Beruflich Dokumente
Kultur Dokumente
Publ. no VDRT02.02GB
Workshop Manual in original
WORKSHOP MANUAL
DRT 450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DRT 450
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index
A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the Workshop Manual........................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About machine version............................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read the Maintenance manual .................................................................. A:4
The workshop manual's contents............................................................... A:5
Function group structure ............................................................................ A:6
References between different information types ........................................ A:7
Product alternatives and optional equipment ............................................. A:8
Machine card.............................................................................................. A:9
Function descriptions ............................................................................... A:10
About the documentation .............................................................................. A:12
The documentation's parts ....................................................................... A:12
Ordering documentation........................................................................... A:12
Feedback ...................................................................................................... A:13
Form for copying ...................................................................................... A:13
VDRT02.02GB
A:2
VDRT02.02GB
A Foreword Foreword
A:3
A Foreword
About the Workshop Manual
General
Thank you for choosing Cargotec as your machine supplier. We hope
that we will meet your expectations.
Conditions
The instructions are based on the use of generally available standard
tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet the national standards and regulations in force for lifting devices.
Cargotec will not accept any responsibility in the event of a modification
performed without permission from Cargotec. Further, Cargotec will not
accept any responsibility if other lifting devices, tools or work methods
are used other than those described in this manual.
Storage
NOTE
The workshop manual should be accessible to service personnel.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Extreme hazard to personal health and risk of property
damage!
Only use equipment that is approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
All duplication by any means, such as copying, printing, etc., is
prohibited.
VDRT02.02GB
A:4
Reading instructions
Warning information
Warnings provide information about potential dangers that, if the
warnings are not followed, could result in injury or product damage.
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regulation
is not followed.
CAUTION
Situation that could lead to product damage if regulation
is not followed.
Important information
Important information is denoted with NOTE and is intended to
facilitate the work process, handling or to increase understanding of
the information.
NOTE
Important information not related to safety.
The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
001128
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A:5
Foreword
General information about the workshop manual's purpose, contents and reading
instructions as well as survey for feedback of views and any inaccuracies.
Safety
Preventive maintenance
Complete machine
Engine
Transmission
Power transmission
Brakes
Steering
Suspension
Load handling
Control system
10
Common hydraulics
11
Common electrics
12
Common pneumatics
Error codes
Error code information and instructions for reading error code information.
Schematics
Technical data
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A:6
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A:7
Function descriptions
Hydraulic diagrams
(Technical description)
(Section E)
Component descriptions
Error codes
(Section D)
Diagnostics
Wiring diagrams
(Section E)
VDRT02.02GB
A:8
Product alternative
Product alternative describes options that are fitted instead of a specific
piece of standard equipment (e.g. engine alternative).
Equivalent information for different product alternatives is described
consecutively in separate segments within the same function group.
To indicate that there are different alternatives, "Product alternative"
is added to the heading together with a simple description of the
alternative, e.g. "(Product alternative Climate control system ECC)". In
addition, the alternative that is an option is marked with the symbol for
optional equipment.
000264
Optional equipment
Optional equipment
Optional equipment refers to options that can be added to standard
equipment for more or improved functions.
Information on auxiliary equipment is described in separate segments
together with the standard equipment as the basis. The optional
equipment description covers how the equipment option affects the
standard function and what additional components are involved.
VDRT02.02GB
A:9
Machine card
NOTE
If the machine has been modified after delivery, information on the
machine card may be incomplete or incorrect.
IMPORTANT
Modifications made to the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent when the customer
requests this.
The machine card indicates of which drawings the machine consists.
In many cases these can be associated with options and product
alternatives. For more information about handling of product
alternatives and optional equipment, see Product alternatives and
optional equipment, page A:8. The machine card is supplied with the
spare parts catalogue.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance and workshop manuals. For practical
reasons, the machine card only uses the first and second level in the
function group register. The function groups are written in groups of
four characters, e.g. group 0107 corresponds to group 1.7 Cooling
system in the manual.
For more information about how the machine card is used for ordering
spare parts, see the spare parts catalogue's foreword.
If the information on the machine card is not of any assistance, contact
Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.
VDRT02.02GB
A:10
Function descriptions
The function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.
