GB
Hydraulic System
17
03.2.3 Adjusting and Measuring Points for

Brake System
PM27
PS22
8.4
PM26
8.3
PM21
PM24
8.2
PM22
8.1
S13
PM23
Drive axle
5
Y12
17
18
Figure 2. Adjusting and Measuring Points for Brake

System
5
Pressure filter
8.1-8.4
Pressure accumulators
17
Oil cooler
18
Brake tank
PM21
Pressure measuring for charging pressure
PM22
Pressure measuring for accumulator pressure, handbrake
PM23
Pressure measuring for accumulator pressure, footbrake
PM24
Pressure measuring for brake pressure
PM26
Pressure measuring for handbrake
PM27
Pressure measuring for cooling pressure
PS22
Pressure adjusting for charging pressure
S13
Pressure switch for low brake pressure
Y12
Parking brake valve
Numbering corresponds to the brake hydraulics flowchart.
UDRS01.01GB
18
Hydraulic System
03.2.4 Adjusting of Brake Pressure
PM26
PM26
PM26
PM21
PM22
S13
PM23
Figure 3. Adjusting of Brake Pressure

1. Adjust the pressure adjusting valve PS22 in charging
valve of pressure accumulators full open.
2. Start the engine.
3. Connect the pressure gauges measuring 0-250 bar to
the measuring points PM21 and PM22.
4. Adjust the pressure adjusting valve PS22 to160 bar,
which is the end point of charging and lock the adjusting screw.
5. Check the indication of pressure gauge connected to
measuring point PM21 when the engine is running at
idle. The charging valve of pressure accumulators is
functioning as planned, if the gauge shows 5-10 bar
pressure, when the pressure accumulators are full
charged. When the charging valve is charging the
pressure accumulators, the pressure gauges connected measuring points PM21 and PM22 show the charging pressure of that moment. When the adjusted 160
bar pressure is reached, the pressure gauge connect-
UDRS01.01GB
Hydraulic System
19
ed measuring point PM22 shows 160 bar and the pressure gauge connected measuring point PM21 shows
5-10 bar.
6. Follow the changes in pressure accumulators charged
hydraulic pressure on the pressure gauge connected
in pressure measuring point PM22, when the engine is
running at idle. The charging valve is functioning as
planned, if the gauge shows 123-132 bar, when the
charging valve starts to charge again the pressure accumulators. The starting pressure of charging can not
be adjusted. If the starting pressure is under 123 bar,
please inform the manufacturer of the machine for
pressure cartridge calibration.
UDRS01.01GB
20
Hydraulic System
03.2.5 Adjusting the Brake Pedal
S52
1
2,S23
Figure 4. Brake Pedal
UDRS01.01GB
Brake pedal
Brake pedal valve
Adjusting screw
S23
Braking light switch, 2.0bar
S52
Declutch
Hydraulic System
21
03.2.6 Adjusting the Parking Brake
1
1
2
1
Figure 5. Parking Brake

1
Adjust screw
Release screw of the parking brake
Brake disc
Brake pad
Locknut
Start to adjust switching the parking brake out of function

(pressure in cylinder) by pressing the operating switch.
Make sure, that the pressure accumulators are charged.
Adjust the nut 5 (picture 1) close and switch the parking
brake on by pressing the operating switch (pressure out
of cylinder). Adjust with hook plug spanner the adjusting
screw 1 and close until the brake pads (4) touch the brake
disc (3). After that open the adjusting screw 1 adjusting
1,5 revolutions. Switch the parking brake out of function
(pressure in cylinder) by pressing the operating switch
and then open the nut 5 (picture 2) ending the adjusting
work.
UDRS01.01GB
22
Hydraulic System
03.3
Maintenance of Diaphragm
Accumulators
03.3.1 Structure of a Diaphragm Accumulator

and Filling Device
M28X1.5
SW6
17
5
2
8
1/2
12
11
W24.32x1/13
14
15
13
SW36
16
9
M28X1.5
Figure 6. Diaphragm Accumulator and Filling Device
UDRS01.01GB
Diaphragm accumulator
Sealing ring
Diaphragm
Shut-off valve
Shut-off screw
Bleed valve
Intermediate piece
O-ring
11
Non-return valve
12
Connection to nitrogen bottle
13
High-pressure hose
14
Pressure gauge
15
Shut-off screw
16
Diaphragm accumulator
17
Filling device for diaphragm accumulator
Hydraulic System
23
03.3.2 Checking of the Pressure Accumulators
8.1
8.2
8.3
8.4
Figure 7. Pressure Accumulators

During adjustment and maintenance works of the brake
system you must pay special attention to the operating
condition of the pressure accumulators. If the common
pressure accumulators of the whole system are damaged, the charging valve is operating frequently and the
braking effect is declining rapidly when the engine is
stopped. To ensure planned operation of the braking system, the pressure accumulators should be checked at
least twice a year. The accumulator used in the brake
system is a precharged diaphragm accumulator with a
non-replaceable diaphragm. The precharging pressure of
the brake system pressure accumulators is 100 bar. An
exact measuring of the precharging pressure and possible increasing is described in group KH03-0106.
Check the precharging pressure from the "oil side" as follows:
1. Install a pressure gauge with pressuer area 0-250 bar
to the pressure measuring point PM22.
2. Start the engine and run at idle speed for a while to increase the pressure reading to
150 bar. Stop the engine.
3. Engage the parking brake. If the pressure gauge
shows a reading at the measuring point PM22 still after
several engagings of the parking brake, the accumulator diaphgrams are OK.
4. Checking of the pressure accumulators of the circuits
after non-return valves:
UDRS01.01GB
24
Hydraulic System
Install a pressure gauge to the pressure measuring point

PM24. Depress the brake pedal several times while observing the pressure gauge reading. The pressure drops
when the brakes are applied until the pressure drops very
quickly close to zero. The pressure reading before this
sudden dropping is the precharging pressure of the accumulator to be checked.
UDRS01.01GB
Hydraulic System
25
03.3.3 Filling Pressure Accumulators with

Nitrogen Gas
Diaphragm accumulators are precharged with nitrogen
gas to the required precharging pressure before installation. The precharging pressure for each accumulator is
specified in the hydraulic flowcharts in the operation and
maintenance manuals of the machine. The precharging
pressures specified by the manufactured must absolutely
be observed.
03.3.3.1 Filling
By measuring the hydraulic accumulator make sure that
there is no hydraulic pressure in the system. The oil must
flow free out of the hydraulic accumulator. If there is no
free outflow, the filling pressure may be too low. To empty
the pressure in the hydraulic system, pump the brake
pedal many times.
A filling device is used for precharging pressure accumulators and checking the precharging pressure. First, remove the cap and the sealing lacquer on the shut-off
screw. Clean the sealing surface in the end of the accumulator, and the external thread, and loosen the shut-off
screw just a little with an allen key.
Connect the filling device to the pressure accumulator
and the hose to a nitrogen gas bottle. Make sure that the
O-ring is properly positioned between the filling device
and the accumulator sealing surface. Using a square key,
open the pressure accumulator shut-off screw with the
aid of the intermediate piece in the filling device. Open
just enough to get the precharge pressure reading in the
pressure gauge.
If the precharging pressure is too high, you can lower it to
the specified value by opening the bleed valve of the filling device. Note that the bleed valve must be closed to
check the correct reading.
03.3.3.2 Note !
As the precharging pressure changes with the temperature, recheck the accumulator precharging pressure approximately 2 minutes after filling. Correct possible
deviations from the specified value.
Tighten the pressure accumulator shut-off screw to 25
Nm, and close the nitrogen gas bottle valve. Open the
bleed valve of the filling device to let out the gas in the filling device.
UDRS01.01GB
26
Hydraulic System
Remove the filling device, and check the shut-off valve for
tightness using, for example, soap liquid. Repair possible
leaks at once as it may cause damage to the pressure accumulator diaphragm. Seal the shut-off screw with sealing lacquer and install the shut-off screw cap. The
pressure accumulator is now ready to be installed.
Warning!
Oxygen or air should never be used for precharging.
Danger of explosion!
UDRS01.01GB
Hydraulic System
03.4
27
Steering Hydraulic System
03.4.1 Steering System

Steering system has the following characteristics:
1. A defined amount of hydraulic oil passes from steering
device to the steering cylinder, whereby the wheels
turn according to the turning of the steering wheel.
2. The required steering power remains low in all circumtances.
3. The system incorporates no mechanical connections
between the steering wheel and the road wheels.
4. Load sensing.
In steering system with load sensing both load sensing
and working hydraulics pressure can be produced with a
common pump. Load sensing device have an extra connection for load sensing (LS) so that the load sensing signals can be transferred from the steering device to the
priority valve. The LS connection is open directly into the
tank when steering is in the middle position. The structure
of the steering system is described on the following page.
The operation of the system is as follows:
When the steering wheel is turned, the inner rotary sleeve
(5) turns and shuts off free circulation of oil. It directs the
incoming oil to the other side of the metering pump, depending on the turning direction of the steering wheel. As
the metering pump has a constant flow volume, the rotator (1) makes it possible to have a precise amount of oil
flow to the steering cylinder. The rotator is mechanically
connected to the outer rotary sleeve (6), whereby the
turning of the rotator also moves the rotary sleeve.
The rotary sleeve shuts off the oil flow to the metering
pump, when the rotator has turned the same amount as
the steering wheel. Thus, the amount of oil corresponding
to the turning of the steering wheel can be accurately determined. Steering responds already to a relative small
turning of the steering wheel, corresponding to a 2 to end
from turning rotary sleeve.
When this turning is 6 as an average, the valve is completely open. The turning of the rotary sleeves is mechanically restricted in both directions to an average of 8 from
the middle position. The oil returning from the steering
cylinders is directed through the tank channel back into
the tank.
UDRS01.01GB
28
Hydraulic System
03.4.2 Steering Device
Figure 8. Steering Device
UDRS01.01GB
Rotor
Centering springs
Body
Ball-valve
Inner control spool
Outer control spool
Drive-shaft
Stator
LS
Load-sensing-line
Hydraulic System
29
03.4.3 Oil Flow in Load Sensing Steering

System
Figure 9. Load Sensing Steering System

A
Middle position - Oil flow situation
Steering right - Oil flow
Oil to priority valve
Oil to steering divice
Oil in load sensing line
Oil in steering cylinder
Oil not flowing
UDRS01.01GB
30
Hydraulic System
Oil to working hydraulics
Oil to tank connection
Oil in intake pipe line
Load sensing LS-line connected to tank
03.4.4 Fault Diagnosis

Possible disturbances in steering system operation, and
instructions for their removal.
1. Slow steering
a) Overpressure valve or steering device ball partly
open because of dirt and causing constant bypass flow
of oil.
b) Clamped pressure hose resticking oil flow.
2. Lack of steering power
a) Insufficient amount of oil in tank, due to leaking.
b) As in 1a above.
3. Jerky or sticky steering
a) Clamped hose causing overpressure in return side.
4. Motoric operation (self-steering)
a) Dirt in oil causing steering device rotary sleeves to
stick. Clean the system troughly and fill with new clean
oil.
UDRS01.01GB
Hydraulic System
03.5
31
Hydraulic Components for Basic

Machine
18
32
36
PM2
16
PM1
29
27
PM5
30
37
31, PM8
26, PM4
PM3
17
15
Figure 10. Hydraulic Components for Basic Machine

1
Hydraulic oil tank
15
Return filter
16
Pumps
17
Pumps
18
Oil cooler
27
Priority valve
26
Directional control valve
29
Pressure accumulator
30
Directional control valve M400LS
31
Pressure reducing valve
32
Pressure release- free circulation valve
36
Directional control valve, miniratti (optional)
37
Pressure filtres (optional)
PM
Pressure measuring
UDRS01.01GB
32
Hydraulic System
03.5.1 Hydraulic Oil Tank Maintenance Points
4
2
3
10
11
Figure 11. Hydraulic Oil Tank Maintenance Points
UDRS01.01GB
Hydraulic oil return filter
Magnet rod. Clean when change filter
Hydraulic oil filling cap. Do not open plug when the engine is
running
Hydraulic oil tank breather
Sight glass/ oil temperature
Hydraulic oil tank draining plug
Brake hydraulic oil tank draining plug
Brake hydraulic oil filling cap
Filter indicator, hydraulic system (S239A)
10
Hydraulic oil cooler
11
Brake hydraulic oil cooler
12
Filter indicator, brake system (S239B)
Hydraulic System
33
Warning!
Do not open the plug when the engine is running!
Hydraulic oil level is correct when it is between the
min. and max. lines. Retract the telescope and lower
the boom before checking hydraulic oil level.
UDRS01.01GB
34
Hydraulic System
03.5.2 Pumps
16.1
17.1
PM1
16.2
17.2
17.3
PM2
Figure 12. Pumps
UDRS01.01GB
16.1
16.2
Steering, lift and boom in/out
17.1
17.2
Spreader and fast lifting
17.3
Brakes
PM1
PM2
PM3
PM3
Hydraulic System
35
03.5.2.1 Adjusting Pressure of Adjustable

Displacement Pump
1. Connect a pressure gauge to pressure measurement
point (PM) of pump to be adjusted.
2. Open safety valve A.
3. Twist stand-by controller B closed.
4. Start the engine.
5. Twist safety valve A to requested adjustment value.
Open stand-by controller B, until yo reach the correct adjustment value, 30 bar.
B
A
Figure 13. Adjustable Displacement Pump
UDRS01.01GB
36
Hydraulic System
03.6
S97A,S97B
Hydraulic Components for the

Cabin Transfer
S97b
3
Y96a
Y96b
2
Pm1
5
A
B
Rv
S296
S297
Figure 14. Hydraulic Components of the Cabin Transfer
UDRS01.01GB
Pm1
Pressure measuring
Rv
Relief valve
S97a
Cabin transfer forwards
S97b
Cabin transfer backwards
S296
Cabin transfer forwards
S297
Cabin transfer backwards
S97A,S97B
Inductive limit switchs for cabin transfer
Cabin transfer cylinder
Locking valve
Pump and tank
Filling, V=2.8L
Hydraulic System
37
03.6.1 Pressure Adjusting for the Load Control

Valve
1. Open locking anticlockwise.
2. Turn the adjusting screw (5) fully closed anticlocwise.
3. Adjust 3 turns clockwise.
4. Lock the adjusting screw (5).
Working pressure for cabin movements:
Forward Pm1 90bar
Rearward Pm1 40bar
03.6.2 Pressure Relief Valve (Rv) Adjusting

1. Connect the pressure gauge (min.150bar) to the
measuring point Pm1.
2. Take off the sockets (6) from the directional valve.
3. Adjust pressure to 120bar.
4. Take off the pressure gauge and put the sockets on.
UDRS01.01GB
38
Hydraulic System
60
60
96a
96b
Pm1
120
Rv
5
Rv
Figure 15. Hydraulic Schema of the Cabin Transfer
UDRS01.01GB
Pm1
Pressure measuring
Rv
Relief valve
Cabin transfer hydraulic cylinder
Locking valve
Pump unit
Adjusting screw
Socket
Hydraulic System
39
03.6.3 Oil Changing to the Cabin Transfer

Hydraulic
1. Move the cabin to the rear position (the cylinder full
stroke in).
2. Open the pipe (A) from the pressure side of the pump
and drain the tank by using the
pump carefully.
Warning!
Do not use the pump without oil in any circumstances!
3. Plug the pipe (A) from the pressure side of the pump
and fill the tank (2,8l) through filling
cap (5).
4. Move the cabin forwards and backwards 1-2 times and
check oil quantity.
UDRS01.01GB
40
Hydraulic System
03.7
Hydraulic Components for the

Spreader
Figure 16. Hydraulic Components for the Spreader
UDRS01.01GB
1.1 1.2
Cylinders for sideshifting
2.1 2.2
Cylinders for spreader lengthening/shortening
3.1 3.2
Cylinders for twistlocks
4.1
Valve for sideshifting
4.2 4.3 4.4
Valve block for twistlocks and spreader lengthening/

shortening
32.1 32.2
Counterbalance valves of twistlocks
Hydraulic System
41
03.7.1 Adjusting the Spreader Lengthening

4.2
4.3
4.4
1
Figure 17. Valves of Spreader Lengthening / Shortening
and Twistlocks
1
Adjust screw
33.1
Locking valve, left
33.2
Locking valve, right
4.2
Spreader lengthening/shortening, left
4.3
Spreader lengthening/shortening, right
4.4
Twistlocks
PM41
Pressure measuring
PM33
Pressure measuring
Counterbalance Valves Setting (100bar) :

- Open locking anticlockwise.
- Turn screw fully open anticlockwise. (1)
- Adjust 3 turns clockwise. (1)
- Lock the adjust screw.
Locking valve (33.1, 33.2) opening pressure after adjusting is 100bar.
Pilot ratio is 3:1
UDRS01.01GB
42
UDRS01.01GB
Hydraulic System
Electric Systems
04 Electric Systems
04.1 Electrical System General ................................................................ 2
04.1.1 Safety ...................................................................................... 2
04.2 Maintenance of Electric System ......................................................
04.2.1 Batteries ..................................................................................
04.2.2 Alternator ................................................................................
04.2.3 Welding Machine ....................................................................
04.2.4 Locating Electric Faults ...........................................................
04.2.5 Electric Diagram's Reading Order ..........................................
3
3
4
5
6
7
04.3 Reach Stacker's CAN-based Control System ................................ 8

04.3.1 System Structure .................................................................... 8
04.3.2 Multi-function Display A80 .................................................... 11
04.3.3 Alarms ................................................................................... 16
04.3.4 Tests ..................................................................................... 18
04.3.5 Control Module A81 .............................................................. 20
04.3.6 Control Module A82 .............................................................. 23
04.3.7 Control Module A83 .............................................................. 26
04.3.8 Control Module A84 .............................................................. 29
04.3.9 Engine Control ...................................................................... 31
04.3.10 Control of Boom and Spreader ........................................... 35
04.3.11 Monitoring of Stability ......................................................... 46
04.3.12 Load Weighing .................................................................... 46
04.3.13 Calibrations ......................................................................... 48
04.3.14 Functions of By-pass and Emergency Switches ................. 55
04.3.15 Bus Errors ........................................................................... 56
04.3.16 Replacement of a Module ................................................... 58
04.4 Electric Equipment for the Power Unit Scania DI12 EDC/PDE ... 59
04.5 Electric Equipment for the Power Unit .......................................... 60
04.6 Electrical Equipment in the Frame ................................................ 61
UDRS01.01GB
Electric Systems
04.1
Electrical System General
The nominal voltage of the electric system is 24 VDC.