The function descriptions describe the function in a logical flow from
input signal to desired output signal. Most functions require that preset
conditions are fulfilled for the function to be activated. In these cases,
the conditions are listed above the illustration.
The function descriptions use symbols to illustrate components such
as valves, sensors, etc.
4 B ro m s a r S e rv o b ro m s s y s te m
4 .3 S e r v o b r o m s s y s te m
S e r v o b r o m s s y s te m , fu n k tio n s b e s k r iv n in g
1
10
13
D790-2
B
P
D10
10
D797-R
D797-F
11
C5
Pa
D8
D11
C3
9, 12
Pa
7
B
ACC
C1
3
P
P os
F r k la r in g
S ig n a lb e s k r iv n in g
H n v is n in g
B ro m s o lje p u m p e n p u m p a r o lja fr n
b ro m s o lje ta n k e n .
P = 2 0 ,5 1 ,0 M P a
B ro m s o lje ta n k , b e s k riv n in g , s id a 3 6
A c k u m u la to re rn a la g ra r o lje try c k .
S e try c k s k y lt A c k u m u la to rtry c k b ro m s s y s te m , p
v n s te r ra m b a lk .
A c k u m u la to r, b e s k riv n in g , s id a 1 3
B ro m s v e n tile n s ty r try c k fr n
a c k u m u la to re rn a till b ro m s c y lin d ra rn a
p ro p o rtio n e llt m o t p e d a ltry c k e t.
B ro m s v e n til, b e s k riv n in g , s id a 1 7
B ro m s c y lin d ra rn a p re s s a r s a m m a n
la m e lle rn a i b ro m s e n h e te n .
S e try c k s k y lt B ro m s try c k , p
v n s te r ra m b a lk .
H ju lb ro m s , b e s k riv n in g , s id a 2 5
H ju lb ro m s a rn a b ro m s a r m a s k in e n .
H ju lb ro m s , b e s k riv n in g , s id a 2 5
B ro m s o lje p u m p , b e s k riv n in g , s id a 6
014123
4
013153
6.
2.
7.
8.
9.
3.
4.
5.
VDRT02.02GB
A:11
10
1.
2.
Electric force
3.
4.
Hydraulic force
5.
Hydraulic motor
6.
7.
8.
Electric motor
9.
Accumulator
11
12. Radiator
12
13. Bulb
14. Control and monitoring system, two control units with CAN bus
D790-1
13
15. Restriction
14
D797-F
15
16
17
18
19
21
23 Pa
20 C
22
Pa
24
25
26
27
28
29
014726
VDRT02.02GB
A:12
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied for the machine as a separate documentation kit.
Supplementary documentation
There is supplementary documentation that can be ordered for the
machine.
Workshop manual.
Ordering documentation
Documentation is ordered from your Cargotec dealer.
Always indicate publication number when ordering.
For publication number, see machine card.
VDRT02.02GB
A Foreword Feedback
A:13
Feedback
Form for copying
Cargotec's ambition is that you who work with maintenance of Kalmar
machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thanks for
your help!
To:
Cargotec Sweden AB
Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Phone: ...............................................................................................................................................................
E-mail: .................................................................................................................................................................
Suggestions,
views, remarks,
etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
VDRT02.02GB
A:14
VDRT02.02GB
B:1
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under the machine ....................................................................... B:8
Lifting heavy components .......................................................................... B:9
Vibration ..................................................................................................... B:9
Noise ........................................................................................................ B:10
Dissolvent................................................................................................. B:10
Fire and explosion risk ..............................................................................B:11
Fluid or gas under pressure ..................................................................... B:13
Coolant ..................................................................................................... B:13
Refrigerant ............................................................................................... B:14
Air pollution .............................................................................................. B:14
Tensioned springs .................................................................................... B:15
Electric motors ......................................................................................... B:15
Rotating components and tools................................................................ B:15
Tyres and rims.......................................................................................... B:16
Lifting equipment ...................................................................................... B:17
Spare parts............................................................................................... B:17
Non-ionised radiation ............................................................................... B:18
Environment.................................................................................................. B:19
General .................................................................................................... B:19
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B:2
VDRT02.02GB
B Safety Safety
B:3
B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions given in this manual
must make absolutely sure that the work is performed without risks of
personal injury and without risks of damage to the machine or property!