The electric system follows the 1-conductor principle,
where the frame acts as the other conductor.
To make detecting of possible malfunctions and troubleshooting easier, all leads are numbered according to the
markings specified in the electric diagrams.
04.1.1 Safety
The insulation material of the conductors is oil resistant.
Wiring may not, however, be in contact with oils or other
solvent fluids.
Close to the engine and other hot surfaces, make sure
that the cable insulations are not damaged of the heat.
Replace cables with damaged insulations immediately.
Warning!
Blowing of a fuse always indicates a fault in the electric system. Repalr the fault prior to fitting a new fuse.
Warning!
The new fuse must absolutely have the same specification as the previous one!
The size and locations of fuses are specified in the wiring
diagram.
Warning!
The control and alarm system of the machine protects it and gives warnings to the driver and the environment. Don't make any alterations in the electric
system without manufacturer's permission.
The alterations in the electric system may deteriorate
the safety of the machine and will release the manufacturer from all warranty liabilities.
UDRS01.01GB
Electric Systems
04.2
Maintenance of Electric System
04.2.1 Batteries
G1
Figure 1. Batteries
The 24V electric system of the stacker is provided with
two 12V lead-acid batteries connected in series. Regular
maintenance of the batteries lengthens their life.
04.2.1.1 Checking and Service Instructions for
Batteries:
Check that the batteries are properly fastened in their
mountings.
Keep the outside of the batteries clean.
Clean away possible dirt and oxidation from the battery terminal connections.
When connecting the cable lugs to the battery terminals, observe that the positive cable is always connected to the positive terminal. Incorrect connecting
damages the battery and the electric equipment.
Connect the negative (frame) cable to the negative
battery terminal after connecting the positive cable.
When connecting the cable lugs, take care not damage the battery terminals or the lugs, which are made
of soft material. After connecting, smear the cable with
protective grease
Check the electrolyte level in the battery cells at 250 h
intervals. The level should be approx. 1 cm above the
plates. Check also that the vent holes in the battery
caps are clear.
Use a hydrometer to check the state of charge of the
battery, if the electric system of the machine has malfunctions. The specific gravity of the electrolyte in a ful-
UDRS01.01GB
Electric Systems
ly charged battery is approx. 1.280 and approx. 1.150

in a partially charged battery.
If the specific gravity of the electrolyte is approx. 1.150
it will freeze at approx. -10C.
Warning!
Do not leave a partially charged battery where it may
freeze.
04.2.2 Alternator
Figure 2. Alternator
An alternator has been chosen to supply the electrical energy due to its long life and small need for service. The
bearing houses are sealed and they should be repacked
with grease only at major overhauls.
Due to the construction of the alternator the following precautions must be kept in mind, since severe damage
might be otherwise caused to the electrical equipment.
UDRS01.01GB
Electric Systems
04.2.2.1 Warnings
When connecting the battery to the circuit, always
make sure that the battery and the alternator are
grounded by terminals of same polarity.
Never short circuit or ground the terminals of the alternator or the regulator.
Never run the alternator at "no load" and therefore
make sure all connections are clean and tight.
When the battery is in the circuit and you have to connect a charger to the circuit, make sure that terminals
of similar polarity are connected.
Do not switch off the main electrical switch with engine
running.
When repairing the vehicle by electric welding, all alternator and regulator terminals must be disconnected.
Warning!
Repairs and adjustments of the alternator and the
regulator should only be carried out by professional
personnel.
04.2.3 Welding Machine

Before starting to weld:
Disconnect the negative battery cable from frame.
Disconnect the alternator cables at their terminals on
the alternator.
Disconnect the electronic control modul of engine.
Connect the ground cable of the welding machine as
close to the welding point as possible. This is prevent
the welding current from flowing through and damaging the bearing surfaces of parts and components.
UDRS01.01GB
Electric Systems
04.2.4 Locating Electric Faults

Check the fuse if an electric function of the machine is not
working. If the fuse is not blown, check the circuit of the
function with the aid of the wiring diagram.
If the fuse is blown, turn all electric switches open, and replace the blown fuse with a new one of the same amperage. Switch the electric functions on one by one to
determine which of the functions causes the fuse to blow.
When the fault has been located, switch off the machine's
electric circuit with the main switch or the ignition key
while carrying out the repairs.
If the fault is in the starter motor or alternator circuits, disconnect the negative cable between the battery and the
frame while carrying out the repairs.
Warning!
When the machine is used, the frame cables of the
cabin, the engine, and the frame structures must be
connected. Insufficient ground connections cause
fire hazards !
UDRS01.01GB
Electric Systems
04.2.5 Electric Diagram's Reading Order

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Nimi
Title
T T ASIAKIRJAA EI SAA ILMAN SUOSTUMUSTAMME KOPIOIDA, ESITT
TAI LUOVUTTAA KOLMANNELLE HENKIL LLE EIK K YTT MUIHIN KUIN
MEID N SALLIMIIMME TARKOITUKSIIN
IT IS FORBIDDEN TO COPY THIS DOCUMENT OR REPRODUCE IT OR SURREND ER IT TO A THIRD PARTY. IT MUST NOT BE USED FOR ANY OTHER
PURPOSES THAN THOSE APPROVED BY US.
El. schema
Piirustus n:o
Drawing n:o
T5656860
Muutos
Rev.
Lehti
Sheet
16
Muutosehdotuksista on heti ilmoitettava piirustuskonttoriin.
Figure 3. Electric Diagrams Reading Order

1
Page number of electric diagram
Drawing number of electic diagram
X-coordinate on the margin
Because there are no wire numbers on card, L3 is a line

edentification with a direct relation to the corresponding line
identifications on the next page.
Device identification
Connector number and pole number
Wire number
Pole number on the device
Y-coordinate on the margin
10
Wire continues on page 3 of the el. diagram, coordinate position 27B.
11
Grounding on the frame
UDRS01.01GB
Electric Systems
04.3
Reach Stacker's CAN-based

Control System
04.3.1 System Structure

The system consists of control modules located in various
parts of the machine. They are located in accordance with
actuators or sensors, A81 in the frame's electric box, A82
and A84 in the cabin's electric box, A83 in the boom end
and display module A80 in the left dashboard. The modules are connected to each other with a CAN bus, through
which communication between the modules takes place.
(CAN=Controller Area Network) A display module is used
as the user interface. Each module has its own application program.
*
A96 (ECU)
*
*
K19 K33 K17
35
1
7
9 113
15 VASTUKSET
35
1
7
9 11 3
15
46
2
18
0 12
14
16
46
2
18
0 12
14
16
+5V
REF OUT
SY T T
SUMMERI
KIN
9 40
8
41
7
42
4 43
50
8
7 51
53
6 54
4
5
52
55
3 56
1
2
57
F1
F13 F1
4 F1
5
F1F1
8 F2
9 0 F2
F21
2
1
7
3
5
4
6
1
3
2
4
5
6
7
9
6
5
4
2
3
1
9
8
7
6
5
4
3
2
1
48
0
44
21
443
45
44
67
44
89
50
55
12
53
5
4
55
56
57
17
18 2
16
3
15 4
14
13 5
12 7
6
9
10
11 8
8 1
9
2
7 43
6
5 6
4
5
3 7
2
1 9
8
182
1
4
15
16
37
13
6
5
14
119
7
20
87
1
9
5 16
5
4
2
3
4
7
8
3
1
2
9
F2F2
6 F2
7 8 F3
F29 F3
0
F3
1 2F33
XR1
XSR
X44
XPO
SX1
X191
XR2
XR3
XHR
X115
XKTS X22
X32
X37
XPC
A80
A84
A82
A81
A83
Figure 4. Location of modules and wiring of CAN-bus

Modules control functions of the machine as follows:
A81 Hydraulics module
Boom lifting/lowering
Lock valves of lowering
Retardation of lowering
Quick movement of lifting
oom movements out/in
Spreader rotation
UDRS01.01GB
Electric Systems
dditional limits of spreader rotation

Spreader indicator lights
Cabin transfer
Electric gas
Coolant level
A82 Cabin module
Monitoring of engine
Monitoring of stability
Automatic changer (option)
Mini-steering wheel (option)
Load display (option)
Pressure weighing, (option)
Vertical lifting/lowering (option)
Idling stop (option)
A83 Spreader module
Spreader rotation
Limits of rotation
Spreader extension/shortening
Tilting forward/backward
Locking of tilting
Sideshift
Automatic gripping of spreader
Movements of shafts manually
Container contact
End dampening of boom movements
Spreader indicator lights
Active tilting (option)
A84 Input module
Cabin's switch data has been collected to the input module. (Module does not contain a program).
A80 Display module
Driver's displays, gauges
Alarms
Error messages
UDRS01.01GB
10
Electric Systems
Settings of functions
- Automatic gripping on/off
- Automatic changer on/off
aintenance displays
Calibrations
- Stability
- Gas pedal
- Load weighing
Maintenance personnel can see the statuses of module
outputs and inputs on the maintenance displays, so separate measurements are not needed. From the calibration displays you perform, depending on the options,
calibration of gas pedal, stability and load weighing.
04.3.1.1 General
When you switch on the power to the machine, the display will show the type of the machine (e.g. DRS4531-S5)
for 1 second. After this the display will show the basic display and you can start the machine. Displays vary according to the options installed.
Stability 1
40 %
N
Stability 2
1.1 m
40 %
3.5 t
Figure 5. 1 = Basic display 2 = Basic display with

options
UDRS01.01GB
Electric Systems
11
04.3.2 Multi-function Display A80

Module-controlled functions of the machine are displayed
on a multi-function display. In normal operation the display shows a basic display, which is one of the ones below depending on the options installed in the machine. In
addition to the driver's displays, there are also maintenance and calibration displays, which are protected with
key switch S3 (located in the cabin's electric box). The
display also shows alarms reporting errors in the engine,
bus and sensors. See item Alarms.
Number and contents of displays depend on the options
installed in the machine. You can select a language version for the display from 13 alternatives. If you select English USA, the units of measurement will change to those
used in the USA.
1
2
40 %
3.5 t
1.1 m
1F
Figure 6. Multi-function Display

1
1st line of display
2nd line of display
Change display to maintenance displays (only for professional

maintenance personnel)
Scrolling of displays
Return to driver's displays, to basic display
Container counter reset: press * key for two seconds (optional)
Automatic gripping on/off / Automatic gearshift on/off (optional)
04.3.2.1 Driver's Displays

There are 7-9 driver's displays, (depending on options)
which can be scrolled with the arrow keys.
UDRS01.01GB
12
Electric Systems
Driver's display 1, Basic display

line 1
Stability %
line 2
Gear and driving

direction
Spreaders
reach
(option) *
Load (option)
1 2 3 4 F = Forward
N = Neutral
1 2 3 4 R = Reversed
m (ft)
t (l.t.)
*) Horizontal distance from the centre of the drive axle to

the centre of the spreader.
Driver's display 2
line 1
Speed
km/h (mph)
line 2
Slip ratio
engine/transmission
Driver's display 3
line 1
Engine
rpm
rotation speed of
engine
line 2
Gears
rpm
rotation speed of
transmission
C (F)
engine water temperature
bar
engine oil pressure
operating hours /
effective operating
hours
Driver's display 4
line 1
Engine Water
line 2
Driver's display 5
line 1
Engine oil
line 2
Driver's display 6
line 1
Operating hours
line 2
Driver's display 7
line 1
Containers
Containers counter
(optional)
line 2
Container counter reset: press * key for two seconds.
UDRS01.01GB
Electric Systems
13
Driver's display 8
line 1
Autom. gripping
line 2
on/off
automatic gripping
on / automatic gripping off
on/off selecting with OK key

Driver's display 9
line 1
Autom. changer
(option)
line 2
on/off
automatic gearshift
on/off
on/off selecting with OK key

04.3.2.2 Maintenance Displays
Maintenance displays are only intended for professional
maintenance personnel, so they can correct error situations and make the necessary calibrations in connection
with repairs.
Move to maintenance displays by turning key switch S3
to the ON position and then pressing the M key once.
Select module to check with arrow keys: Module A81,
A82, A83 or A84. Use OK key to move to displays of the
selected module, and browse displays with arrow keys.
Module displays show: DI=digital inputs (1 or 0), A =analog inputs (0,005,00V), DO =digital outputs (1 or 0) and
PR =proportional outputs (%).
In order to locate the error, values are compared to module-specific reference values. (see Control module A80 A84).
Maintenance Display Module A81
line 1
Module A81
line 2
Can bus
module 1
1/0
bus in operation /
bus oout of order
Maintenance Display Module A81 Sub-display 1

line 1
line 2
DI 1234567890
0000000000
digital input 1-12

status of said input 1
or 0
UDRS01.01GB
14
Electric Systems

Analog input and its voltage value 0.0 ...5.00 V.
line 1
A1 0.00
A2 0.00
line 2
A3 0.00
A4 0.00

Analog input and its voltage value 0.0 ...5.00 V.
line 1
A5 0.00
A6 0.00
line 2
A7 0.00
A8 0.00

line 1
DO 123456789012
line 2
000000000000
digital output 1-12

status of said output
1 or 0

Value of propo outputs %.
line 1
PR1 0
PR2 0
line 2
PR3 0
PR4 0

line 1
PR5 0
PR6 0
line 2
PR7 0
PR8 0

line 1
PR9 0
PR10 0
Corresponding displays for modules A82 and A83.

Maintenance Display Module A84
UDRS01.01GB
line 1
Module A84
line 2
Can bus
xxxx
1/0
bus in operation /
bus out of order
Electric Systems
15

line 1
DI 123456789012
digital input 1-12
line 2
A 000000000000

or 0

line 1
DI 345678
digital input A 13-18
line 2
A 000000

or 0

line 1
DI 123456789012
digital input B 1-12
line 2
B 000000000000

or 0

line 1
DI 345678
digital input B 13-18
line 2
B 000000

or 0
UDRS01.01GB
16
Electric Systems
04.3.3 Alarms
Alarms are divided into alarms and critical alarms. The division is explained in the tables below.
04.3.3.1 Critical Alarm
When a critical fault appears, the display shows an alarm
text and the buzzer sounds twice for 1 second
(1s_1s_1s). When the driver has noticed the message,
he can return to the basic display with the OK button. The
alarm text will disappear from the display after a specified
time. If the reason for the error disappears, the message
will also disappear from the display.
If there are several alarms on the display at the same
time, the most critical will be topmost [P]. You can scroll
them with the arrow key. If alarms have been acknowledged from the display with the OK button and there is a
new alarm, the already acknowledged alarms will also appear on the display if the errors have not been removed.
P
Alarm
Reason
Consequence
LOAD PARAMETERS
Parameters have not been loaded
Movements controlled by modules

are forbidden
ERROR CAN ENGINE
Breakdown in Can communication

or Emergency-button is pressed
Lifting/lowering and boom out movements are forbidden, only permitted if

you press stability by-pass button S85
ERROR ENGINE
Wrong engine type selected with

parameter
Engine will start and stop but gas

pedal will not work. Display shows
zero.
ERROR ENGINE 00000
QSM Engine error
Fault code on display has to be

checked and done according that.
ENGINE WATER TOO HOT Temperature over set alarm limit
ENGINE WATER TOO HOT Temperature has been over set limit Engine stalls, will not start
value for a specified amount of time
ENGINE OIL PRESSURE

LOW
Oil pressure below set alarm limit
ENGINE OIL PRESSURE

LOW
Oil pressure has been below set

Engine shut-off
value for a specified amount of time
ERROR CAN A82

10
ERROR CAN A83

11
ERROR CAN A84

12
ERROR R60
Sensor value is not within acceptable limits. Calibration < 100mV
Boom movements permitted only by

pressing stability by-pass button S85.
UDRS01.01GB
Limit maximum power
Limit maximum power
Electric Systems
17
Alarm
Reason
Consequence
13
ERROR R61
Sensor value is not within acceptable limits. Calibration value <

100mV

14
ERROR B6
Sensor value is not within acceptable limits 0.1-4.9V.

15
ERROR B8
Sensor value is not within acceptable limits 0.1-4.9V.

16
ERROR CAN A81

17
ERROR A312
Sensor value is not within acceptable limits 0.1-4.9V (during calibration 0.75-1.25V)
Gas demand is 0% , engine is idling
18
LOW BRAKE BRESSURE
Low brake pressure when starting

or driving
Driving direction cannot be selected
19
ERROR ENGINE TEMPERA- Engine error code on display

TURE
Limit maximum power
20
ERROR OIL PRESSURE
Engine error code on display
Limit maximum power
21
ERROR ENGINE RPM
Engine error code on display
Limit maximum power
04.3.3.2 Non-critical Alarms

When an error appears, the display shows an alarm text
and the buzzer sounds once for 1 second. When the driver has noticed the message, he can return to the basic
display with the OK button. The alarm text will disappear
from the display after a specified time. If the reason for the
error disappears, the message will also disappear from
the display.
If there are several alarms on the display at the same
time, the most critical will be topmost. You can scroll them
with the arrow key.
Alarm
Reason
Consequence
DIRECTION SELECTED, WILL

NOT START
You try to start with the direction

selected
Engine will not start until you select

direction into neutral
F/R SELECTED
Direction forward and rearward are Engine will not start until you select
selected at the same time
direction into neutral
IDLING, ENGINE WILL STALL
Pedal and lever have not been

used for the specified idling alarm
time
Engine shut-off in 2 min
IDLING, ENGINE WILL STALL
Pedal and lever have not been

used for the specified idling stopping time
Engine shut-off
STEERING AXLE OVERLOAD
Rear-axle is overloaded
Lifting and boom in movements are forbidden, only permitted if you press stability by-pass button S85.
ENGINE UNDER-TEMPERATURE Temperature has been below the

set limit value for a specified
amount of time
Check thermostat
UDRS01.01GB
18
Electric Systems
Alarm
Reason
Consequence
SHUT-OFF DELAY
Option to stop after-running has

been selected and the engine is
shut off with the key
Engine will only shut off after a time

specified by the parameter
EMERGENCY STOP PRESSED
S112 emergency stop switch has

been pressed
Engine shuts off, will not start until

switch has been released
HANDBRAKE
Handbrake was pressed when

starting
Driving direction cannot be selected
ENGINE WATER
LOW
LEVEL TOO
Engine water level too low
04.3.4 Tests
04.3.4.1 Tested During Operation
When the machine is operated, you should make sure
that counter-movements are not controlled simultaneously. Input voltage B6 and B8 of lifting cylinder's pressure
transmitters (right and left) must be greater than 0,1V and
smaller than 4,9V. Otherwise the display will show alarm:
ERROR B6 or ERROR B8, and boom movements are
only allowed by pressing stability by-pass button S85.
Steering axle loading is tested during operation, and if it
is overloaded the display will show alarm: STEERING
AXLE OVERLOAD.
Gas pedal voltage is monitored during use. The display
will show alarm ERROR A312 and request for gas will be
0% (idling), if voltage is 0,1V or smaller, or if voltage is
4,9V or greater, or if voltage is 25% smaller than calibrated minimum, or if voltage is 25% greater than calibrated
maximum. If voltage is between the 25% alarm mimit and
the calibration value, control will be according to minimum
or maximum. There will not be a gas pedal alarm from a
25% deviation, if the gas has not been calibrated.
When the emergency stop switch has been pressed, after
the half-second delay the display will show message
EMERGENCY STOP SWITCH PRESSED. If the machine was shut off from the emergency stop switch, it will
not start until you have lifted the "mushroom switch".
When A82_DI5 =0 (shut-off from key), there will be no
alarm. If handbrake is pressed and you try to move, the
display will show message HANDBRAKE and direction
solenoids will not go on until you disengage the handbrake. Also, if you get a handbrake alarm during driving,
direction solenoids go into neutral. When you start moving, brake pressure is checked, and if it is too low
(A84_DI13B=1), the display will show message LOW
BRAKE PRESSURE and direction solenoids will not go
on. Also, if you get a brake pressure alarm during driving,
direction solenoids will go into neutral.
UDRS01.01GB
Electric Systems
19
04.3.4.2 Testing of Stability Sensors