Remember to:
use the correct equipment and tools intended for the work in
question
use common sense and work carefully. Do not take any risks!
VDRT02.02GB
B:4
Safety instructions
General
Read and observe the following safety instructions below before
starting to work with the machine:
Service position
General
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
012924
VDRT02.02GB
Engine off.
B:5
Turn the start key to position 0 and switch off the system voltage.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
013400
Check that the relief valve for top lift is closed before
starting the engine.
NOTE
Keep the drain valve open as long as work is in progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
VDRT02.02GB
B:6
Oils
The following safety instructions must be followed for work when
handling oils.
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems
completely before starting to work in the systems. The
hydraulic and brake systems are pressurised and the
oil may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil may also be corrosive to mucous membranes
in, e.g. the eyes, skin and throat.
IMPORTANT
Always clean the area around components and
connections before they are loosened. Dirt in
oil systems causes increased wear, resulting in
subsequent material damage.
Always take action to avoid spills. In locations where
drainage containers cannot be used, use a pump or
hose for safe handling.
Always check that plugs are sealed tightly before
receptacles are moved.
Handle all oil as environmentally hazardous waste. Oils
freely discharged cause environmental damage and can
also be a fire hazard. Waste oils/fluids must always be
handled by an authorised company.
VDRT02.02GB
B:7
Fuel system
The following safety instructions must be followed for work when
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system must be avoided when the
engine is warm since fuel can spill on hot surfaces and
may ignite.
Make sure that open flames, sparks, or red-hot/glowing
objects have been extinguished before starting work
on or near the fuel system.
Do not smoke near the machine during work on the
fuel system.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can injure
the skin, resulting in severe injuries.
Risk of personal injury.
Use protective gloves and protective safety glasses,
avoid skin contact with fuel. If a component is being
loosened then hold a rag over the connection as
protection and collect the fuel. Fuel is corrosive to
mucous membranes in e.g. the eyes, skin and throat.
CAUTION
Always clean the area around components and
connections before they are loosened. Dirt in the fuel
may cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in
subsequent material damage.
IMPORTANT
Always take action to avoid spills. In locations where
drainage containers cannot be used, use a pump or
hose for safe handling.
Always check that plugs and connections are sealed
tightly before receptacles are moved.
Handle the fuel as environmentally hazardous waste.
Fuel freely discharged cause environmental damage
and can also be a fire hazard. Fuel must always be
handled by a company authorised for this activity.
VDRT02.02GB
B:8
Clothing, etc.
Clothes should be in good repair. Remove loosely hanging garments
(e.g. tie, scarf). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in
moving parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Exercise caution when working with welding or an
naked flame since hair easily catches on fire.
WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental movements
do not injure any other person. Communicate so that
everyone knows where everyone is, and what they are
doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
Operations controlled from the operator's station, e.g. all movement of
lifting equipment, may cause severe personal injury.
Safety precautions
Move the battery disconnector to position zero and remove the key.
Do not work with the drive wheels on the both sides of the machine
at the same time.
Risks
Mechanical or hydraulic tools and lifting devices may fall over or
accidentally lower due to malfunctions or incorrect use.
Safety precautions
VDRT02.02GB
B:9
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other tools to move
heavy components. Make sure that the device is sturdy
and intact.
Risks
Unsuitable lifting straps, etc. may break or slide.
The centre of gravity of the component may shift while work is in
progress, and the component may then make unexpected movements
which may cause severe personal injury and material damage.
A component lifted with lifting equipment may start to turn if the centre
of gravity shifts.
A component lifted using an overhead crane may start to swing
back and forth, which can cause severe crushing injuries or material
damage.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, in particular
when there are such tools available adapted for specific work
operations. See the workshop manual for methods.
If lifting must be performed without lifting device:
Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
Vibration
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from the
tool to hands. In particular when fingers are cold.
Safety precautions
Use heavy gloves that protect against the cold and the transfer of
vibrations.
Vary your work position and grip so that your body is not affected
in only one position by the vibration.
VDRT02.02GB
B:10
Noise
Noise louder than 85 dB (A) that lasts for longer than 8 hours is
considered to damage hearing. (Limit values may differ between
different countries.) High pitches (high frequencies) do more damage
than low pitches with the same sound level. Noise in the form of
impulse sounds may also be damaging, e.g. hammer strikes.
Risks
At noise levels higher than the limit values hearing damage may occur.
In more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it's tested and protects
against the right noise level.
Dissolvent
Fluids that (as opposed to water) dissolve grease, paint, lacquer,
wax, oil, glue, rubber, etc. are called organic dissolvents.
Example: Petroleum spirits, petrol, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many dissolvents are flammable.
Risks
Products with dissolvents give off fumes that may cause dizziness,
headache and nausea. They may also irritate mucous membranes
in the throat and bronchi.
If dissolvent comes in direct contact with the skin it can dry and crack.
Increased risk of skin allergies. Dissolvents may also cause injury if
they penetrate through the skin and are absorbed by the blood.
If the body is continuously exposed to dissolvents, there may be
damage to the central nervous system. This manifests itself in
sleeping problems, depression, nervousness, poor memory and
general tiredness. Continuous inhalation of petrol and diesel fumes is
suspected to cause cancer.
Safety precautions
VDRT02.02GB
B:11
DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at
the slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the
risk area.
DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people! Smoke
can cause damage to lungs and respiratory organs
even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work with
burnt material.
Examples of fire and explosion prone substances are oils, petrol, diesel
fuel oil, organic solvents (paint, plastics, detergents), rust preventive
agents, welding gas, gas for heating (acetylene), high concentrations
of dust particles consisting of combustible materials. Rubber tyres are
flammable and can cause fire with explosive development.
Risks
Examples of the cause of ignition are welding, cutting with gas flame,
tobacco smoking, sparks when grinding with grinding machines,
contact between hot engine parts and flammable materials, heat
generation in rags soaked with oil or paint (linseed oil) and oxygen.
Oxygen containers, lines and valves must be kept clean of oil and
grease.
Fumes from e.g. fuel are heavier than air and may "run" down a slope,
or down into a grease pit, where welding flames, grinding sparks or
cigarette embers may cause an explosion. Vaporised fuel has a very
powerful explosive effect.
VDRT02.02GB
B:12
Special cases
Diesel fuel oil with added petrol has a lower flashpoint. Risk of
explosion even at room temperature. The explosion risk for heated
diesel fuel oil is higher than for petrol.
When changing the oil in the engine, hydraulic system and
transmission, keep in mind that the oil may be hot and cause burn
injuries.
Welding on or in the vicinity of the machine. If diesel or other oils
have leaked and soaked rags, Absol/absorbing agents, paper or other
porous material then glowing welding sparks can cause ignition and
the explosive spread of fire.
When a battery is being recharged the battery electrolyte water is
divided into oxygen and hydrogen gas. This mixture is highly explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge unit is used, as they increase the risk of sparks.
There is a lot of electronic equipment on today's machines. When
welding, the control units must be disconnected and the electric power
must be switched off with the battery disconnector. Powerful welding
currents may otherwise short-circuit the electronics, destroy expensive
equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least
10 cm around the welding or cutting point). Use gloves, breathing
protection and protective glasses. Also, welding work must not be
done near plastic or rubber materials without first protecting them from
the heat. Paints, plastics and rubber develop a number of substances
when heated that may be hazardous to health. Exercise caution with
machines that have been exposed to intense heat or fire.
Safety precautions
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove residue of flammable materials in the engine
compartment as soon as they are detected. Be extra
careful on hot surfaces such as exhaust systems,
manifolds or turbochargers. If leakage of oil, fuel or
coolant is detected, the reason should be investigated
and the fault corrected before starting the engine.
VDRT02.02GB
B:13
Risks
Risk of damage/injury in connection with work on:
Fuel system.
Tyre changing.
Air conditioning.
Safety precautions
Never use your hands to check for any leaks. A fine jet from a
hydraulic hose may have such high pressure that it easily cuts
through e.g. a hand and causes very severe injuries.
Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in the event of leaks or when
the cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
First open the cap for the filling point slowly, so that the high
pressure is released. Exercise caution. Hot steam and coolant
may jet out.
VDRT02.02GB
B:14
Refrigerant
Refrigerant is used in the machine's air conditioning system.