Values of boom's angle and length sensors and of lifting
cylinder's pressure transmitters (right+left) must be within
the acceptable range after calibration during operation.
Otherwise the display will show alarm: ERROR R60 or
ERROR R61. Then boom movements are only permitted
by pressing the by-pass button S85.
04.3.4.3 CAN Testing
If communication in the Can bus breaks down (monitored
constantly) lifting/lowering, telescope out movements will
be forbidden and the display will show message: ERROR
CAN Axx or ERROR CAN ENGINE. After the bus has returned to normal, the alarm will disappear and the movements are permitted. Bus error overrides short-circuit
error. S85 permits movements during the error, but then
stability monitoring will not operate reliably.
04.3.4.4 Engine Alarms
If you try to start the engine while direction forward or
rearward is selected, the display will show alarm DIRECTION SELECTED, WILL NOT START, and the engine
will start only after you select the direction into neutral. If
direction forward and rearward are selected at the same
time (mini wheel in use), the display will show alarm F/R
SELECTED.
If the engine has been idling for a certain time and the option has been selected, the display will show alarm
IDLING, ENGINE WILL STALL. The temperature of the
engine's coolant is monitored, and in an error situation the
display will show alarm ENGINE WATER TOO HOT or
ENGINE UNDERTEMPERATURE. If the oil pressure is
low while the engine is running, the display will show
alarm ENGINE OIL PRESSURE LOW. If engine water
level is too low (A81_DI1=1), the display will show alarm
ENGINE WATER LEVEL TOO LOW, alarm does not affect operation of the machine in any way . If option to stop
after-running has been selected and the engine is shut off
with the key, the display will show alarm: SHUT-OFF DELAY and engine will only shut off after a time. If there is a
sensor error the display will show alarm: ERROR ENGINE TEMPERATURE, ERROR OIL PRESSURE or ERROR ENGINE RPM. If you have selected the wrong
engine type (Scania/Cummins) with a parameter, the display will show alarm ERROR ENGINE. Cummins engines
show an error code, which is displayed as ERROR ENGINE and error code.
UDRS01.01GB
20
Electric Systems
04.3.5 Control Module A81
1
2
3
4
5
6
7
8
39
38
37
36
35
34
59
58
26
25
24
23
22
21
20
19
1
2
3
4
5
6
7
8
DI3
DI4
GND
+24VOut
DI5
DI6
DI12
137
DI11
DO12 151
DO11 152
GND
DO10
DO9
155
DO8
GND
PRO8
A81 controls following functions: boom hoisting and lowering, lowering locking valves, quick function of hoisting,
boom out, boom in, spreader rotation and limits of
spreader rotation, spreader automatic gripping, spreader
signal lights, stability by-pass, el. gas, coolant level, pressure weighing (optional).
X3
S100 114
S79 113
A312
R58
R58
R53
R54
R52
R51
129
128
127
126
125
124
123
122
121
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
X5
X6
X1
5
6
S99 S100 117
DI1
DI2
+24VOut
GND
DI7
DI8
DI9
DI10
AI8
AI7
AI6
AI5
AI4
AI3
AGND
AI2
AI1
RefOut
CONTROL UNIT
A81
X2
X7
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
PRO7
GND
PRO6
PRO5
DO7
DO6
GND
DO5
DO4
PRO4
GND
PRO3
DO3
PRO2
DO2
GND
PRO1
DO1
165
166
Y96A
Y96B
M97
171
Y57
173
174
175
176
Y52
Y87
Y58
Y67, Y68
178
179
Y51
Y56
6
5
4
3
2
1
60
61
62
63
64
65
X8
RxD
TxD
GND
PRO9
PRO10
GND
GND
GND GND
VCC
VCC
WH CAN High
CAN Low
BN
CAN Shield
7
6
5
4
3
2
1
27
28
29
30
31
32
33
X4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
Figure 7. Control Module A81

Note! When checking the reference values, the engine
must not be running.
Connector Code
Function
Rating
Wire no.
Note
X1.1
AI8
X1.2
DI10
Jacks down
X1.3
DI9
Scaling position angle
0V off, +24V on
113
S79
X1.4
DI8
Rotation extra limits in use
0V off, +24V on
114
S100
X1.5
DI7
UDRS01.01GB
Electric Systems
Connector Code
X1.6
21
Function
Rating
Wire no.
Note
+24V out
+24V
117
S79/
100
GND
X1.7
X1.8
DI2
X1.9
DI1
Coolant level
0V off, +24V on
X2.1
Refout
Ref. out, Hand lever feed
+5VDC
121
X2.2
AI1
Boom lifting
0V...5V
122
R51
X2.3
AI2
Boom lowering
0V...5V
123
R52
X2.4
AGND
X2.5
AI3
Boom in
0V...5V
125
R54
X2.6
AI4
Boom out
0V...5V
126
R53
X2.7
AI5
Rotation counter-clockwise
0V...5V
127
R58
X2.8
AI6
Rotation clockwise
0V...5V
128
R58
X2.9
AI7
El. gas accelerator pedal
0V...5V
129
A312
X3.1
DI3
X3.2
DI4
X3.3
GND
X3.4
+24
X3.5
DI5
X3.6
DI6
X3.7
DI12
0V off, +24V on
137
S85
X3.8
DI11
X4.1
CAN
CAN shield
X4.2
CAN
CAN Low
BN
X4.3
CAN
CAN High
WH
X4.4
VCC
X4.5
VCC
Feed voltage +24V
F38
X4.6
GND
Earthing rail
X4.7
GND
X5.1
DO12
Twistlocks open information
+24V 10W max
151
H180
X5.2
DO11
Twistlocks closed information
+24V 10W max
152
H191
X5.3
GND
X5.4
DO10
X5.5
DO9
Container contact information
+24V 10W max
155
H195
X5.6
DO8
X5.7
GND
X5.8
PRO8
X6.1
PRO7
X6.2
GND
X6.3
PRO6
X6.4
PRO5
X6.5
DO7
Cabin forward
+24V
165
Y96A
124
+24V out
Stability By-pass
UDRS01.01GB
22
Electric Systems
Connector Code
Function
Rating
Wire no.
Note
X6.6
DO6
Cabin rearward
+24V
166
Y96B
X6.7
GND
X6.8
DO5
Cabin transfer pump
168
M97
Boom lowering
171
Y57
173
Y52
174
Y87
X6.9
DO4
X7.1
PRO4
X7.2
GND
X7.3
PRO3
Boom in
X7.4
DO3
Lifting quick function
X7.5
PRO2
Boom lifting
175
Y58
X7.6
DO2
Locks of lowering
176
Y67,
Y68
X7.7
GND
X7.8
PRO1
Boom out
178
Y51
X7.9
DO1
Free circulation valve
179
Y56
X8.1
GND
X8.2
PRO10
X8.3
PRO9
X8.4
GND
X8.5
TxD
X8.6
RxD
UDRS01.01GB
+24V
Electric Systems
23
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
X5
X6
X1
CONTROL UNIT
A82
X2
X7
18
17
16
15
1
2
3
4
14
13
12
11
5
6
7
8
9
1
2
3
4
5
10
9
8
7
6
5
4
3
2
1
Y27 B
Y27 A
268
H13B
271
K2
273
274
275
276
Y4
Y5
Y3
Y2
278
279
S6
Y1
GND
PRO9
PRO10
61
62
63
64
65
4
3
2
1
RxD
TxD
60
6
5
CAN Shield
31
32
33
4
3
2
1
GND
GND GND
FI6
VCC
FI6
VCC
WH
CAN High
BN
CAN Low
7
6
5
263
264
265
X8
27
28
29
30
X4
6
7
8
9
PRO7
GND
PRO6
PRO5
DO7
DO6
GND
DO5
DO4
PRO4
GND
PRO3
DO3
PRO2
DO2
GND
PRO1
DO1
GND
A32
A32
S56
S56
A312
R61
R60
B6
B8
219 DI1
218 DI2
+24VOut
BN GND
215 DI7
214 DI8
213 DI9
212 DI10
211 AI8
229 AI7
228 AI6
227 AI5
226 AI4
225 AI3
224 AGND
AI2
AI1
221 RefOut
PRO8
DO9
DO8
GND
X3
S2
B1
6
7
8
5
6
7
8
1
2
3
4
5
35
34
59
58
26
25
24
23
22
21
20
19
1
2
3
4
39
38
37
36
DI3
DI4
GND
+24VOut
DI5
DI6
DI12
DI11
DO12
DO11
GND
DO10
234
235
236
237
238
231
232
A82 controls following functions: engine control, stability,

automatic gearshift system (optional), mini steering
wheel (optional), display of the load (optio), vertical lifting
and lowering (optional), idling shut-off (option).

Connector
Code
Function
X1.1
AI8
Electric gas accelerator pedal
X1.2
DI10
Direction Reverse
212
S56
X1.3
DI9
Direction Forward
213
S56
X1.4
DI8
Mini steering wheel
214
A32
X1.5
DI7
Mini steering wheel
215
A32
X1.6
GND
X1.7
Rating
Wire no.
Note
211
A312
BN
+24V out
+24V
UDRS01.01GB
24
Electric Systems
Connector
Code
Function
X1.8
DI2
X1.9
Wire no.
Note
Transmission operating speed
218
B1
DI1
Start
219
S2
X2.1
Refout
Ref. out
X2.2
AI1
X2.3
AI2
X2.4
AGND
X2.5
AI3
Stability sensor lift
0V...5V
225
A85
X2.6
AI4
Pressure of cylinder, left
0V...5V
226
B8
X2.7
AI5
Pressure of cylinder, right
0V...5V
227
B6
X2.8
AI6
Sensor of boom angle
0V...5V
228
R60
X2.9
AI7
Sensor of boom length
0V...5V
229
R61
X3.1
DI3
2 speed
231
S56
X3.2
DI4
3 speed
232
S56
X3.3
GND
X3.4
+24
+24V out
+24V
234
X3.5
DI5
Engine stop, option
0V off, +24V on
235
X3.6
DI6
1 speed
0V off, +24V on
236
S56
X3.7
DI12
Declutch
0V off, +24V on
237
S52
X3.8
DI11
Service Switch
0V off, +24V on
238
S3
X4.1
CAN
CAN shield
X4.2
CAN
CAN Low
BN
X4.3
CAN
CAN High
WH
X4.4
VCC
X4.5
VCC
Feed voltage +24V
F16
X4.6
GND
Earthing rail
X4.7
GND
X5.1
DO12
X5.2
DO11
X5.3
GND
X5.4
DO10
Machine speed < 10 km/h
X5.5
DO9
Neutral speed
X5.6
DO8
X5.7
GND
X5.8
PRO8
X6.1
PRO7
X6.2
GND
X6.3
PRO6
Mini steering wheel
263
Y27B
X6.4
PRO5
Mini steering wheel
264
Y27A
X6.5
DO7
Shut-off delay
265
X6.6
DO6
X6.7
GND
X6.8
DO5
Buzzer
268
UDRS01.01GB
Rating
+5VDC
221
224
S2
F16
H13B
Electric Systems
Connector
Code
X6.9
DO4
X7.1
PRO4
X7.2
GND
Function
25
Rating
Start relay
Wire no.
Note
271
K2
X7.3
PRO3
Direction Reverse
273
Y4
X7.4
DO3
3 speed
274
Y5
X7.5
PRO2
Direction Forward
275
Y3
X7.6
DO2
2 speed
276
Y2
X7.7
GND
X7.8
PRO1
Engine Start/Stop
278
S6
X7.9
DO1
1 speed
279
Y1
X8.1
GND
X8.2
PRO10
X8.3
PRO9
X8.4
GND
X8.5
TxD
X8.6
RxD
UDRS01.01GB
26
Electric Systems

A83 controls following functions of spreader and boom :
spreader rotation, limits of spreader rotation, spreader
lengthening/shortening, tilting forward/rearward, locking
of tilting, sideshift, twistlocks functions, container contact,
damping of telescope.

Connector
Code
Function
Rating
Wire no.
Note
X1.1
AI8
X1.2
X1.3
DI10
Stop, rotation counter-clockwise
0V off, +24V on
312
S99
DI9
Stop, rotation clockwise
0V off, +24V on
313
S98
X1.4
DI8
Twistlocks open
0V off, +24V on
314
S121
S122
X1.5
DI7
Twistlocks closed
0V off, +24V on
315
S123
S124
UDRS01.01GB
Electric Systems
Connector
Code
X1.6
GND
X1.7
27
Function
Rating
Wire no.
+24V out
+24V
317
Note
X1.8
DI2
Landing pin right
0V off, +24V on
318
S127
S128
X1.9
DI1
Landing pin, left
0V off, +24V on
319
S125
S126
X2.1
Refout
Ref. out
+5VDC
X2.2
AI1
Limit, rotation counter-clockwise
0V...5V
322
S99B
(option)
X2.3
AI2
Limit, rotation clockwise limit
0V...5V
323
S98B
(option)
X2.4
AGND
X2.5
AI3
X2.6
AI4
X2.7
AI5
X2.8
AI6
X2.9
AI7
X3.1
DI3
20" - 40", right
0V off, +24V on
331
S136
X3.2
DI4
30" , right
0V off, +24V on
332
S236
X3.3
GND
X3.4
+24
+24V out
+24V
334
X3.5
DI5
20" - 40", left
0V off, +24V on
335
S135
X3.6
DI6
30", left
0V off, +24V on
336
S235
X3.7
DI12
Boom out, damping
0V off, +24V on
337
S81
X3.8
DI11
Boom in, damping
0V off, +24V on
338
S80
X4.1
CAN
CAN shield
X4.2
CAN
CAN Low
BN
X4.3
CAN
CAN High
WH
X4.4
VCC
X4.5
VCC
Supply voltage +24V
F36
X4.6
GND
X4.7
GND
X5.1
DO12
Pile slope locking
351
Y66
X5.2
DO11
Pile slope to right
352
Y64A
X5.3
GND
X5.4
DO10
Twistlocks open light
354
H304
X5.5
DO9
Twistlocks closed light
355
H303
X5.6
DO8
Landing pin
356
H305
X5.7
GND
X5.8
PRO8
Pile slope to left
358
Y64B
X6.1
PRO7
Longit. tilting locking
361
Y63
X6.2
GND
X6.3
PRO6
Rotation counter-clockwise
363
Y59A
UDRS01.01GB
28
Electric Systems
Connector
Code
Function
X6.4
PRO5
X6.5
Wire no.
Note
Rotation clockwise
364
Y59B
DO7
Sideshift left
365
Y62A
X6.6
DO6
Sideshift right
366
Y62B
X6.7
GND
X6.8
DO5
Longit. tilting forward
368
Y65A
X6.9
DO4
Longit. tilting rearward
369
Y65B
X7.1
PRO4
X7.2
GND
X7.3
PRO3
Twistlocks open
373
Y71A
X7.4
DO3
Twistlocks closed
374
Y71B
X7.5
PRO2
20-40, right
375
Y73A
X7.6
DO2
40-20, right
376
Y73B
X7.7
GND
X7.8
PRO1
20-40, left
378
Y74A
X7.9
DO1
40-20, left
379
Y74B
X8.1
GND
X8.2
PRO10
X8.3
PRO9
X8.4
GND
X8.5
TxD
X8.6
RxD
UDRS01.01GB
Rating
Electric Systems
29

Module A84 is an input module from different switches in
cabin.
INPUT B
INPUT A
X2
X7
MCKC-MODULE
A84
X6
X1
S7
S990, S980
S60
S97A
S97B
S97A-B S7
F16
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
24V out
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
DI9
DI10
DI11
DI12
DI13
DI14
DI15
421
422
423
424
425
426
427
428
411
412
413
414
415
416
417
418
S89
S90
S99
S86
S95
S180
S92
S192
S237
S194
S189
S193
S193
S191
S191
WH
Pink
BN
WH
6
5
4
3
2
1
X4
+VCC
-GND
CANLO
CANHI
CANLO
CANHI
X5
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
457
456
455
454
453
453
452
S23
S13
S199
S115
24V out
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
DI9
DI10
DI11
DI12
DI13
DI14
DI15
DI16
DI17
DI18
DI18
DI17
DI16
24Vout
S112
S58
S97
S97
S192
S251
S251
S71
S72
S68
478
477
476
475
474
473
472
471
468
467
466
465
464
463
462
461

Connector Code
Function
Rating
Wire no. Note
X1.1
DI8
Twistlocks closed, manual
0 V off, +24 V on
411
S192
X1.2
DI9
Spreader 30' position
0 V off, +24 V on
412
S237
X1.3
DI10
Hoist prevent by-pass
0 V off, +24 V on
413
S194
X1.4
DI11
Spreader autom. lenghtening
0 V off, +24 V on
414
S189
X1.5
DI12
Spreader lengthening, right T-balk
0 V off, +24 V on
415
S193
X1.6
DI13
Spreader shortening, right T-balk
0 V off, +24 V on
416
S193
X1.7
DI14
Spreader shortening, left T-balk
0 V off, +24 V on
417
S191
X1.8
DI15
Spreader shortening, right T-balk
0 V off, +24 V on
418
S191
X2.1
Refout
Ref. output
+24 VDC , max 2 A
421
X2.2
DI1
Side shift, right
0 V off, +24 V on
422
S89
X2.3
DI2
Side shift, left
0 V off, +24 V on
423
S90
X2.4
DI3
Hand lever change button/vertical lift
0 V off, +24 V on
424
S99
X2.5
DI4
Spreader lenghtening/ tilting forward
0 V off, +24 V on
425
S86
X2.6
DI5
Spreader shortening/ tilting rearward
0 V off, +24 V on
426
S95
X2.7
DI6
Twistlocks open
0 V off, +24 V on
427
S180
X2.8
DI7
Spreader tilt locking
0 V off, +24 V on
428
S92
X4.1
CAN
CAN High
WH
X4.2
CAN
CAN Low
BN
X4.3
CAN
CAN High
Pink
X4.4
CAN
CAN Low
WH
UDRS01.01GB
30
Electric Systems
Connector Code
Function
X4.5
GND
GND Earthing rail
X4.6
+VCC
Feed voltage
X5.1
Refout
Ref. output
+24 VDC , max 2 A
451
S97A-B
S7
X5.2
DI16
Cabin rearward, limit
0 V off, +24 V on
452
S97B
X5.3
DI17
Cabin forward, limit
0 V off, +24 V on
453
S97A
X5.4
DI18
Pile slope locking
0 V off, +24 V on
454
S60
(option)
X5.5
DI18
Door switch
0 V off, +24 V on
455
S990,
S980
X5.6
DI17
Seat switch
0 V off, +24 V on
456
S7
X5.7
DI16
Rotation speed range
0 V off, +24 V on
457
(option)
X6.1
DI15
Rotation limit by-pass
0 V off, +24 V on
461
S115
X6.2
DI14
Container contact by-pass
0 V off, +24 V on
462
S199
X6.3
DI13
Brake pressure, 115 Bar
0 V off, +24 V on
463
S13
X6.4
DI12
Brake information, 2,5 Bar
0 V off, +24 V on
464
S23
X6.5
DI11
Buzzer on
0 V off, +24 V on
465
X6.6
DI10
Speed locking
0 V off, +24 V on
466
S68
(option)
X6.7
DI9
Starting gear
0 V off, +24 V on
467
S72
(option)
X6.8
DI8
Automatic gear shift on/off 0V off, +24V

on 468 S71
0 V off, +24 V on
468
S71
(option)
X7.1
DI7
Jacks up
0 V off, +24 V on
471
S251
(optio)
X7.2
DI6
Jacks down
0 V off, +24 V on
472
S251
(option)
X7.3
DI5
Automatic gripping, on
0 V off, +24 V on
473
S192
(option)
X7.4
DI4
Cabin transfer, rearward
0 V off, +24 V on
474
S97
X7.5
DI3
Cabin transfer, forward
0 V off, +24 V on
475
S97
X7.6
DI2
Parking brake
0 V off, +24 V on
476
S58
X7.7
DI1
Emergency stop switch
0 V off, +24 V on
477
S112
X7.8
Refout
Ref. output
+24 VDC , max 2 A
478
UDRS01.01GB
Rating
Wire no. Note
F16
Electric Systems
31
04.3.9 Engine Control

The engine is controlled by an ECU (Engine Control Unit).
The ECU is connected to the CAN bus, and control module A82 carries out communication with it. Control module
A82 reads the position of the gas pedal and transmits it to
the ECU. A82 also performs starting and stopping of the
engine. ECU transmits several messages, which contain
information about engine status. Control module A82 receives and interprets these messages.
04.3.9.1 Starting the Engine
Switch on power to the engine A82:DI1 1 and set
A82:PRO1 (control 100%)
Upon starting there are safety checks made to make sure
that the engine will start safely.
- Direction forward A82 DI9 or rearward A82 DI10 must
not be selected. If direction is selected, the display will
show alarm: DIRECTION SELECTED, WILL NOT
START.
- Temperature of the engine coolant must be within the
acceptable range, otherwise the display will show error
message: ENGINE WATER TOO HOT.
- If ECU falls out of the bus, starting is forbidden.
When the above conditions are met, activate A82:PRO4
to set the starter motor on. If one of the above conditions
is not met during start, A82:PRO1 ja PRO4 will be reset.
Starter motor will be on as long as the engine rpm value
is below a limit value. While starting boom movements
and spreader rotation are forbidden.
When the rpm limit is reached, starter motor A82:PRO4
will be deactivated (control 0%), operating hour counter
will be activated and oil pressure will be monitored. If the
engine stalls, re-start will not begin until rpm is 0.
04.3.9.2 Stopping the Engine
Normal stopping by turning the key:- A82:DI5 0, operating hour counter is deactivated and A82:PRO1 deactivated.
- If you have selected idling option, the display will show
message SHUT-OFF DELAY and the engine will be shut
off after delay once the key has been turned.
If you stop the engine in any other way than the usual
turning of the key, the display will show an alarm before
UDRS01.01GB
32
Electric Systems
the engine stops. The engine is stopped, if one of the following is true: A82:DI5 0
- Idling option, engine is shut off after delay from turning
of key and the display immediately shows message:
SHUT-OFF DELAY. If operation has been selected, it will
be activated for the specified time, when rpm is over
400rpm and A82_DI5=1 and A82_PRO1=100% and
A82_DO7=0. Operation: DO7 goes on, when DI5=0 and
for specified time PRO1 is 100%. During operation gas is
forbidden. Shut-off: PRO1=0% for 3 seconds, and after
that DO7=0 and PRO1=100%. Operation is reset immediately, if DI5=1. Re-start is not possible (A82_PRO4)
during operation.
- Engine idling stop: gas pedal and lever have not been
used, the engine has been idling for a certain time, and
the handbrake is on. After a warning delay the display will
show: IDLING, ENGINE WILL STALL. The engine will
stall after the shut-off delay. Idling stop is an option. If the
option has not been selected, there will be no alarm and
the engine will not be shut off.
- If temperature of the engine coolant has been over the
set limit value for a specified amount of time, the display
will show alarm: ENGINE WATER TOO HOT and the engine will be shut off. (If temperature has been over set
alarm limit, maximum power will be limited and display
will show alarm: ENGINE WATER TOO HOT)
- If oil pressure has been under the set value for a specified amount of time, the display will show alarm: ENGINE
OIL PRESSURE LOW and the engine will be shut off. (If
oil pressure is below alarm limit, maximum power will be
limited and the display will show alarm: ENGINE OIL
PRESSURE LOW)
- Engine's temperature/pressure stopping is an option. If
the option has not been selected, the engine will not stall
but maximum power will be limited.
When one of the above conditions is met, A82_PRO1 is
deactivated for 3 seconds, then the engine will be shut off
but you can get engine data after that. At the same time
the operating hour counter is deactivated
04.3.9.3 Normal Operation of the Engine
Normal operation of the engine mainly consists of analysis of position of the gas pedal, transmission of engine
control messages to A86 and reception of status messages from A86. Information regarding errors is also brought
UDRS01.01GB
Electric Systems
33
to the display. Engine rpm value can also be limited according to the status of the engine.
Maximum rpm value is limited according to the following
conditions. If the cause for limitation disappears, gas limitation will only disappear after the gas value falls below
10%.
- RSV: If the gas pedal has been pressed and direction
has been selected forward and rpm is above runaway limit gas request at 0%.
Changing of direction situation and speed below direction
change limit km/h gas request at 0% and rpm below
runaway limit.
- Changing gears gas request at 0% until slide ratio is
reached.
- After declutch gas request at 0%, max speed 15km/h.
- Engine coolant has overheated (shut-off limit _C)
alarm to display and shut-off of engine. If the coolant has
overheated above alarm limit, maximum power is limited
and display will show alarm: ENGINE WATER TOO HOT.
Time coercion will prevent wandering of the engine rpm.
- If engine oil pressure is below alarm limit, maximum
power will be limited and the display will show alarm: ENGINE OIL PRESSURE LOW.
- If A86 has detected an error in the engine's temperature
or oil pressure or engine's rpm sensor, maximum power
is limited and the display will show alarm: ERROR ENGINE TEMPERATURE, ERROR ENGINE OIL PRESSURE or ERROR ENGINE RPM. The driver's display
shows as values 0 _C, 0 bar or 0 rpm, but the program
uses normal values, so the engine operates otherwise
normally. If the display shows any of the above alarms,
you must take in the machine for maintenance immediately.
When the rpm value is higher than 900 or the lever is in
motion, effective operating hour counter is activated. Correspondingly, the effective operating hour counter is deactivated, when rpm is lower than 900 or the lever is not
in motion.
If engine's under-temperature option has been selected,
engine water's temperature is monitored while the machine is running. If temperature has been below the set
value for a specified amount of time, the display will show
UDRS01.01GB
34
Electric Systems
alarm: ENGINE UNDERTEMPERATURE. The alarm

does not affect operation of the machine.
If engine's water level is low (A81_DI1=1) the display will
show alarm: ENGINE WATER LEVEL TOO LOW. The
alarm does not affect operation of the machine.
If data transfer to the engine (to A86) breaks down, the
display will show alarm: ERROR CAN MOOTTORI. The
program monitors that the engine sends an rpm value at
regular intervals. If the bus is broken, the engine control
unit (A86) will guide the engine into idling.
UDRS01.01GB
Electric Systems
35
04.3.10 Control of Boom and Spreader

04.3.10.1 Valve Control in Various Functions
Function
Y58
PRO2
LE
LR
Y57
PRO4
Y51
PRO1
Y52
PRO3
Y56
DO1
Y67,
Y68
DO2
Y59a
PRO6
Y59b
PRO5
Y71b
DO3
X
X
X
R
LO
LOE
LOR
X
X
X
X
X
X
A81
QL
Y87
DO3
RCC
RC
X
X
X
Function code:
L
Lifting
Extension
Retraction
LO
Lowering
QL
Quick lift
RC
Rotation clockwise
RCC
Rotation counter clockwise
A81
Free rotation
E.g. function LE = Lifting + Extension

04.3.10.2 Boom Movements
Boom movements are controlled by the joystick. Lifting,
lowering, telescope out and in movements have pwm per-
UDRS01.01GB
36
Electric Systems
centage control Rotations specify power mA. Lowering

and lifting movements are also affected by the pressure
of the lifting cylinder. Boom out and in movements are
also affected by a damping function.
twist locks open=1 or

twist locks closed=1 or
(S194=1 and
S189 = 1)
yes
kyll
Rear stability disconnect
yes
kyll
Stability disconnect
yes
kyll
S85 = 1
S85 = 1
ei
no
no
ei
kyll
yes
yes
kyll
kyll
yes
Container
contact
Conteiner
contact
yes
ei
yes
kyll
S85 = 1
ei
no
yes
Parameter
time past
no
ei
rotating
clockwise
limit=0
no
hoisting=1
and
owering=0
yes
LIFTING
lowering=1
and
hoisting=0
yes
LOWERING
yes
tel out=1
and tel
in=0
yes
EXTENSION
rotating
counter- clockwise
limit=0
yes
rotating
clockwise=1
and
rotating
counter- clockwise
=0
rotating
counter- clockwise
=1
and
rotating
clockwise
=0
yes
yes
ROTATING
CLOCKWISE
tel in=1
and
tel out=0
yes
ROTATING
RETRACTION
COUNTERCLOCKWISE
Figure 11. Conditions of Boom Movements when using

Stability Guard1
UDRS01.01GB
Electric Systems
37
twist locks open=1 or

twist locks closed=1 or
(S194=1 and
S189 = 1)
yes
yes
kyll
yes
kyll
Stability disconnect
Yes
S85 = 1
S85 = 1
S85 = 1
no
ei
No
no
ei
yes
Yes
yes
kyll
Reached
angle <50
degree
yes
kyll
Container
contact
Container
contact
ei
no
kyll
yes
Gabarity
> -1,0 m
Gabarity
> - 1.0m
Parameter
time passed
yes
ei
yes
kyll
no
lifting =1
and
lowering=0
yes
LIFTING
lowering=1
and
hoisting=0
yes
LOWERING
rotating
counter- clockwise
limit=0
rotating
clockwise
limit=0
yes
tel out=1
and tel
in=0
yes
EXTENSION
yes
rotating
clockwise=1
and
rotating
counter- clockwise
=0
rotating
counter- clockwise
=1
and
rotating
clockwise
=0
yes
yes
ROTATING
CLOCKWISE
yes
tel in=1
and
tel out=0
yes
ROTATING
RETRACTION
COUNTERCLOCKWISE
Figure 12. Conditions of Boom Movements when using

Stability Guard2
The boom movements are defined with four handle (%)
and control /(mA) value, parameters I9-L28. To the lift
and drop movement it affects also the pressure of lifting
cylinder. To the telescope out and in movements it affects
also the decelerations.
04.3.10.3 Spreader Movements
Extension and Shortening
In order for you to extend or shorten, container contact is
not allowed and the twistlocks must be open. You can select with switches to extend/shorten with one button bot
left and right side, or extend/shorten left side with one button and right side with another button.
If automatic function or 30' stop buttons have not been selected, valve control occurs without limit switches. Auto-
UDRS01.01GB
38
Electric Systems
matic function has limit switches on right and left side,

and 30' stop has also limit switches on right and left side.
A83_DI1=0
AND A83_DI2=0
AND
A84_DI14B=0
A83_DI7
=0 OR
A84_DI10A
=1
A84_DI4A
=1
A84_DI15A
=1
/S191
/S86/
A84_DI12A
=1
/S193/
A84_DI14A
=1
/S191/
A84_DI13A
=1
/S193/
=1
/S95/
A84_DI9A
TRUE
A84_DI11A
A84_DI5A
=1
=1
/S237/
/S189/
FALSE
TRUE
FALSE
A83_DI3=0
A83_DI4=0
/S236/ AND
A83_DI3=0
A83_DI5=0
A83_DI6=0
/S235/ AND
A83_DI5=0
/S136/
/S135/
A83_PRO1
=100%
SPREADER
LENGTHENING LEFT
A83_PRO2
=100%
SPREADER
LENGTHENING RIGHT
A83_DO1=1
SPREADER
SHORTENING LEFT
A83_DO2=1
A81_DO1=1
SPREADER
SHORTENING RIGHT
FREE CIRCULATION
VALVE
Figure 13. Extension and Shortening of Spreader
UDRS01.01GB
Electric Systems
39
Rotations
Rotation is allowed, if stability is not on cut-off, if there is
no container contact, if the twistlocks are open, closed or
if their by-pass is pressed. There are limit switches for
both directions (clockwise, counterclockwise). You can
also take into use the "additional limits" option with a parameter. If the option has been selected and if the boom's
position data is correct, additional limits will be used.
There is a by-pass switch for the additional limits.
UDRS01.01GB
40
Electric Systems
A81_AI5 > 0
A81_AI6 > 0
TRUE
TRUE
STABILITY <
100% OR
A81_DI12=1
STABILITY <
100% OR
A81_DI12=1
TRUE
TRUE
A83_DI1=0 AND
A83_DI2=0 AND
A84 DI14B=0
A83_DI1=0 AND
A83_DI2=0 AND
A84 DI14B=0
TRUE
TRUE
A83_DI7=1 OR
A83_DI8=1 OR
A84_DI10A
A83_DI7=1 OR
A83_DI8=1 OR
A84 DI10A
TRUE
TRUE
A83_DI10=0
A83 DI9=0
TRUE
OPTIONAL
parameter extra
limits =1 AND
A81 DI8=0
TRUE
TRUE
FALSE
A83_PRO6=X%
ROTATION CLOCKWISE
A83_AI1>4V AND
A84 DI15B=0
FALSE
A81_DO1=1
FREE CIRCULATION
VALVE
OPTIONAL
parameter extra
limits =1 AND
A81 DI8=0
FALSE
A83_PRO5=X%
ROTATION COUNTERCLOCKWISE
Figure 14. Rotation of Spreader
UDRS01.01GB
TRUE
A83_AI2>4V AND
A84 DI15B=0
FALSE
Electric Systems
41
Tilting
Tilting is allowed, if there is no container contact. In addition to the direction (left, right, forward, backward) button,
you must use the S99 button. Cross-tilting is an option,
which you can select into use with parameter F28. Locking switches control the locking valves.
UDRS01.01GB
42
Electric Systems
A83_DI1=0 AND
A83_DI2=0 AND
A84_DI14B=0
TRUE
OPTIONAL
parameter
pileslope=1
TRUE
A84_DI1A=1
/S89/
A84_DI2A=1
/S90/
TRUE
TRUE
A84_DI3A
=1
/S99/
TRUE
/S99/
TRUE
A83_PRO8
A83_DO11
=1
=100%
PILE SLOPE TO LEFT
PILE SLOPE TO RIGHT
TRUE
A84_DI3A
=1
/S99/
A84_DI3A
=1
TRUE
A84_DI5A=1
/S95/
A84_DI4A=1
/S86/
A84_DI3A
=1
/S99/
TRUE
A81_DO1=1
FREE CIRCULATION
VALVE
TRUE
A83_DO4
A83_DO5
=1
=1
SPREADER LONGIT.
SPREADER LONGIT.
TILTING FORWARD
TILTING BACKWARD
A84_DI18A=1
/S60/
TRUE
A84_DI7A=1
/S92/
A83_DI7=0
TRUE
TRUE
A83_PRO7
=100%
A83_DO12=1
SPREADER LONGIT.
PILE SLOPE LOCKING
TILTING LOCKING
Figure 15. Tilting of the Spreader
UDRS01.01GB
Electric Systems
43
Sideshift
Sideshift is allowed, if there is no container contact and if
stability is not on cut-off Right and left sideshift are selected with their own buttons.
UDRS01.01GB
44
Electric Systems
A83_DI1=0 AND
A83_DI2=0 AND
A84_DI14B=0
TRUE
STABILITY < 100%

OR A81_DI12=1
TRUE
A84_DI2A=1
/S90/
A84_DI1A=1
/S89/
TRUE
TRUE
A84_DI3A
A84_DI3A
=0
/S99/
=0
/S99/
FALSE
FALSE
A81_DO1=1
A83_DO6=1
SIDE SIFT TO LEFT
FREE CIRCULATION
VALVE
Figure 16. Sideshift of the Spreader
UDRS01.01GB
A83_DO7=1
SIDE SIFT TO RIGHT
Electric Systems
45
Twistlocks Manually
The twistlocks open and closed movement require container contact. Both movements have a limit switch, which
is used to control the indicator lights.
A84_DI6A=1
A84_DI8A=1
/S180/
/S192/
TRUE
TRUE
A83_DI7=0
A83_DI8=0
/S123,S124/
/S121,S122/
TRUE
TRUE
A83_DI8=1
/S121,S122/
TWIST LOCKS
OPEN
/S123,S124/
TRUE
TRUE
A83_PRO3
=100%
A83_DO10=1
A83_DI7=1
A83_DI2=1)
A83_DI2=1)
TRUE
(A83_DI1=1
A84_DI14B=1
OR (A83_DI1=1
AND
A84_DI14B=1
OR (A83_DI1=1
AND
A81_DO1=1
FREE CIRCULATION
VALVE
TRUE
A83_DO9=1
A83_DO3=1
TWIST LOCKS
CLOSE
AND A83_DI2=1)
OR
A84_DI14B=1
TRUE
A83_DO8=1
CONTAINER
CONTACT
Figure 17. Twistlocks Open and Closed Manually
UDRS01.01GB
46
Electric Systems
04.3.11 Monitoring of Stability

Status of stability is displayed continuously on the driver's
basic display graphically and in percentages %
When stability has been over 90% for more than 1 second, boom movement out or spreader rotation is active,
the buzzer alarms periodically (except stability guard2: If
reach is < 3,5 m, there will be no alarm but movements
are forbidden). When stability exceeds 100%, lifting, lowering, boom movement out and spreader rotation are prevented, the buzzer alarms constantly. Stability by-pass
switch S85 permits movements. If there is a sensor error
(B6, B8, R60, R61), the buzzer rings twice and the display
will show an alarm. Then boom movements are prevented (stability by-pass switch S85 permits movements).
Monitoring of stability can be carried out in two ways:
Stability guard 1 = rear axle sensor and amplifier,
standard. Rear axle's overload protector is available
as an option.
Stability guard 2 = length and angle sensor and two lifting cylinder pressure transmitters, option.
04.3.12 Load Weighing

04.3.12.1 Stability Guard 1
Operation of the weighing system is based on change in
pressure of the lifting cylinder, which is measured by
pressure transmitter B6. Pressure transmitter's data is
converted into weight of the container on the display.
Weighing is done in boom position determined by sensors S79. Conditions of weighing display are: boom in
A83:DI11 = 1 and angle data S79 A81:DI9 = 1 and machine does not move A82:DI2<100Hz and boom movements are not made. When the above conditions are met,
item "load weighing" on basic display will always show
stars, which means that weighing is done, if the machine
does not move and boom movements are not made. First
weighing result comes in 3 seconds, when pressure level
has stabilized. After that the weighing result is shown on
the display as long as you are in that status, the display is
updated at 1 sec. Intervals. When you leave the weighing
status, the display does not show any weighing result. A
weighing result shown on the display is always in the
range of 0-46 tons. Weighing should always be done after
a lifting movement.
Weighing is an option, when you are using stability guard
1.
UDRS01.01GB
Electric Systems
47
04.3.12.2 Stability Guard 2

Load's value is calculated from lifting cylinder's pressure
transmitters B6 A82:AI5 and B8 A82:AI4 as an average
value. Measurement result is the average value of two
sensors. The measurement result is shown on the display
for load weighing only, when the machine's speed is 0-2
km/h and there is no lifting or lowering movement (3 second delay after lifting and lowering). A weighing result
shown on the display is always in the range of 0-46 tons.
If the machine is in motion, the weighing value on the display is not updated (result does not change).
Weighing is standard, when you are using stability guard
2.
UDRS01.01GB
48
Electric Systems
04.3.13 Calibrations
Calibration settings must be checked and calibrated at
1000 h intervals and every time you have handled sensors (A312, B6, B8, R60, R61), which affect the calibrations.
Calibration settings are made on the display. Move to calibration displays by turning S3 key switch to ON position
(located in the cabin's electric box) and then pressing M
button 3 times during 2 seconds. The display will show
message: CALIBRATION ARE YOU SURE? Move to calibration settings by pressing the OK key. (Use the -> key
to stop calibration and return to basic display.)
CALIBRATION
ARE YOU SURE
Figure 18. Calibration Display

Calibration displays vary according to options installed in
the machine as follows:
Calibrate Stability 1 (if there are no options, Stability 2)
Calibrate gas
Calibrate pressure weighing, option (if there are
Stability 1)
Calibrate Stability 2, option
Calibrations should be performed, while the machine is
on an even surface. For load you need a container,
whose weight you know precisely (over 20 t).
During calibration the stability guard is not in operation,
but the buzzer will alarm at 90%. Boom retardation is not
in use during calibration.
UDRS01.01GB
Electric Systems
49
Warning!
You must make calibrations carefully according to
the instructions, otherwise operation of the machine
and safety are compromised!
04.3.13.1 Calibrate Stability 1
Display shows text: CALIBRATE STABILITY 1.
1. Press OK
Display shows text: BOOM DOWN AND IN n.n.
2. Drive boom fully in and down without a load.
3. Wait for 10 seconds and press OK
Program reads a value, which corresponds to stability
0%. Next display appears automatically.
Display shows text: REAR WHEELS UP n.n
4. Grab the load and drive the boom slowly out with the
load low (about 10 cm from the ground), so that the
rear wheels just about rise into the air.
5. Wait for 10 seconds and press OK
Program accepts a value, which is at least 2V smaller
than the previous value, which had no load. Program
caclulates the stability linearly with the help of the
points and determines an alarm limit (90%) and max.
allowed limit (100%).
When the acceptable calibration values have been
stored, the next display appears automatically.
Display shows text: CALIBRATION OK for 2 seconds,
and after that it returns to the basic display.
6. Finish calibration by resetting the system by switching
off and on again power of the machine.
Warning!
Note. Do not switch off power of the machine until
display shows the basic display. Otherwise the calibration values are not saved correctly.
04.3.13.2 Calibrate Stability 2
The boom decelerations are not valid when the calibrate
stability2 is accepted with OK in the calibration menu, so
the situation is the same as the by-pass switch pressed to
bottom.
UDRS01.01GB
50
Electric Systems
When calibrated the boom is asked to drive completely in,

then the minimum value of the length sensor will be received. When driven the boom out, it will be have the
maximum value of the length sensor.
BOOM IN
The boom is telescoped completely in.
0,1 < length sensor voltage < 0,3
Boom in is accepted with the OK button
0,2V is a recommended value; also 0,1 and 0,3 are
acceptable.
BOOM OUT
The boom is telescoped completely out.
4,7 < length sensor voltage < 4,9
Boom out is accepted with the OK button.
4,8V is a recommended value, also 4,7 and 4,9 are
acceptable
When the boom is down it will have the minimum value for
the angle sensor and when up the maximum value.
BOOM DOWN
The boom is dropped completely down.
0,4 < angle sensor voltage < 0,8
Boom down is accepted with the OK button.
About 0,5V is a recommended value 0,4 is minimum
and 0,8 maximum which are also accepted.
BOOM UP
The boom is lifted completely up.
2,9 < angle sensor voltage < 3,5
Boom up is accepted with the OK button.
About 3,5V is an accepted value. 2,9 is minimum and 3,5
maximum values which are also accepted. When the calibration is made and the calibration values are saved,
OK will appear on the display.
UDRS01.01GB
Electric Systems
51
04.3.13.3 Calibrate Gas