Work on the air conditioning system must be performed by
accredited/authorised and trained personnel in accordance with
national legislation and local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g. when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety precautions
Air pollution
Air pollutants are the impurities in the air around us and are regarded
as hazardous to health. Certain impurities are more prevalent in
certain environments.
The following health-hazardous air pollution is particularly prominent in
workshops:
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or present
in aerosol) when cutting, grinding or welding. May give mucous
membrane irritation with asthma-like symptoms as well as impaired
lung function. Even brief exposure to high concentrations can give
problems with permanent oversensitiveness.
VDRT02.02GB
B:15
Safety precautions
Tensioned springs
Examples of tensioned springs:
1.
2.
3.
Lock rings
4.
Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries amongst other things.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
Electric motors
Safety precautions
Always switch off the battery disconnector when working on electric
motors.
Always block the machine's wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Cooling fan
Drive belts
Propeller shafts
Drills
Grinding machines
VDRT02.02GB
B:16
Risks
Rotating components, e.g. fans or shafts, can cause severe injury
if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothing or hair gets caught and becomes wound
into the machine.
Safety precautions
DANGER
Tyres should be regarded as pressure reservoirs. If
handled incorrectly, they constitute fatal danger.
Parts could be thrown out with explosive force and
cause severe injuries.
Never repair damaged tyres, wheel rims or lock rings.
Tyre changes must be performed by authorised
personnel.
Risks
Dismantling of wheels: Tyres, rims and lock rings may be ejected.
Inflating of tyres: Tyres, rims or lock rings may be ejected.
Safety precautions
VDRT02.02GB
Check that tyres, rims and lock rings are not damaged. Never
repair damaged wheel rims or lock rings.
B:17
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regards
to securing the boom and attachment.
Therefore, always make a habit of having the boom fully lowered and
completely retracted when working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic
system, see Hydraulic and brake systems, depressurising, page B:5.
Safety precautions
Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
Brake valve
Drive axle
Steering axle
Steering cylinder
Rim
Lift cylinder
Tilt cylinder
Twistlock
Emergency stop
Accumulator
VDRT02.02GB
B:18
Non-ionised radiation
WARNING
Optional equipment such as two-way radio, telephone,
etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, telephone, etc. when no persons
with active or non-active medical products are in the
vicinity.
NOTE
When persons with active or non-active medical products are not
nearby, telephone and two-way radio may be used in the cab.
Equipment should not be used during operation or load handling as
this takes away from the operator's concentration.
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer
approved by Cargotec.
VDRT02.02GB
B Safety Environment
B:19
Environment
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.
There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, the
machine is more than 90% recyclable by weight.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the
"greenhouse effect" if released into the open air. Special training is
required for all service work on the air conditioning. Many countries
also require certification by a governing authority for such work. When
scrapping an air conditioning unit, the refrigerant shall be taken care
of by a certified company.
VDRT02.02GB
B:20
B Safety Environment
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In
certain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, refrigerant of type
R134a is used, in an amount totalling between 1-3 kg.
VDRT02.02GB
C:1
C Preventive maintenance
C Preventive maintenance
The information is available in the
Maintenance Manual
The information is available in the Maintenance Manual.
For information on how to order the Maintenance Manual, see the
section A Foreword.
VDRT02.02GB
C:2
VDRT02.02GB
0:1
0 Complete machine
VDRT02.02GB
0:2
VDRT02.02GB
0:3
0 Complete machine
Complete machine, description
The Kalmar DRT 450 is a "Reachstacker" for container handling. The
machine a lifting capacity of 45 tonnes.
It is powered by a six-cylinder, four-stroke diesel engine with direct
injection.
The transmission is hydro-mechanical with gears constantly in mesh.
It has four forward gears and four reverse gears. Engine power is
transmitted using a torque converter.
The power transmission consists of one propeller shaft and one rigid
drive axle with hub reduction. Drive takes place on the front wheels.
The service brakes are wet multiple disc brakes which are attached to
the drive wheel hub. The parking brake is the disc brake type and
operates on the drive axle input shaft.
Steering operates on the rear wheels with a double acting hydraulic
cylinder. The steering axle is suspended in the frame with pendulum
suspension.
The wheels are fastened to the hub with clamps. Double wheels are
fitted on the drive axle; single wheels on the steering axle.