You should calibrate the sensor of the gas pedal every
time you replace the pedal. The program contains default
values, which allow the gas pedal to function before parameters are loaded. However, you must calibrate the
gas as soon as possible.
Calibrate the gas pedal as follows: power is on but engine
is not running.
1. Move to calibration displays. Press the OK key, and if
the display then shows text: CALIBRATE STABILITY
1, move to calibration by pressing the "arrow down"
key.
Display shows text: CALIBRATE GAS.
2. Press OK
Display shows text: PRESS GAS ALL THE WAY
DOWN.
3. Press gas all the way down and at the same time press
the OK key, and the program will read the voltage value. Next display appears automatically.
Display shows text: RELEASE GAS.
4. Release the gas pedal and press the OK key, and the
program will read the voltage value. The program accepts the calibration when the previous, with the pedal
all the way down, is at least 1V higher.
When the acceptable calibration values have been
stored, the next display will appear automatically.
and after that it returns to the basic display.
Warning!
display shows the basic display.Otherwise the calibration values are not saved correctly.
UDRS01.01GB
52
Electric Systems
04.3.13.4 Calibrate Pressure Weighing (option)

Pressure weighing shows weight of the load based on
voltage values of one pressure transmitter in one position
of the boom as determined by sensors S79. Conditions of
the weighing display are: boom in A83:DI11 = 1 and angle
data S79 A81:DI9 = 1 and machine does not move
A82:DI2<100Hz and boom movements are not made.
Note. We recommend that you make the calibration after
a lifting movement.
1. Move to calibration displays. After you have pressed
OK button, if the display shows text: CALIBRATE STABILITY 1, you can access weighing calibration by
pressing "arrow down" key 2 times.
Display shows text: CALIBRATE PRESSURE
WEIGHING
2. Press OK
Lift boom without a load to weighing spot, and the display will show signs **.* t
Display shows text: BOOM WITHOUT LOAD **.* t
3. Press OK
Pressing of OK key is allowed, after you have been at
the calibration item for at least 3 seconds. Program
read the voltage, which corresponds to 0,0 t. Following
display changes automatically.
Display shows text: BOOM WITH LOAD **.* t
4. Lift load container (whose weight you know) to weighing spot, and the display will show sign **.* t . Enter
from the display weight in tons with accuracy of one
decimal (nn,n).
5. Press OK
Pressing of OK is allowed, after you have been at the
calibration item for at least 3 seconds. Program reads
the voltage, which corresponds to the entered weight
and checks that the previous value without a load is
smaller than with the load. When acceptable calibration values have been saved, the following display
changes automatically.
and then returns to the basic display.
UDRS01.01GB
Electric Systems
53

Warning!
display shows the basic display.Otherwise the calibration values are not saved correctly.
04.3.13.5 Pressure Weighing Fixed Scale
When the calibration point is correct, A83_DI11 = 1 and
A81_DI9 = 1, stars will appear on the calibration display
indicating that the calibration can be made. It is recommended that the fcalibration will be made after the lifting
movement.
The boom is lifted without load to the calibration point and
the OK button is pressed on the display. Pressing of the
OK button is allowed when A83_DI11 and A81_DI9 have
been 1 at least for three seconds. When pressing the OK
button the program reads the corresponding voltage (X),
which corresponds to 0 ton.
The container, the weight of which is known in tons, is lifted to the calibration point. The weight is written with one
decimal from the display and is exited with the OK button.
Pressing of the OK button is allowed when the A83_DI11
and A81_DI9 have been at 1 for at least three seconds.
When pressing the OK button, the program reads the corresponding voltage (/) which corresponds to the written
load.
UDRS01.01GB
54
Electric Systems
The program checks that the calibration value boom

without load is less than the value boom with load and
that the calibration values will be saved. The calibration
has been made correctly if an OK message appears on
the display. The program makes scaling linear with two
calibration points. The scaling top level, max is counted
according to the formula described in the following figure.
Figure 19. Calibration Points, Scaling
UDRS01.01GB
Electric Systems
55
04.3.14 Functions of By-pass and Emergency

Switches
S189
A84_DI11A. Locking switch, which in its bottom position
stops toplift's automatic extension/shortening movement.
S194
A81 DI10A. By-passes shafts open/closed data of toplift's
sensors. If S194 is pressed down, boom's lowering and
lifting functions are possible, even if shafts open/closed
data is missing. Switch does not by-pass stability.
S85
A81 DI12. Stability guard's by-pass switch by-passes stability guard, when the shafts are open or closed or when
you have pressed S189+S194. Switch permits lifting and
lowering of the boom and telescoping out, also permits
rotations. Stability does not affect telescoping in of the
boom. Telescoping in of the boom is allowed, when stability is 100%.
S199
A84_DI14B. Container contact by-pass switch. Permits
open movement of shafts, even if container contact is
missing. You can only use the switch when the container
is on a stable surface (on the ground).
S112
A84_DI1B. Emergency stop switch shuts off the engine,
and you cannot start the engine until you have released
the switch
S186*
A82_AI8 gas control. Controls the gas directly without
conditions 1,6V.
S187*
A82_PRO4 start of engine and A82_PRO1 engine running/stop. Press the button during starting, engine will remain running, you can also shut off the engine from the
switch. Controls directly without conditions.
S188*
A82_PRO3, A82_PRO2 directions and A82_DO2,
A82_DO3 2-gear. You can use the switch to select direction forward or backward and 2-gear. Controls directly
without conditions.
UDRS01.01GB
56
Electric Systems
*) Use of the by-pass button by-passes all protectors of

the control system. Use is only permitted for transfer driving to the repair shop.
04.3.15 Bus Errors

The display monitors that it receives messages from each
module (A81, A82,A83,A84 and A86 (ECU engine) at
specified intervals. If reception of message stops (>1s),
the display will show an alarm. A81 module also checks
that it receives messages from A82 module. If it does not,
critical movements will be forbidden. A bus alarm occurs
when a bus is broken or a module has fallen out of the entire system. First you should check whether a modules
LED lights are burning, and if they are, then you should
check the bus for errors.
1. Bus connection broken between A80 and A84
Machine operates normally without the display.
Display will show alarms ERROR CAN A81, ERROR
CAN A82, ERROR CAN A83, ERROR CAN ENGINE
Stability on display 0%, boom movements are forbidden, by--pass switch S85 permits movements, spreader movements do not function (switches on A84
module).
Display shows engine data (rpm, _C, bar) as zeroes,
engine will not start from the key but will start from by-pass switch S187. Directions do not function normally, but will function with by--pass switch S188. Gas
functions.
CAN A83, ERROR CAN ENGINE
module).
Display shows engine data (rpm, _C, bar) as zeroes,
engine will not start from the key but will start from the
by--pass switch S187. Directions do not function normally, but will function with the by--pass switch S188.
Gas functions, A81 controls it.
UDRS01.01GB
Electric Systems
57
4. Bus connection broken between A81 and engine A86

(ECU)
CAN ENGINE
module).
Display shows engine data (rpm,_C, bar) as zeroes,
engine will not start from the key but will start from the
by--pass switch S187. Directions do not function normally, but will function with the by--pass switch S188.
Gas does not function.
5. Bus connection broken between engine A86 (ECU)
and A83
Display will show alarms ERROR CAN A83
module).
Display shows engine data normally, engine will start
from the key. Directions do not function normally, but
will function with the by--pass switch S188. Gas functions.
6. Control unit falls out of the system
A81, alarm ERROR CAN A81. Boom movements do
not function even with the by--pass switch. Spreader
movements do not function, because free rotation is
on A84 module. Stability is 100%, engine functions
and starts and gears function.
A82, alarm ERROR CAN A82. You can engage
gears and direction with the by--pass button S188.
You can start and shut off the engine with S187 button.
Gas functions with the by-pass button S186. By-pass
switch S85 permits boom movements.
A83, alarm ERROR CAN A83. Spreader movements
do not function, boom movements will function with
S194 by--pass.
A84, alarm ERROR CAN A84 and EMERGENCY-STOP PRESSED. Boom movements function,
UDRS01.01GB
58
Electric Systems
spreader movements do not function. Engine will start

with the by--pass switch S187, gears and directions
function with the by-pass switch S188. Gas functions.
04.3.16 Replacement of a Module
If you replace a control module of the machine, you must
load the machine-specific software to it. Loading is done
at the factory in connection with the spare part delivery.
When you order a new module, you must specify the device code of said module (A80, A81, A82 or A83) and the
machine's serial number.
You must always perform the calibrations after you have
replaced a module. See item Calibration.
UDRS01.01GB
Electric Systems
04.4
59
Electric Equipment for the Power

Unit Scania DI12 EDC/PDE
A
R6- S11
R9
R7- S12
S12- R7
K201
S6
G1
K2
M1
Y3
Y2
Y1
Y4
Y5
B1
B1
S10
R4
S12- R7
R9
R6
S11
R7
S12
R9
B1
R4/S10
3
4
S11- R6
Figure 20. Electric Equipment for the Power Unit

1
Engine oil pressure sensor
Boost temperature / pressure sensor
Coolant temperature sensor
Engine RPM sensor
B1
Transmission output sensor
G1
Alternator
K2
Start solenoid
K201
Air conditioner magnet switch (optional)
M1
Start motor
R9
Hydr.oil temperature
R4/ S10
Engine coolant temperature sensor / switch
S6
Electronic control module ECM
R6/ S11
Transmission temperature sensor / switch
R7/ S12
Transmission pressure sensor / switch
Y1 -Y5
Solenoids of gear shift
UDRS01.01GB
60
Electric Systems
04.5
Electric Equipment for the Power

Unit
S10- R4
S12- R7
G1
S11- R6
B1
S11
B2
S12
B1
B2
A86
ECM
K2
S9
S12 R7
R6
R5
Y4
Y5
Y2
Y1
Y3
M1
Figure 21. Electric Equipment for the Power Unit
UDRS01.01GB
A86
Electronic control module ECM
B1
Transmission output sensor
B2
Engine RPM sensor
G1
Alternator
M1
Starting motor
K2
Starting solenoid
R6
Transmission temperature
S11
Transmission temperature switch
S12
Transmission pressure switch
Y1 -Y5
Solenoids of gear shift
Electric Systems
04.6
E39
Electrical Equipment in the Frame
V1- V7
F1
1
7
9 1 1315
1 3 5 7 9 111315
F2
X3
X1
2 4 6 8 10 14
12
16
4
2
8
10
F3
X2
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
XR3
X85
X78
3 2 1
6 5 4
9 8 7
X95
X35
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
X7
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
F42
F43
F44
F45
F46
F47
F48
F49
F34
F35
F36
F37
F38
F39
F40
F41
DI12
XEC
X37
3 2 1
6 5 4
9 8 7
X31
X38
3 2 1
6 5 4
9 8 7
3 2 1
6 5 4
9 8 7
X5
X6
A81
X4
X21
(X39)
F4
3 2 1
6 5 4
9 8 7
61
QSM11
S297
S296
Figure 22. Electrical Equipment in Frame
UDRS01.01GB
62
Electric Systems
A81
Control module
A85
Amplifier (stability)
E39
Service light
K71
Relay, brakes cooler
K72
Relay, hydraulics cooler
S296
Switch, cabin transfering
S297
Switch, cabin transfering
Diodes
QSM11
Cummins datalink
DI12
Scania datalink
Fuses
F1
Main fuse, cabin (50A)
F2
Main fuse, cabin (50A)
F3
Main fuse, frame/hydraulics (50A)
F4
Main fuse before main switch (50A)
F34
Hydraulics cooler (15A)
F35
Brakes Cooler (15A)
F36
Control module A83 (10A)
F37
Hydraulics (10A)
F38
Control module A81 (10A)
F39
Engine (10A)
F40
Cabin before main switch (25A)
F41
Cabin transfer, engine (10A)
F42- F49
Options
F43
Scania power (90A)
Connectors
UDRS01.01GB
X37
Cabin - boom
X35
Cabin - frame
(X39)
Main switch, Cabin boom in
X85
Cabin - frame
X95
Cabin - frame
XR3
Main switch - cabin
X38
CAN-connector, boom - engine
X21
Cabin - engine
X31
Cabin - engine
X78
Cabin - engine
XEC
Cabin - engine
Cabin
05 Cabin
05.1 Electric Equipment for Cabin ........................................................... 2
05.1.1 Electric Box for Cabin ............................................................. 2
05.1.2 Connectors for Cabin .............................................................. 5
05.2 Electric Control System of Engine Speed - Scania ........................ 6
05.2.1 General ................................................................................... 6
05.3 Electric Control System of Engine Speed - Cummins ................... 7
05.3.1 General ................................................................................... 7
05.4 Intake Air Filter and Windscreen Washer Filling ............................ 8
UDRS01.01GB
Cabin
05.1
Electric Equipment for Cabin
05.1.1 Electric Box for Cabin
S186 S187 S188
A13
*
A12
Option
Seat heater
R6 R8
K19 K13
1 3
17
1
17
1
12
8
10
12
8
10
K17
H13
F10 F11 F12 F13 F14 F15 F16 F17
S3
F18 F19 F20 F21 F22 F23 F24 F25
F26 F27 F28 F29 F30 F31 F32 F33
1
2
3
4
5
6
A84
40
18
41
42
17
16
6
5
43
15
14
3
4
45
46
13
12
47
11
7
8
10
2
3
3
2
1
1
2
3
4
5
6
7
44
48
49
50
7
6
51
A82
7
6
52
53
54
3
2
55
3
2
1
56
57
X44
XPO
XR1
XSR
XS1
X191
XR2
XR3
XHR
X115
X82
X32
X36
X21
X31
X95
XGE5
4
5
6
7
8
9
X35
Figure 1. Electric Box for Cabin
UDRS01.01GB
Cabin
A12
Voltage reducer (optional)
A13
Voltage reducer (optional)
A82
Control module
A84
Control module
H13
Alarm buzzer
R6
Resistor 200ohm
R8
Resistor 200ohm
S3
Maintenance switch
S186
Gas pedal by-pass
S187
Engine start
S188
Gear holding
Relays
K13
Sound signal
K17
Flashing relay
K19
Reversing light and alarm
Fuses
F10
Fan Heater (15A)
F11
Condenser fan (15A)
F12
Seat heater / compressor seat (15A) (optional)
F13
Alarm lights gauges (10A)
F14
Reserved (10A)
F15
Reserved (10A)
F16
Control modules A80, A82 and A84 feed (10A)
F17
Parking brake (10A)
F18
Driving and parking lights (10A)
F19
Flashing beacon (10A)
F20
Reversing lights alarm (10A)
F21
Turn signal lights (10A)
F22
Working lights, boom (10A)
F23
Working lights, boom (10A)
F24
Working lights, front on the roof (10A)
F25
Working lights, rear on the roof (10A)
F26
Working lights, spreader (10A)
F27
Front window wiper and washer (10A)
F28
Rear window wiper and washer (10A)
F29
Roof window wiper and washer (10A)
F30
By-pass
F31
Reserved (10A)
F32
Cabin transferring (10A)
F33
Engine stopping delay, (10A)

(optional)
switches (10A)
UDRS01.01GB
Cabin
Connectors
UDRS01.01GB
XR1
Spare wirings from hand lever panel
XSR
XR2
XHR
Spare wirings from front panels
XR3
Spare wirings from supply cable chassi
XP0
Forced drive control panel
X44
From air conditioner
X191
From mini steering wheel
XS1
XGE5
From hand lever panel
X22,
X37
From front panels
X21,
X31,
X35,
X95,
X82,
X115
From frame
X32
X36
From roof
XPC
From display
Cabin
05.1.2 Connectors for Cabin

*
E35
+12V 6A MAX
X32B
X36B
E30
+24V 6A MAX
F37
*
E32
M7
A312 X190
XGE
XR1
*
E34
S97A
S97B
*
E33
M5
S980
XR2
X308
X309
X310
*
+24V / 12V 6A MAX
XSR
S7
X1
X2
X3
S990
F37
H13
S52
S23
M911 M3
M212
M222
RM212
RM222
+24V 6A MAX
A80
X350 X355
X351 X356
X352 X319
XS2
X304
X305
X306
X307
XSR
M4
M6
M8
K33
K34 *
K35 *
*OPTION
X32
X36
XS1
GE5
XR1
X191
X44
XP0
XSR
XR2
XHR
XR3
X115
X82
X21
X31
X35
X95
Figure 2. Connectors for Cabin
UDRS01.01GB
Cabin
05.2
Electric Control System of Engine

Speed - Scania
05.2.1 General
The movement of the acceleration pedal in the electric
control system of engine speed is transferred as an electric signal message to the engine.
A312
A82
A96
Figure 3. Devices of the Electric Control System of

Engine Speed
1
Acceleration pedal
Engine Scania DSI12
A82
Control unit
A312
Potentiometer
A96
Engine control unit
Message of the function position of the acceleration pedal

(1) is transmitted through the potentiometer (A311) and
control unit (A82) to an engine control unit (A96), which
controls the function of the engine injectors .
UDRS01.01GB
Cabin
05.3
Electric Control System of Engine

Speed - Cummins
05.3.1 General
The movement of the acceleration pedal in the electric
control system of engine speed is transferred as an electric signal message to the engine.
1
A312
2
A86
Figure 4. Devices of the Electric Control System of

Engine Speed
1
Acceleration pedal
Engine Cummins QSM11
A86
Engine control unit
A312
Potentiometer
Message of the function position of the acceleration pedal

(1) is transmitted through the potentiometer (A312) to the
engine control unit (A86), which controls the function of
the engine injectors.
UDRS01.01GB
Cabin
05.4
Intake Air Filter and Windscreen

Washer Filling
Take care, that the visibility in the working area is not limited.
Check the function of windscreen wipers (1) and the level
of the washing fluid in the reservoir. Fill up, if necessary
(3). Pay attention to the machine operating temperature,
by defining the mixture ratio of washing fluid.
Figure 5. Air Filter and Windscreen Washer Filling
UDRS01.01GB
Windscreen wipers
Intake air filter
Filling cap for windscreen washer liquid
Working Devices
06 Working Devices
06.1 Maintenance of the Boom ................................................................
06.1.1 Maintenance Points of the Boom ............................................
06.1.2 Slide Guides and Telescope Cylinder .....................................
06.1.3 Adjustment of Play in the Boom ..............................................
06.1.4 Checking the Slide Parts ........................................................
06.1.5 Replacing Slide Parts in Front End of the Boom ....................
06.1.6 Replacing Slide Parts in Rear End of the Boom: ....................
06.1.7 Mounting the Telescope Cylinder ...........................................
06.1.8 Electrical Equipment of Boom .................................................
06.1.9 Lift Cylinder .............................................................................
2
2
3
4
4
5
6
7
8
9
06.2 Maintenance for Lifting Device ......................................................

06.2.1 Turning Device and Side Sift Carriage .................................
06.2.2 Container Handling Device (Toplift) ......................................
06.2.3 Rotation Transmission Maintenance Points .........................
06.2.4 Electrical Equipment for Spreader ........................................
10
10
11
13
14
06.3 Inspection Intervals for the Twistlocks of the Spreader .............

06.3.1 Disassembly and Assembly ..................................................
06.3.2 Inspection of the Twistlocks ..................................................
06.3.3 Information for Guidance ......................................................
16
16
17
17
UDRS01.01GB
Working Devices
06.1
Maintenance of the Boom
06.1.1 Maintenance Points of the Boom
A
2
6
3
KP06- 0117
Figure 1. Maintenance Points of the Boom
UDRS01.01GB
Item
Obs.
Slide pieces for boom front

end
Daily lubrication, if there is not

central lubrication
Boom bearings
Daily lubrication, if there is not

central lubrication
Upper sliding surfaces of

inner boom
Spread coating
Boom support rollers
Lubrication
Shims for bearings
Centralize the boom with

shims
Working Devices
06.1.2 Slide Guides and Telescope Cylinder

1
7
8
9
10
11
A-- A
13
12
Min. 19- 21
A
B
B
5
A
10
11
9
8
7
10 11 9
B- B
Figure 2. Slide Guides and Mounting the Cylinder
UDRS01.01GB
Working Devices
Slide part
Slide part
Slide part
Slide part
Slide part
Slide part
Screw
Mounting plate
Shim
10
Slide plate
11
Screw
12
Guide
13
Adjustment screw
06.1.3 Adjustment of Play in the Boom

You should always adjust the play in the boom's outer
and inner pipe when replacing slide parts, and at other
times in accordance with the scheduled maintenance program.
Adjust the play between the slide parts ( 1, 2, 3, 5 and 6)
and the boom with shims (9), and the play of slide parts
(4) with regard to the boom with adjustment screws (13).
Total play in the lateral direction can be in range 2 - 4 mm.
When adjusting the play, you should try to use the same
number of shims on opposite sides of the boom, so that
the gap between the outer and inner boom is sufficient on
both sides.
06.1.4 Checking the Slide Parts

Measure the thickness of slide plate (10) in the slide part.
Replace side and upper slide plates (10) if measured
thickness is 14 16 mm, and lower slide parts (4) if
measured thickness is 19 21 mm. When chamfer C in
the lower slide part (4) has worn off, replace the slide part.
Warning!
When slide parts wear to minimum thickness, lubrication grooves D are so low that lubrication is not
sufficient. This may damage inner pipe of the boom
and the telescope cylinder.
UDRS01.01GB
Working Devices
06.1.5 Replacing Slide Parts in Front End of the

Boom
In container handling machines, lower spreader on top of
container; in forest machines, lower grapple to the
ground. Move the boom carefully, so that the play between inner and outer pipe is loosened on that side of the
slide part you want to replace. Remove central lubrication
pipes from all slide parts you want to replace (option).
Replacing Lower (4) and Upper Slide Parts (1):
1. Remove upper slide parts by opening the mounting
screws (7) of the mounting plate (8) and by pulling out
the mounting plate and its slide parts. You must remove the upper slide parts, so that the lower slide
parts can come out.
2. Lower the boom, so that the play between inner and
outer pipe moves to the bottom side of the boom.
3. Open the guide's (12) adjustment screws (13) and pull
out the guide and its slide parts.
4. Replace the new slide part and re-install the guide
The guide's bottom surface is designed, so that it

can adapt to movements of the boom. When installing, make sure that the guide can roll freely.
5. Adjust later play of lower slide parts to 2 4 mm with
adjustment screws (13).
6. If necessary, replace new slide plates (10) to upper
slide parts (1) and mount them and their mounting
plates back into place.
7. Measure lateral play with a feeler gauge and adjust it
to 2 4 mm by adding or removing shims (9) between
mounting plate (8) and slide plate (10).
Replacing Side Slide Pats (2 and 3):
1. Check that there is play between the slide part you
want to replace and the boom, so that the slide part
can come out.
2. Open mounting screws (7) of the mounting plate (8)
and pull the slide part out.
3. Replace the new slide plate (10) and mount it and its
mounting plate back into place.
UDRS01.01GB
Working Devices
4. After you have replaced slide parts on one side, replace them on the other side.
06.1.6 Replacing Slide Parts in Rear End of the

Boom:
Replacing Side Slide Parts (5):
1. Push out the inner boom by 0,5...1 m.
can come out. If necessary, move the boom carefully.
3. Open mounting screws (7) of the mounting plate (8)
and pull the slide part out.
4. Replace the new slide plate (10) and mount it and its
mounting plate back into place.
5. After you have replaced slide parts on one side, replace them on the other side.
Replacing Bottom Slide Parts (6):
1. Pull the inner boom fully in. Check that the mounting
screws (11) of the slide parts are at the holes on the
bottom surface of the boom, so that you can open the
screws.

can come out. If necessary, move the boom carefully.
UDRS01.01GB
Working Devices
3. Open mounting screws (11) of the slide part (6) and

pull the slide part and its shim out.
4. Mount the new slide part back into place.
boom and slide plate (10).
When all Slide Parts have been Replaced:
Push the boom fully out carefully, and at the same time
check that the play is not smaller than the adjusted 2 4
mm at any point. If necessary, re-adjust the play. Re-
install central lubrication pipes (option) and test to

make sure all lubrication items receive enough
grease.
06.1.7 Mounting the Telescope Cylinder
Warning!
Make sure that the cylinder can move in the flange
holes. Item X.
UDRS01.01GB
Working Devices
06.1.8 Electrical Equipment of Boom

X200
Pg21
7
6
5
4
3
2
1
27
28
29
30
31 X4
32
33
6
5
4
3
60
61 X8
62
63
64
65
Pg21
Pg21
Pg21
Y63 Y65a
Y59b
X2
X1
A83
X7
X6
39
38
37
36
X3 35
24
59
7
58
8
26
25
X5 24
1
2
3
23
22
21
20
4
5
6
7
19
1
2
3
54
6
H21
X60 BOOM/ CAN

E27
E29
Pg21
X57
R60
120
R61
S79
Y65b Y59a
E27
E29
S81
S80
E28
E26
E26
E28
X200
H304 H305 H303
X30
RED
YELLOW GREEN
Figure 3. Electrical Equipment of Boom
UDRS01.01GB
E26
E29
Working light
H21
Flashing light
H303
Signal light green, twistlocks closed, 10W
H304
Signal light red, twistlocks open, 10W
H305
Signal light yellow, container in connection, 10W
R60
Boom's angle sensor (optional)
R61
Boom's length sensor (optional)
S79
Sensor, pressure weighing (optional)
S80
Sensor, damping of telescope in
S81
Sensor, damping of telescope out
X57
Connector, boom end
X60
Connector, basic boom end / CAN
X83
Connector, spreader
Y59
Solenoid valve, spreader rotating
Y63
Solenoid valve, spreader tilting locking
Y65
Solenoid valve, spreader longitudinal tilting
Working Devices
06.1.9 Lift Cylinder

Pm6
Figure 4. Lift Cylinder

1
Lock valve
Guide bearing
Pm6
Gasket set
06.1.9.1 Cylinder Mounting

Absolute cleanliness is necessary when assembling the
cylinder. Wash the used parts carefully before starting the
assembly, close with plastic plugs the open connection
points and open the gasket packages just when starting
the assembly. Make sure before starting to work, that
greases and oils used in assembly are suitable for hydraulic mounting.
Mount the guide rings so that the connection points of the
rings are not on the same central line. Lubricate with
vaseline the gasket set and guide ring surface before
mounting the piston into the cylinder liner.
Pull the piston carefully into the cleaned cylinder liner.
Make sure that the central lines of the piston rod and the
piston line are so accurately parallel as possible. Oil the
piston rod with hydraulic oil when the piston is pulled into
the pipe. Use for lifting crane or forklift truck, then the
gross weight of the cylinder is about 800 kg.
UDRS01.01GB
10
Working Devices
06.2
Maintenance for Lifting Device
06.2.1 Turning Device and Side Sift Carriage
1
3
2
1
3
4
3
7
8
3
330 - 350 Nm
Figure 5. Turning Device and Side Sift Carriage

Maintenance item
1
Lubricate bearings of cylinders1)
Lubricate shafts of turning device 1)
Lubricate slide surfaces for side sift car- Spread coating

riage
Lubricate bearings
Lubricate bearings of gear rim 1)
4 grease points
Gear rim
Spread coating
Gear oil filling / level dipstick
Gear oil drain plug
1)
UDRS01.01GB
Note
Central lubrication point (optional equipment)
Working Devices
11
06.2.2 Container Handling Device (Toplift)

The container handling device, toplift is welded steel construction with telescopes on both ends. The length of the
device is hydraulic adjustable for the container sizes according ISO and Seeland standards, with length of 20'
and 40'. Optional device for handling of containers of 30'
is available.
2
5
A
3
9
10
11
7
A- A
Figure 6. Container Handling Device (Toplift)
UDRS01.01GB
12
Working Devices
Container Handling Device

Maintenance item
Note
Toplift frame
Side sift carriage
T-beam
Length cylinder
Both T-beams
Lubricate bearings of the length

cylinde
T-beams have to be in 40'

position
Sliding pads in frame
Both ends
Sliding pads in T-beam
Both T-beams
Lubricate slide planes
Spread coating, especially

under sides of the beams
Lubricate twistlock turning cylinder
10
Twistlocks
11
Lubricate twistlocks
Moveable parts greassed

thoroughly at assembling
06.2.2.1 Check Sliding Pads

Check the sliding pads during lubrication maintenance.
Adjust the total spacing 1...2 mm with spacing plates.
Change outworn sliding pads.
UDRS01.01GB
Working Devices
13
06.2.3 Rotation Transmission Maintenance

Points
3
4
6
5
80 Nm
Figure 7. Rotation Transmission Maintenance Points

1
Transmission brake oil filling/draining. Fill to sight glass (2)

level (0.6l). Draining: Turn elbow down.
Transmission brake oil sight glass
Transmission brake breather
Transmission oil filling. Fill to sight glass (5) level (2.2l).
Transmission oil sight glass
Transmission breather
Transmission oil drain plug
UDRS01.01GB
14
Working Devices
06.2.4 Electrical Equipment for Spreader

The valves of hydraulics
S125
S99B
S99
Y73A Y74A Y71B
Y62B Y62A
Y66--1
Y73B Y74B Y71A
Y64B Y64A
Y66--2
S127
S98B
S98
S236
S136
S121
S123
S235
S135
X62
E37
E36
S128
S126
X83
Figure 8. Electrical Equipment for Spreader
UDRS01.01GB
S124
S122
Working Devices
15
S98
Sensor, rotation clockwise stop
S98B
Sensor, 20 limit rotation clockwise (optional)
S99
Sensor, rotation counter-clockwise stop
S99B
Sensor, 20 limit rotation counter-clockwise (optional)
S121
Sensor, twistlocks open, left
S122
Sensor, twistlocks open, right
S123
Sensor, twistlocks closed, left
S124
Sensor, twistlocks closed, right
S125
Container contact, front left
S126
Container contact, rear left
S127
Container contact, front right
S128
Container contact, rear right
S135
Sensor, spreader 20 - 40 left limit
S136
Sensor, spreader 20 - 40 right limit
S235
Sensor, 30 function left limit
S236
Sensor, 30 function right limit
X83
Connection
X62
Connection box
E36
E37
Spreader working lights
Y62A
Side shift, left
Y62B
Side shift, right
Y64A
Pile-slope to right (option)
Y64B
Pile-slope to left (option)
Y66-1
Pile-slope locking, left (option)
Y66-2
Pile-slope locking, right (option)
Y71A
Twistlocks open
Y71B
Twistlocks closed
Y73A
Lengthening right
Y73B
Shortening right
Y74A
Lengthening left
Y74B
Shortening left
UDRS01.01GB
16
Working Devices
06.3
Inspection Intervals for the

Twistlocks of the Spreader
Warning!
The twistlocks must be checked:

First time 5000 operating hours or 2 years whichever
occurs first. Then after the twistlocks must be
checked once a year.
300 Nm
4
5
Figure 9. Twistlock Housing
06.3.1 Disassembly and Assembly

1. Disjoin the mounting nut (1) and locking washers (2).
2. Draw the twistlock out (3) from the under side.
3. Check condition of the pivoted level (4) and bearing
housing (5).
4. Check condition and functioning of the contact pin (6)
and spring.
5. Check condition of the twistlock according to the instructions.
6. While assembling set the key and locking washers and
tighten the mounting nut 300 Nm.
7. Check that the parts are functioning correct in accordance with the others.
UDRS01.01GB
Working Devices
17
06.3.2 Inspection of the Twistlocks

Liquid penetrant examination or magnetic particle examination shall be used. The area of testing is shown in figure
10. Crack check shall take place every second year or
every 5000 operating hours.
Figure 10. 1 = The area of the testing

Note 1: If any cracks are found the twistlocks must be replaced immediately!
Note 2: Twistlocks must be replaced if they are visibly
distorted.
Max. 4 mm
in
.7
Note 3: Twistlocks must be replaced latest at 10.000 h.
Figure 11. Wear Limits, Lift Pin
06.3.3 Information for Guidance

06.3.3.1 Liquid Penetrant Examination
Detailed instructions for liquid penetrant examination is
available in, the following publications:
ASME Boiler and Pressure Vessel Code
Section V, Nondestructive Examination
Article 6, Liquid Penetrant Examination
UDRS01.01GB
18
Working Devices
Article 24, Standard methods for liquid penetrant inspection, SE-165 (=ASTM E 165)
SIS 11 45 01
Draft International Standard ISO/DIS 2694:1973
UDRS01.01GB
Working Devices
19
06.3.3.2 Magnetic Particle Examination

References
Draft International Standard ISO/DIS
2694
SIS 11 44 01 Magnetpulverprovning
DIN 54 121 Magnetpulver-Prfung
ASME Boiler and Pressure Vessel Code,
Section V; Nondestructive Examination:
Article 7, Magnetic Particle Examination
Article 25, Magnetic Particle Standards
SE-109 (=ASTM E 109-63) and
SE-138 (=ASTM E 138-63) and
UDRS01.01GB
20
UDRS01.01GB
Working Devices
Equipment
08 Equipment
08.1 Air Conditioner ..................................................................................
08.1.1 Function of the Air Conditioning Device ..................................
08.1.2 Operating Instructions for the Air Conditioner .........................
08.1.3 Maintenance ...........................................................................
08.2 Automatic Central Lubrication .......................................................
08.2.1 General .................................................................................
08.2.2 Indicator Lights and Switch in the Instrument Panels ...........
08.2.3 Central Lubrication Diagram K5698190 ................................
08.2.4 Central Lubrication Diagram, Toplift .....................................
2
2
3
4
12
12
12
14
16
UDRS01.01GB
Equipment
08.1
Air Conditioner
08.1.1 Function of the Air Conditioning Device

The circulation of the cold fluid in the air conditioning system R-134A installed in the machine, starts from the compressor;1; which press the hot and gaseous cold fluid to
the cooler;2, mounted on the back side of the machine.
The air flow through the cooler transfers the heat from the
cold fluid to the open air, and the cold fluid will condence.
From the cooler the condenced cold fluid is flowing into
the filter; 3;, which separates from the cold fluid humidity
and impurity. From the filter the cold fluid flows into the
expansion valve; 4; which controls the volume of the cold
substance flowing into the evaporator; 5. After the expansion valve the cold fluid pressure in the system is lowering. In the evaporator the cold fluid will vaporize again,
because of lowering pressure. The vaporizing liquid is
binding heat of the air, which flows through the evaporator cell, and the temperature of the cabin will be lower.
The compressor sucks the hot gas from the evaporator
and press it trough the cooler to one new working circulation
2
L
1
Figure 1. Diagram of the Air Conditioner
UDRS01.01GB
Equipment
Compressor
Cooler
Filter and control glass
Expansion valve
Evaporator
Low pressure
High pressure
08.1.2 Operating Instructions for the Air

Conditioner
08.1.2.1 Warm weather, normal humidity:
Close the recirculation vent and the heating regulator,
turn the cooling system on, and adjust the thermostat as
required.
08.1.2.2 Very warm weather, high humidity:
Open the recirculation vent, close the heating regulator,
turn the cooling system on, and adjust the thermostat as
required.
In autumn and early winter when humidity is high and windows become misty:
Turn the cooling system on, open a window slightly to allow air circulation in the cabin. Adjust the heating regulator for desired cabin temperature.
08.1.2.3 Cold winter weather:
Close the recirculation vent, do not turn cooling system
on. adjust the heating regulator for desired temperature.
UDRS01.01GB
Equipment
08.1.3 Maintenance
The system should be checked once a week, carrying out
the following inspections.
Sight glass. Bubbles should only appear when the
compressor is started and stopped.
Check that the connection between the compressor
pressure plate and the pulley is not slipping, and that it
is clean.
Check that the wire between the thermostat and the
electomagnetic clutch is in good condition.
Check the drive belt tightness and the compressor
mounting.
Clean or replace the fresh air and recirculation filters.
Check the removal of condensate water from the
bottom of the air-conditioner.
Check all hose connections.
08.1.3.1 Sight Glass Checking Procedure
a) Start the engine and run it at 1500 rpm
b) Turn the air-conditioner on.
c) Set the fan and the thermostat to maximum.
Figure 2. Fluid Container and Sight Glass Mounted to

Top/side
UDRS01.01GB
Equipment
Sight glass
Fluid container
Pressure switch
Sight glass Description
Conclusions and remarks
Continuous
stream of bubbles
or foam-like flow
(add refrigerant).
Very little refrigerant

Small temperature difference
between intake and pressure side.
Pressure in output side exceptionally low.
Stop compressor at once, and
have a specialized mechanic check
the system.
A few bubbles
every few seconds (add refrigerant).
Insufficient amount of refrigerant

High-pressure side warm, low-pressure side cool.
Check the system for leaks, and
repair possible leaks without delay.
Add refrigerant into the system.
Clear fluid, few

bubbles pass
when speed of
rotation is
changed.
Correct amount of refrigerant

Normal pressure values in highpressure and low-pressure sides.
Pressure side hot, intake side cold.
No bubbles
(remove refrigerant from system).
Too much refrigerant

Pressure side very hot. Abnormally
high pressure values in intake and
pressure sides.
Remove refrigerant from the system, from the pressure side.
08.1.3.2 Cold and Dry Periods with Minimal use of

Air Conditioner
Start the air-conditioner and allow the compressor to operate a few minutes every week to keep the connections,
seals, etc. lubricated. If a low-pressure switch is connected to the system, it must be bypassed if the ambient temperature is below -1C. Otherwise the compressor cannot
be started.
UDRS01.01GB
Equipment
08.1.3.3 Safety Regulations

When working on air-conditioning systems you should remember the following precautions:
Always wear goggles, because pressurized refrigerant
may leak out unexpectedly. Hands and other parts of the
skin should also be protected against freezing.
If you get refrigerant on your skin, the affected area
should be flushed with cold water and treated like frostbite. If refrigerant gets into your eyes, they should be
flushed with tap water, preferably approx. 15 minutes. If
pain or sight problems occur, seek medical help without
delay.
Refrigerants may never be handled near open fire or live
coals. Toxic gases are formed, if refrigerant and fire get
in touch with each other.
Figure 3. Always wear safety classes and protective

gloves
Figure 4. Do not release refigerant into the air. Use the

recovery unit!
UDRS01.01GB
Equipment
Figure 5. Keep caps closed!

If an R-134a air conditioner system is mistakenly charged
with R12, serious problems such as compressor seizure
can result.
Figure 6. Don't mix refrigerants!

08.1.3.4 Changing the Components of the Air
Conditioning System
Warning!
According to a resolution on refrigerants it has been
forbidden since July 1, 1989, to release refrigerants
into the atmosphere. Therefore, recovery equipment
should always be used. With such equipment, the
gas can be cleaned and then reused for filling up the
system. This procedure should be followed with all
refrigerants as they are harmful if released into the atmosphere.
UDRS01.01GB
Equipment
When a component is replaced, some of the compressor

oil is removed with it from the system. Top up the system
according to the following table.
Part
Oil amount / cm3
Evaporator
60
Condenser
40
Tank
20
Hose (3-8)
10-20
Warning!
Liquid R134-a requires green O-rings. Never use
black O-rings with R134-a.
Figure 7. Green O-ring

Compressor Oil
New compressors are delivered with 1.8 dl of oil in them,
an amount that is sufficient for systems with 1.25 kg of refrigerant. For systems up to 1.6 kg of refrigerant, the
amount of oil to be added can be calculated as follows:
Amount of refrigerant in kg x 1.3 + 0.4
Example: 1.5 kg x 1.3 + 0.4 = 2.35 -> add 0.55 dl (2.351.8=0.55)dl
Warning!
Use only synthetic PAG-oil such as ZXL 100 PG or
equivalent in the air conditioning devices.
When the compressor is replaced, measure the amount
of oil in the old compressor. Also drain the new compressor and then fill it through the intake connection, using the
same amount of oil as was drained from the old one.
UDRS01.01GB
Equipment
Figure 8. Dont mix oil compressors

08.1.3.5 Troubleshooting
No Cooling
Check:
uses, electric connections, compressor's earthing,
compressor's electromagnetic clutch, flow controller,
and pressure controller
drive belt
compressor
expansion valve
temperature regulator valve
refrigerant hoses
Poor Cooling Power
Check:
fan
drive belt tightness
that no air gets past evaporator
that the evaporator and condenser are not clogged
that the fresh air filter is not dirty and clogged
that the capillary tube of the expansion valve is
properly fastened to the evaporator outlet pipe
that the thermostat is not switching off too early
UDRS01.01GB
10
Equipment
Uneven Cooling
Check:
that all electric connections at the control switches,
magnetic clutch, and pressure controller are properly
fastened
that the expansion valve is not clogged
that the system is correctly filled
that the thermostat is not faulty
Abnormal Noise
Check:
that the compressor drive belt is correctly tightened
that the compressor mounting screws are properly
tightened
that the amount of refrigerant in the system is correct
Abnormal noises of the system often result from incorrect
mounting of components. If, for example, the compressor
is noisy at a certain speed and the noise disappears when
the speed is raised or lowered, it is likely that the fault is
not in the compressor.
All machines have their specific resonance frequency
where vibrations occur. The speed of rotation at which
noise is heard may vary between different machines.
Often these vibrations can be eliminated by increasing or
decreasing the tightness of the drive belt, or by replacing
it with a belt of different length. Too much tightness causes faster wear of the compressor bearings, the drive belt,
and the pulleys. Therefore, the drive belt should not be
adjusted too tight.
The compressor need not be replaced if the drive belt
'jumps' and causes unusual noise. In such cases, it is advisable to try adjusting the belt tightness or change a belt
of different length. Also a compressor pressure hose of
different length may reduce noise.
UDRS01.01GB
Equipment
11
Figure 9. Abnormal Noise

The pressure differences between the intake and output
sides also affect the noise level. A compressor with a low
intake pressure causes more noise than one with a high
intake pressure. Similarly, a compressor with a high output pressure causes more noise as it strains the bearings,
etc.
You should also check that the system is correctly filled
with refrigerant, and that the expansion valve works properly. Make also sure that the air flow through the evaporator is sufficient.
Also check that the condenser is clean and the air flow
sufficient, and that the system is not too full with refrigerant.
As the compressor has many moving parts, all noise cannot be removed. For instance, the compressor's pistons
generate noise and vibrations of relatively high frequency.
UDRS01.01GB
12
Equipment
08.2
Automatic Central Lubrication
08.2.1 General
This machine is equipped with a central lubrication system, which lubricates the most important lubrication
points on a regular basis. See Central Lubrication Diagram.
Figure 10. Automatic Central Lubrication Machine

See detailed operating instructions in the attached P203
Operating instructions.
08.2.2 Indicator Lights and Switch in the

Instrument Panels
H200
S200
H202
Figure 11. Instrument Panel
UDRS01.01GB
H200
Lubrication system indicator light, green (light is ON when

lube pump is working)
H202
Warning light, red
S200
Central lubrication switch / Extra lube interval / Reset after

warning
Equipment
13
08.2.2.1 Filling the Tank

Progressive system is designed to feed so-called base
greases until classification NLGI 2. You must take into account pumping ability of the grease in very low temperatures. When you change the grease quality or brand,
remember that different types of grease may react to
each other.
Figure 12. Filling the Tank

Fill the tank through a filling nipple, which is equipped with
a filter, with a pneumatically or manually operated pump.
UDRS01.01GB
14
Equipment
08.2.3 Central Lubrication Diagram K5698190
0.16ccm/min
0.08ccm/min
2
6
8
10
12
2
4
6
1
5
7
9
11
0.08ccm/min
0.17ccm/min
1
3
0.08ccm/min
0.17ccm/min
0.13ccm/min
0.25ccm/min
2
4
6
2
4
1
3
5
1
3
5
0.17ccm/min
2
4
0.33ccm/min
1
3
2
4
6
8
3
7
0.5ccm/min
1
5
1.0ccm/min
distributor
lubricant
quantity
g/h
4.0ccm/min
0.33ccm/min
2
4
6
1
3
5
bypass
4.0ccm/min
2.0ccm/min
Figure 13. Central Lubrication Diagram
UDRS01.01GB
cycle/
pause
Equipment
Luprication pump
Distributor
Distributor, steering axle, right
3:1
King pin, upper cap
3:2
Cylinder eye
3:3
Pivot axle, rear end
3:4
Cylinder lever
3:6
King pin, lower end
Distributor, steering axle, left
4:1
Cylinder eye
4:2
King pin, upper cap
4:3
Cylinder lever
4:4
Pivot axle, front end
4:5
King pin, lower end
Distributor, boom end
5:1,2
Joint pin for turning device
5:5.6
Turning device
5:7.8
Turning device
5:9,10
Longitudinal cylinder, upper end
5:11,12
Longitudinal cylinder, lower end
Distributor, boom
6:1,2
Side slide pads
6:3,4
Side slide pads
6:5,6
Lower slide pads
Distributor, boom
7:1,2
Hoist cylinder, lower end
7:3,4
Boom end
Distributor, jacks (optional)
8:1,2
Lower bearing
8:3,4
Cylinder, lower end
8:5,6
Cylinder, upper end
15
UDRS01.01GB
16
Equipment
08.2.4 Central Lubrication Diagram, Toplift
2
1
7
Figure 14. Central Lubrication Diagram
UDRS01.01GB
3S1221450
Equipment
17
Main distributor, toplift
Side distributor, shafts
2:1,2
Shaft cylinder
2:3,4
Rotating lever
2:5,6
Bearing housing
2:7,8
Steering piece
Side distributor, shafts
3:1,2
Shaft cylinderi
3:3,4
Rotating lever
3:5,6
Bearing housing
3:7,8
Steering piece
Side distributor, toplift
4:1,3
Rotating bearing
4:2
Upper head of pitching cylinder
4:4
Upper head of pitching cylinder
4:5,7
Rotating bearing
4:6
Bottom head of pitching cylinder
4:8
Bottom head of pitching cylinder
4:9
Suspension pin, left
4:10
Suspension pin, right
Side distributor,
6:1,3
Side shift cylinder
6:5,7
Length adjustment cylinder
Side distributor,
7:1,2
Support bearing for side shift wagon
7:3,5
Side shift cylinder
7:4,6
Support bearing for side shift wagon
UDRS01.01GB
APPENDIXES
1.
Warranty information
2.
Environmental issues
3.
Hydraulic diagram
4.
Electrical diagram
5.
Lifting boom assembly: KG6027/1--5
6.
Engine manual
7.
Transmission manual
MANAGEMENT OF
PRODUCT
ENVIRONMENTAL ISSUES
Contents
1.1
KALMAR ENVIRONMENTAL POLICY ........................................................................................................ 3
1.2
PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS ................................................................ 3
1.2.1
Effects of exhaust gases on health and the environment............................................................................. 3
1.2.2
Use of materials.......................................................................................................................................... 4
1.2.3
Energy consumption ................................................................................................................................... 4
1.2.4
Emissions into water and soil ..................................................................................................................... 4
1.2.5
Environmental problems............................................................................................................................. 4
1.2.6
Occupational health and safety .................................................................................................................. 4
1.2.7
Use of products........................................................................................................................................... 4
1.2.8
Complete overhaul or disposal................................................................................................................... 5
1.2.9
Preventive actions....................................................................................................................................... 5
1.3
RECOGNISING ENVIRONMENTAL ISSUES ............................................................................................... 5
1.3.1
Enhancing your environmental awareness................................................................................................. 5
1.3.2
Laws and regulations.................................................................................................................................. 5
1.4
RECYCLING ..................................................................................................................................................... 6
1.4.1
General ....................................................................................................................................................... 6
1.4.2
Sorting ........................................................................................................................................................ 6
1.5
REMEMBER THESE ........................................................................................................................................ 6
1.1 KALMAR ENVIRONMENTAL POLICY

ENVIRONMENTAL POLICY
The management of environmental issues at Kalmar Industries Oy Abs Tampere factory is based on Kalmar
Industries AB's operational policy, to which this environmental policy is a supplement.
Our operations are based on making continual improvements to prevent pollution of the environment, and on
developing environmentally friendly products and services.
The operations of the factory are developed in accordance with the principles of sustainable development.
Each year, the factory management looks at the main environmental concerns, determines its environmental
objectives and develops an environmental management programme to meet the objectives.
The management will keep track of the environmental objectives and corrective actions by conducting
internal audits as part of the operations system.
Reacting to possible environmental abnormalities and taking the necessary corrective actions is the
responsibility of the entire staff.
Kalmar Industries Oy Abs Tampere factory adheres to the current legislation and regulations in its
operations.
Our operations comply with the international environmental system standard ISO 14001 and the principles of
sustainable development set by the International Chamber of Commerce.
1.2 PRODUCT-SPECIFIC ENVIRONMENTAL CONSIDERATIONS

1.2.1 Effects of exhaust gases on health and the environment
Diesel engine emissions are the cause of both health and environmental problems. The most serious
environmental problem is soil acidification, which is manifested in problems in tree growth and plant
formation as well as eutrophication.
Of the diesel engine emissions, nitrous oxide (Nox) will form nitric acid when coming into contact with water,
and sulphur dioxide will form sulphuric acid. Both of these are strong acids that have an effect on plant
formation by decreasing the ability of roots to absorb water and minerals.
Particles are primarily the result of poor combustion of the fuel-air mixture in the diesel engine. They consist
of small carbon particles (<10 m) on which toxic hydrocarbons have concentrated. These come from the
fuel and lubricating oil. The particles are released into the air along with the exhaust gases and the
mutagenic and carcinogenic hydrocarbons may then enter human lungs.
Emissions
Maximum allowable exhaust emissions [g/kWh]

EU level 1 (1999)
EPA level 1 (1996)
EPA level 2 (1.1.2001)

Power range: 225450 kW
NOx
9.2
9.2
--
CO
5.0
11.5
3.5
HC
1.3
1.3
--
NMHC + NOx
PM
6.4
0.54
0.54
0.2
Hazardous emissions are mainly the result of incorrect adjustment of the motor and lack of maintenance. For
this reason, it is essential that adjustments and maintenance are as described in the instruction manuals.
1.2.2 Use of materials

Reasonable and appropriate use of materials can yield surprisingly high savings in costs and also decrease
environmental load. Preventive maintenance has a decisive influence on decreasing machine downtime.
User and maintenance manuals are intended to teach how to use the machine correctly and safely. Always
use spare parts recommended by the manufacturer, and perform maintenance and repairs in accordance
with the instructions. Follow all fluid changing intervals. Use environmentally friendly materials when
possible. Also try and use recycled materials. In this way, you will achieve the best possible results both for
the environment and safety.
1.2.3 Energy consumption

When using a machine, energy consumption is most influenced by the condition of the machine and the
machine operators skills. The manufacturer has installed and set the adjustable values of your machine to
the optimal level for both consumption and emissions. Regular maintenance and immediate repair work
when necessary are a prerequisite for optimal machine operation. Pay special attention to starting the
machine from cold and the instructions given for this.
1.2.4 Emissions into water and soil

The main consideration for the environment is to prevent oil and other toxic liquids from entering ground
water and surface water courses. Even small oil spills can cause significant damage to water courses. Pay
attention to any possible spills on your machine. Make sure the hoses are in good condition to prevent
unpleasant surprises.
When there is a spillage, absorb the spilled oil in sawdust, for example, and remove the contaminated
sawdust according to your site instructions. In case of an accident, immediately contact your supervisor or
the person responsible for environmental issues.
1.2.5 Environmental problems

By environmental problems, we mean faults detected in machine operation that will or might be harmful to
the environment. The most common of these are oil and other liquid spills, toxic waste, leaks and fires. If
seals on cabs are damaged or worn, this can also lead to an environmental problem, in case it causes the
operator to be exposed to noise levels which are too high. If there are possible environmental problems,
immediately contact your supervisor or the person responsible for environmental issues.
1.2.6 Occupational health and safety

Pay attention to your working environment. Perform the necessary maintenance and repair work to prevent
sickness or accidents caused by vibration, noise or other factors. Recognise the needs for safety training,
and get to know the safety bulletins of the hazardous substances you have to work with.
1.2.7 Use of products

Get to know the user and maintenance manuals of your machine well. Find out. For example, which
detergents to use for cleaning the machine. Follow the maintenance and adjustment schedules carefully.
Use the designated oils and other liquids. Check that the oil levels are correct. In general, when using the
machine, make sure that it works properly and is in the appropriate condition for the job.
1.2.8 Complete overhaul or disposal

As the lifetime of the machine draws to a close, there are two options for dealing with the machine: complete
overhaul or disposal. If complete overhaul is selected, use the manufacturer's expertise to determine the
amount of repairs needed. This also ensures that any new environmental and safety requirements will be
taken into account. In the case of complete overhaul, the product needs to be equipped to meet the new
requirements. This is the responsibility of the person conducting the repair work.
Environmental load can be reduced by sorting materials and components. Please note that the machine
mostly consists of various iron structures, which are mainly recyclable.
As to the disposal of toxic waste, you must find out the appropriate methods of disposing of the liquids,
materials and components. The safety bulletins of the various liquids and materials contain instructions for
disposal. You can also consult the suppliers of components and the product manufacturer for disposal and
sorting.
1.2.9 Preventive actions

Continuous monitoring of the machine operation along with preventive maintenance and repairs ensures the
safe and uninterrupted use of the product. Follow the maintenance instructions diligently so as not to
jeopardise the machine and its user. By blocking up leaks and checking the joints and pipe installations, you
can ensure that no unwanted liquids are released from the machine.
1.3 RECOGNISING ENVIRONMENTAL ISSUES

It is the responsibility of the employer to train the employees so that they can recognise environmental and
safety issues in their tasks. It is necessary to make sure that the training has been successful and sufficient
information has been provided.
1.3.1 Enhancing your environmental awareness

Aim to define your own environmental awareness. Ask your supervisor for more training if required. After the
training, make sure that you can adapt the information received to your everyday tasks. Product manuals
also contain environmental information about the product.
Ensure that you have sufficient general knowledge about the matters that have to do with your tasks. You
can improve your product knowledge by studying user manuals and spare parts lists provided by the
manufacturer. The manufacturer will also provide the necessary user training when needed. Find out about
the environmental and safety instructions for using, servicing and repairing the machine. What is most
important is to know how to act in exceptional cases.
Try to decrease emissions and the amount of waste produced as best you can. Do not take any risks, work
with care. Try to do the right things in the right way.
1.3.2 Laws and regulations

There are several laws and regulations that have to do with using the machine. It is the employers
responsibility to make sure the requirements are met in the work. Environmental issues have become
increasingly important. It is important to be aware of the current requirements, but it is equally important to
follow up on the changes in the requirements. The requirements tend to become tighter all the time.
1.4 RECYCLING
1.4.1 General
The primary goal of environmental protection is to decrease the amount of waste produced. If waste is
produced, you must try to utilise it as a material or source of energy. Appropriate and safe processing must
be arranged for all kinds of waste. The sorting of the waste created in our operations is influenced by the
legislation, environmental factors and general tidiness, among other things. The amount of waste driven to
the landfill can be decreased by sorting the waste in the appropriate, labelled receptacles. The most effective
way of protecting the environment is to save material and energy and use environmentally friendly methods
and products.
Become familiar with the waste disposal and recycling instructions of your unit.
1.4.2 Sorting
Metal waste can be collected, sorted and delivered to the industry for use as a raw material and alloying
element. Recycling saves approximately half of the energy that would be consumed if the same amount of
metal were obtained from a mine.
When recovering oil, light oil waste is separated from black oil into a separate receptacle. Used oil of good
quality can be recycled. Take special care when handling oils, as even the smallest amount of oil can cause
extensive damage to the environment and ground water courses. Collect all oil filters and other oily waste,
such as rags, hydraulic hoses, absorbents (sawdust etc.) in the appropriate, labelled receptacles.
Toxic waste means waste that can be hazardous to health or the environment because of some chemical or
other property. When collecting and handling toxic waste, these health and environmental risks need to be
taken into account. Toxic waste typically includes batteries and accumulators, paints, solvents, other special
liquids, fuel waste, coolant waste, aerosols and used fluorescent tubes. Sort all toxic waste and make sure it
is treated appropriately.
1.5 REMEMBER THESE

Being tidy and systematic is the most important consideration.
Remember to:
-
Act according to instructions
Check that all liquids are filled correctly
Check for leaks
Make sure that everything is functioning correctly
Return the tools used for maintenance and repair work to their right place
Store unused components appropriately
Recognise environmental problems
Sort the waste that is produced
Clear up the environment after finishing work
Keep the working areas, emergency exits and electric cabinets clear and unobstructed
Report all abnormal events
Contact your supervisor or the person responsible for environmental issues if necessary.
Keeping your own working environment tidy and in good order is your personal
responsibility. Tidiness and orderliness influence how the workplace functions, decrease
the number of accidents at work, and contribute to the positive image of the company and
its employees.
Hydraulic schemas T561200T91
A48503.0100 Hydr. schema base machine

K5687770 Hydr.schema, Cabin transfer
A50094.0100 Hydr. schema brakes
K5691600 Hydr. instruction, Twistlock
K5692320 Hydr. instruction, Side shift
K5692370 Hydr. instruction, Tilt
K5698240
Hydr. schema for basic machine

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
35
36
Steering
Lift
Boom telescope
Spreader turning
Tilt
Lift cylinder safety valve
Boom telescopecylinder safety valve
Turning pressure shockvalve
Turning directional control valve
Directional control valve for active tilt
Lockvalve for tilt
Speed restrictor for tilt
Shuttle valve
Brake for turning
Return filter
Pump for steering, lifting and telescoping
Pump for lifting, telescoping and spreader
Oilcooler
Pressure switch
Check valve
Relief valve for tilt
Check valve
Steering unit
Indicator for return filter
Check valve
2/2 solenoid valve, normaly closed
Priority valve
Check valve
Pressure reducing valve
Pressure relief and free flow valve for spreader
Shuttle valve
Check valve
N:o 4K5687770 B Tila: APP Nimitys: HYDR.SCHEMA
Tulostettu 16.01.2001 13:20:31
K5687770
Hydraulic schema
Cabin transfer
1
Cabin transfer hydraulic cylinder
Lock valve for cabin motion
Pump unit
K5692470
Hydraulic Diagram
Brakes
1
2
3
4
5
7
8
9
10
11
14
15
16
17
18
19
Brakes for driving axle

Parking brake
Parking brake control valve
Accumulators charging valve
Pressure filter
Pressure switch for brake lights
Hydraulic pump
Pressure switch for low brake pressure
Brake valve for drive axle brakes
Check valve
Restrictor
Indicator for filter
Oil cooler
Termo bypass
Check valve
N:o 4K5691600
Tila: APP Nimitys: Stohje Karojen lukitus
Tulostettu 24.01.2001 09:08:23
_PRELIMINARY N:o 4K5692320
Tila: DR Nimitys: Hydr.stohje sivusiirto
Tulostettu 24.01.2001 09:06:56
N:o 4K5692370
Tila: APP Nimitys: Hydr.stohje pitkittiskallistus
Tulostettu 21.02.2001 13:18:56
Instructions manual
Appendixes
Electrical diagram K52433.50A Cummins
Art no.
K52431.00
K52431.10
K52431.20
K52431.30
K52431.40
K52431.50
K52431.60
K52431.70
K52431.80
K52431.90
K52431.91
K52432.00
K52432.10
A49448.0100
K52432.20
K52432.30
K52432.40
K52432.50
K52432.60
K52432.70
K52432.80
K52432.90
K52433.00
K52433.40
K52433.10
K52433.20
K52433.30
K52410.70
K52410.80
Sheet Edition
A
Module A81
A
Module A82
A
Module A83
A
Module A84
10
A
Battery circuit
11
A
Fuse diagram Cummins QSM11
12
A
Engine start/stop Cummins QSM11
13
A
Alarm lamp indicator
14
A
Gauges
15
A
Lights
15
A
Flasher red lights (optional)
16
A
Working lights
17
A
Intermittent windscreen wipers and washer
17
Windows wipers and washer
18
A
Transmission control, Mini steering wheel
19
A
Oil cooling
20
Transmission operating chart
21
A
Air-conditioner
22
A
Cabin transferring
23
A
Proport control joystick
24
A
Spreader movement
25
A
Stability control
26
A
Lubrication system
27
A
Control handle
28
A
By-pass switches
29
A
Twist locks
30
A
Can-bus Cummins
Download loader
Download programs
Model 36000
Powershift Transmission
3-4-6 Speed
Short Drop
Owner Manual
Technical Description
2.6A-20002-C00
Printed Circuit Board for Pump 203

236-13891-1 Models V10 - V13*
236-13891-2 Models V20 - V23*
Subject to change without notice
with Adjustable Pause and Operating Times

Applications for Commercial Vehicles or Industrial Applications
*See page 4 Applications

10051327a
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Owner Manual
2.6A-20002-C00
Survey
Pump
Voltage [V]
12/24
203
Control unit
Setting ranges
Part no.
integrated
V10-V13*,**
V20-V23*,**
P1: 4 to 60 minutes
P2: 1 hour to 15 hours
A 1: 8 seconds to 120
seconds
A 2: 2 to 30 minutes
236-13891-1
236-13891-2
integrated
M00-M23***
P : 4 to 60 minutes
P : 1 to 15 hours
: 5 or 30 minutes
Applications
236-13870-1
without control
unit or with
external control
unit*
12/24
integrated
V10-V13*,** ADR
203
12/24
203
12/24
203
24 VDC
203
203
24 VDC, 115 VAC,

230 VAC
A - Operating time ranges
236-13891-1
integrated
H*
B : 6 hours, fixed
A: 2 to 30 minutes
236-13857-1
integrated
H * ADR
B : 6 hours, fixed
A : 2 to 30 minutes
236-13857-1
external
PSG 01
P : 0.5, 1, 2...to 12 hrs

A : 2, 4, 8, 16, 32 min
236-13834-1
664-36875-1
external
PSG 02
P : 1 min to 160 hrs

A : 1 min to 160 min
236-13860-2
B - Time of availability
P - Pause time range
- Monitoring time
* 1A1 - Version - Pump without connection for the illuminated pushbutton

**2A1 - Version - Pump with connection for the illuminated pushbutton
***2A4 - Version - Pump with microprocessor control
Note: The applications of the progressive systems are various. There is therefore a corresponding control unit available for each
individual application.
Page 2 from 16
Owner Manual
2.6A-20002-C00
Table of Contents
Page
Survey .............................................................................
Printed circuit board V10-V13 and V20-V23 .............
Applications .....................................................................
Mode of operation ...........................................................
Pause time ................................................................
Operating time ..........................................................
Time storage when the power supply
is switched off .............................................................
Time setting ......................................................................
2
4
4
4
6
6
6
7
Page
Repair .............................................................................. 9
Operational test/To trigger an additional lubrication ..... 9
Troubleshooting .......................................................... 10
Technical data ............................................................... 11
Connection diagram - Industrial applications .............. 12
Connection diagram - Appplications for
commercial vehicles ...................................................... 13
Connection diagram - Appplications for
commercial vehicles ...................................................... 14
Combinations of the jumper positions .................... 15
Further information can be found in the following manuals:
Technical Description Pump Model 203

Technical Description Progressive Metering Devices for Grease and Oil, model SSV
Technical Description for Electronic Control Units of the 203
pump
Printed Circuit Board 236-13857-1 - Model H
Printed Circuit Board 236-13870-1 - Models M 00 - M 15
Printed Circuit Board 236-13870-1 - Models M 16 - M 23
Timer 236-13860-2 Model PSG 02
Installation Instructions
Parts Catalog
Page 3 from 16
Owner Manual
2.6A-20002-C00
Printed Circuit Board V10-V13 and V20-V23

Applications
The printed circuit boards can be used for the following
applications
1.) Lubrication cycles only as a function of the machine working hours.
When the machine contact (external contact) is switched on
the centralized lubrication system is ready for operation.
Caution: On the PCB 236-13891-1 (V10-V13)* do not connect the red core of the connecting cable to connection 1,
Fig. 1, 14, 16 (terminal 30) since terminal 30 is connected
internally with terminal 15.
1191c95
Fig. 1 - Machine contact, printed circuit board 236-13891-1 (V10-V13)
Note: The PCBs 236-13891-1 and 236-13891-2 differ only

as regards their connection of the terminals. In the case of
PCB 236-13891-2 the terminals 30 and 15 are not connected.
1191d95
Fig. 2 - Machine contact, printed circuit board 236-13891-2 (V20-V23)
2.) Lubrication cycles only as a function of the running hours

of the commercial vehicle.
When the driving switch (terminal 15) is switched on, the centralized lubrication system is ready for operation
Note: In the case of PCB 236-13891-2 also connect the
battery voltage (terminal 30).
1060a95
Fig. 3 - Driving switch
This designation shows the version of the PCB installed in the pump. It forms part of the pump designation on the nameplate on each pump.
In the case of P 203-...-.K.-.A. ...-V10 the PCB 236-13891-1 is installed, see connection diagrams 1, 14 and 16.
In the case of P 203 - ... - .K. - .A.. ..-V20 the PCB 236-13891-2 see connection diagram 2, 17.
Page 4 from 16
Owner Manual
2.6A-20002-C00
Mode of Operation
The printed circuit board is integrated in the pump housing.
00002616
Fig. 4 - Printed circuit board installed in the housing
The printed circuit board automatically controls the sequence

of the pause and operating times of the model 203 central
lubrication pump as a function of the vehicle or machine working hours tB (Fig. 5).
The sequence of the pause and operating times is activated
when the machine contact or driving switch is switched on.
20002443b
Fig. 5 - Printed circuit board 236-13891-1
A lubrication cycle consists of one pause time and one operating time. Once the pause time has elapsed, the operating
time starts to run. This lubrication cycle is repeated permanently after the machine or vehicle has been put into operation. Refer to Fig. 5.
During the operating time the pump element dispenses the
lubricant to the lubrication points via progressive metering
devices.
1059a95
Fig.6 - Time sequence diagram
tB - Working hours
tP - Various pause times
T - Lubrication cycle
T1 -Stored pause times
T2 -Operating times
Page 5 from 16
Owner Manual
2.6A-20002-C00
The pause time
The operating time
- determines the frequency of the lubrication cycles within a

working cycle;
- is started and stopped via the machine contact or driving
switch;
- is adjustable.
When the machine contact or the driving switch is switched
off, the pause times which have already elapsed are stored
and added up (refer to T1, Fig. 6) until the time which has
been set on the blue rotary switch (Fig.8) is reached.
The pause time setting may be different for each application.
It must be adjusted in accordance with the respective lubrication cycles. Also see To set the pause time.
- depends on the systems lubricant requirement ;

- is adjustable;
- is finished when the machine contact or the driving switch is
switched off.
The longer the operating time, the greater the lubricant requirement and vice-versa.
When the machine contact or the driving switch is switched
off, the operating times which have already elapsed are
stored and added up until the time which has been set on the
red rotary switch (Fig. 10) is reached. After this, the lubrication cycle starts again.
The operating time setting may be different for each application. It must be adjusted in accordance with the respective
lubricant requirement. Also see To set the operating time.
Time storage
When switching off the ignition voltage and/or the operating voltage the times already expired are saved for an unlimited duration.
When the power supply is switched on again the printed circuit board continues to operate from the point where it had
been interrupted.
Page 6 from 16
Owner Manual
2.6A-20002-C00
Time Setting
* To set the pause or operating time, remove the cover on the
pump housing.
Note: To reset a jumper (Fig. 9), remove the printed circuit
board.
Important: After having set the pause time or operating time,
screw the cover on the pump housing again
00002617
Fig. 7 - The cover to access the printed circuit board has been removed
To set the pause time

The pause time can be set to 15 different settings by means of
the blue rotary switch.
Time ranges: Minutes or hours

20002451b
Fig. 8 - Rotary switch - Pause time
Switch position
Minutes
12
16
20
24
28
32
36
40
44
48
52
56
60
Hours
10
11
12
13
14
15
Note: When the switch is on 0 a fault is shown at the righthand LED 3, see page 9.
At the same time the factory-set pause time is accepted.
Factory setting
Rotary switch on : ........................................................... 6 hours
or ................................................................................ 24 minutes
The time ranges can be modified by replugging the jumper
(Fig. 9) on the printed circuit board.
20002452a
Fig. 9 - Preselection of the time range
Factory setting of the jumper: see chart page 15. The combination number can be learnt from the pump type designation
code mentioned on the nameplate of each pump.
Page 7 from 16
Owner Manual
2.6A-20002-C00
To set the operating time

The operating time can be set to 15 different setting by means of the red rotary switch.
Time ranges: Seconds or minutes
20002453b
Fig. 10 - Rotary switch - Operating time
Switch position
Seconds
16
24
32
40
48
56
64
72
80
88
96
104
112
120
Minutes
10
12
14
16
18
20
22
24
26
28
30
Note: When the switch is on 0 a fault is shown at the righthand LED 3 Fig. 12. At the same time the factory-set operating time is accepted.
Factory setting
Rotary switch on : ...................................................... 6 minutes
or ............................................................................... 24 seconds
The time ranges can be modified by replugging the jumper
(Fig. 11) on the printed circuit board.
Factory setting of the jumper: see chart page 15. The combination numbers can be learnt from the pump type designation code mentioned on the nameplate of each pump.
20002437
Fig. 11 - Preselection of the time range
Fault indication
Rotary switch set at 0
When one of the rotary switches 2, 3 Fig. 12 is on the 0
setting a fault is shown at the right-hand LED 3.
The fault is indicated by 4 flashes of the LED.
The pump motor also runs according the flash frequency. If
the warning is ignored the controller automatically adopts
the factory-set values for the operating or pause time
Pushbutton 5 Fig. 12 continuously actuated (short circuit)

If a short circuit occurs at the pushbutton or is present at
the external illuminated pushbutton Fig.13 or at the connecting parts a fault is shown at the red LED 3, fig. 12.
The fault is indicated by 3 flashes of the LED when the
voltage supply is switched on.
The motor of the pump also runs according to the flash
frequency.
Page 8 from 16
Owner Manual
2.6A-20002-C00
Repair
The defective printed circuit boards should be suitably packed
and returned to the factory.
Operational Test / To Trigger an Additional

Lubrication Cycle
If the printed circuit board must be replaced, a model

V 10 (V20) will always be delivered. See chart page 15.
Before installing another printed circuit board, take care that
the setting of the jumper or that of the operating/pause time
is the same as on the old printed circuit board.
To check the pump operation it is possible to perform an operational test.

Pumps model 203 installed on machines
* Switch on the machine contact.
Pumps model 203 installed on commercial vehicles
* Switch on the driving switch
Fig. 12 - LED on the printed circuit board
For all pumps

To check whether power is applied to the printed circuit
board, observe whether the LED 1 Fig. 12 is lit.
* Press pushbutton 5 on the printed circuit board (> 2 seconds) until the right-hand LED 3 lights up.
1 - LED, left-hand
2 - Rotary switch, pause time
3 - LED, right-hand
A shorter pause time elapses, followed by a normal lubrication cycle.
20002457b
4 - Rotary switch, operating time

5 - Pushbutton for additional
lubrication
Additional lubrication cycles can be triggered at any time.
Note: In the case of model 203 pump, version 2A1, with external illuminated pushbutton, it is also possible to trigger an additional lubrication cycle via this pushbutton.
20002458
Fig. 13 - To trigger an additional lubrication cycle, only pumps with illuminated

pushbutton
Page 9 from 16
Owner Manual
2.6A-20002-C00
Troubleshooting
Note: The pump operation can be checked from the outside by
observing whether the stirring paddle is rotating (e.g. by triggering an additional lubrication), whether the LED on the printed
circuit board are lit or whehter the signal lamp of the illuminated pushbutton (if any) is lit.
Fault: the pump motor does not run

Cause:
Remedy:
Voltage supply interrupted
Check the voltage supply to the pump. If necessary, eliminate the fault.
Voltage supply to the printed-circuit interrupted
Check the line leading from the pump plug to the printed circuit board.
If the voltage is applied, the left-hand LED is lit.
Voltage supply interrupted betweeen the printed circuit board

and the motor
Triggering an additional lubrication cycle

If the voltage is applied, the right-hand LED is lit.
Printed-circuit board defective
Replace the printed circuit board.
Fault: Right-hand LED 3 Fig. 12 flashes
Cause:
Remedy:
One of the two rotary switches 2, 4 Fig. 12 is on 0.

Signal: 4 flashes
Set rotary switch to a number or a letter.
Short circuit at pushbutton 5 Fig. 12 or, if present, at the illuminated push button or at their connecting parts
Signal: 3 flashes
Check whether the short circuit is at he PCB or, if present,

at the illuminated pushbutton.
If necessary, exchange the PCB or the illuminated pushbutton.
Page 10 from 16
Owner Manual
2.6A-20002-C00
Technical Data
Rated voltage ............................................................ 12/24V DC
Operating voltage
12V/ 24V .......................................................... 9V to 30V
Residual rippple in relation
with the operating voltage ................... 5% acc. to DIN 41755
Motor output ............................ Transistor 7A/short-circuit proof
Reverse voltage protection:
The operating voltage inputs are protected against
polarity reversal
Temperature range .................................. -25C to 70C
Lamp current in the case of pump 2A1 ....................... max. 2 A
Class of protection
Printed circuit board installed in housing .................... IP 6K 9K
Time setting
Pause time, depending on the jumper position:
............................................... 4; 8; 12; 24 to 60 minutes
......................................................... 1, 2, 3...to 15 hours
Operating time, depending on the jumper position
............................................ 8; 16; 24;....to 120 seconds
................................................... 2, 4, 6,....to 30 minutes
Factory setting
Pause time .......................................................... 6 hours
or .................................................................... 24 minutes
Operating time ................................................ 6 minutes
or .................................................................. 24 seconds
In order to protect the printed circuit board against condensation it has been covered with a protective varnish.
All the printed circuit boards comply with the EMC (Electromagnetic compatibility) guidelines for road vehicles acc. to DIN
40839 T1, 3 and 4
and the EMC guideline 89 / 336 / EWG
Emitted interference acc. to ................. EN 55011 / 03.91 and
........................................................ EN 50081-1 / 01.92
Noise immunity acc. to ............................. EN 50082-2 / 03.95
The type 203 pumps with PCB V10 - V13 (V20 - V23) comply
with the Automotive EMC Directive 95/54/EEC and with the
EC approval mark e1
021016
shown on the nameplate
Page 11 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Industrial Applications, Printed Circuit Board 236-13891-1 (V10-V13)
1192c95
Fig. 14 - Connection diagram Quicklub 203 with adjustable pause time

Connection via Hirschmann type-in connectors DIN 43650-A
ABCD-
Printed circuit board

Pump housing
Cable connector 1
Line socket 1 (black)
for connection cable, 3-wire
1A1 - Pump without illuminated pushbutton

2A1 - Pump with cable connection for
illuminated pushbutton*
F - Machine contact
* on request
GH-
Cable connector 2*
Line socket 2 (grey)
for connection cable, 3-wire*
IPushbutton for additional lubrication
J - Signal lamp in the case of low-level
control
Attention! If a pump model 103 CS...E2 is replaced by a pump model P203-...-...-2A1.10, the lamp connection of the
illuminated pushbutton must be changed from minus to plus.
- Low-level control*
31 - Earth
N-
Level control*
15 - Driving switch
Z-
Additional lubrication*
1009c93
- Motor
- Signal lamp*
Fig. 15 - Terminals of the printed circuit board
* equipment available on request
Page 12 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-1 (V10-V13)
1155d95

Connection via square type plug DIN 43650-A
ABCD-

Pump housing
Cable connector 1
with connection cable, 3-wire
2A1 - Pump with cable connection

for illuminated pushbutton**
F - Driving switch
G - Fuse 10 A
H - Cable, black
ICable, brown
KLMOP-
Cable connector 2**

with connection cable, 3-wire**
Illuminated pushbutton**
Signal lamp in the case of low-level
control
Battery cutoff*
*does not belong to the scope of delivery

**equipment available on request
Caution: Do not connect the red core (not shown: cf. J Fig. 17)
of the 3-core connecting cable to the wire box 1 (D, Fig. 16)
since the PCB is connected internally between 30 and 15.
Page 13 from 16
Owner Manual
2.6A-20002-C00
Connection Diagram - Applications for Commercial Vehicles

Printed Circuit Board 236-13891-2 (USA)
1155e95

Connection via square type plug DIN 43650-A
ABCD-

Pump housing
Cable connector 1
with connection cable, 3-wire
2A1 -Pump with cable connection

for illuminated pushbutton**
F - Driving switch
G - Fuse 10 A
H - Cable, black
ICable, brown
J - Cable, red
KLMOP-
Cable connector 2**

with connection cable, 3-wire**
Illuminated pushbutton**
Signal lamp in the case of low-level
control
Battery cutoff*
*does not belong to the scope of delivery

**equipment available on request
30 - Battery voltage
31 - Earth
N-
Level control*
15 - Driving switch
Z-
Additional lubrication*
1009b93
- Low-level control*
- Motor
- Signal lamp*
* equipment available on request
Fig. 18 - Terminals of the printed circuit board 236-13891-2
Page 14 from 16
Owner Manual
2.6A-20002-C00
Combinations of the jumper positions - Survey

Possibilities of
preselection
Pause time ranges

P
4 - 60 min
1 - 15 h
Operating time ranges

I
8 - 120 s
2 - 30 min
Jumper positions
See Fig. 8, 10
Combination no.
V 10, V 20
Standard
V 11, V 21
V 12, V 22
V 13, V 23
Page 15 from 16
Owner Manual
2.6A-20002-C00
Page 16 from 16

UDRS01 - 01GBMaintenance DRS Last

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

UDRS01 - 01GBMaintenance DRS Last

Uploaded by

Copyright:

Available Formats

00 General Information/

General Information/Scheduled Maintenance

General Information/Scheduled Maintenace

00.2 Instructions for Initiating into Maintenance Work ......................... 5

00.4 Preparing of the Machine for Maintenance ..................................... 9

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

00.1 General Information

00.1.1 About the Documentation

00.1.2 Warranty Agreement

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

00.1.3 To the Maintenance Personnel

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Instructions for Initiating into

The service and repair personnel must be clear about the

00.2.1 General Instructions

00.2.2 Maintenance and Repair Personnel

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Regulations for Safe Maintenance

The person performing the service shall be physically

00.3.1 General Safety View Points

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

00.3.2 Concerning the Maintenance and Repair

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

17.Always remember to engage the parking brake before

00.3.3 Preparing for Hazardous Situations

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

00.3.3.3 Reporting of Dangers

Preparing of the Machine for

The service and repair work should be performed in the

00.4.1 Maintenance Enviroment

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Lubrication Oil Recommendations

Required oils, greases and fluids

Engine Cummins QSM11

Diesel motor oil

Hydraulic oil tank

Drive axle PRC7534

Transmission oil SAE 5W30

Hypoid oil SAE 80W/90 EP

Lubricating slide planes of boom EP Multi-purpose grease

EP Multi-purpose grease, Class

High-quality diesel fuel

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Required oils, greases and fluids

1. In colder weather, a hydraulic oil heater should be used.

Maintenance Manual DRS 4527-4531

General Information/Scheduled Maintenance

Long life of the machine can be ensured bu avoiding

Maintenance Manual DRS 4527-4531