Load handling comprises components and functions for handling loads.
Loads are lifted with an attachment that is fitted on a liftable telescopic
boom. Load handling is divided into lifting/lowering, extension, side
shift, spreading, rotation, tilt, levelling and load carrier functions.
Side shift is the function for moving the lift attachment laterally in
relation to the machine.
VDRT02.02GB
0:4
Troubleshooting procedure
1
Fuel
Engine oil
Transmission oil
Hydraulic oil
Coolant
Washer fluid
If there are error codes, use the error code lists as a guide. See
Troubleshooting with an error code, example, page 0:5.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
VDRT02.02GB
0:5
Use the function description and check the signals for the function
affected in order to locate where in the function chain that the
signal or reaction is incorrect.
The fault is probably between the two units where the signal is
incorrect. Start by checking the component that should be sending
the signal.
Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see section
D Error codes.
Table Example of error code information in error code list
Code
34
Description
Limitation
Action
Parking brake
cannot be
released.
Check cabling
between the
control unit and the
component with
diagnostic menu.
Connections and
components
D791-1/K8:5 S107, K8:13 S107
Diagnostic
menu
Function
group
HYD, menu
5
4.1.2 Parking
brake control
Check component.
3
VDRT02.02GB
0:6
If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The system voltage must be switched off with the battery
disconnector!
9
VDRT02.02GB
0:7
CAUTION
Wipe and re-grease the connectors.
Risk of corrosion on contact surfaces.
Clean all connectors loosened during troubleshooting
using electronic cleaner 923836.0826 and re-grease
them with connector grease 923836.0552.
4
NOTE
Some components cannot be checked without power supply to
the component. In such an event, proceed to point 5.
a.
b.
b.
c.
VDRT02.02GB
0:8
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems
completely before starting to work in the systems. The
hydraulic and brake systems are pressurised and the
oil may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Hot oil can cause burn injuries, rashes and irritation!
The oil may also be corrosive to mucous membranes
in, e.g. the eyes, skin and throat.
WARNING
Oil under high pressure!
Personal injury!
Always depressurise hydraulic and brake systems
completely before starting to work in the systems.
1
Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Replace damaged hoses. When removing a hydraulic hose,
O-ring replacement is always recommended on the hoses that
have them fitted (ORFS).
VDRT02.02GB
1:1
1 Engine
Contents 1 Engine
1
Engine..................................................................................................................1:3
1.1
Controls and instruments ...............................................................................1:19
1.1.1
Ignition.......................................................................................................1:19
1.1.2
Accelerator ................................................................................................1:19
1.2
Fuel system....................................................................................................1:20
1.2.1
Fuel tank ...................................................................................................1:20
1.2.2
Sensor fuel level........................................................................................1:20
1.2.5
Make-contact (closing switch) water in fuel...............................................1:20
1.6
Air intake and exhaust outlet..........................................................................1:21
1.6.1
Air cleaning system ...................................................................................1:21
1.6.3
Exhaust system .........................................................................................1:21
1.6.4
Intercooler .................................................................................................1:22
1.7
Cooling system ..............................................................................................1:23
1.7.4
Radiator and expansion tank ....................................................................1:24
1.7.5
Cooling fan ................................................................................................1:25
1.7.7
Coolant ......................................................................................................1:26
1.9
Control system, engine ..................................................................................1:30
1.9.1
Engine control unit ....................................................................................1:30
1.11
Start/stop........................................................................................................1:31
1.11.1
Starter motor .............................................................................................1:31
1.11.2
Stopping device.........................................................................................1:31
VDRT02.02GB
1:2
VDRT02.02GB
1 Engine Engine
1:3
1 Engine
Engine, general
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
C
.
0
P
bar
I
II
III
1,6
D 11
D 1
5,7,19
D 6
D 7 9 0 -2
D 7 9 0 -1
2,12,23
D 795
D 7 9 7 -F
18,22
D 7 9 7 -R
17
4,8,21
D 20
D 8
3,13,16,24
D 794
20
D 3
S E N S O R S
10
H 2O
H 2O
15
14
014136
11
VDRT02.02GB
1:4
1 Engine Engine
Pos
Explanation
Signal description
Reference
U = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
10
Checked by control
system, error shown
with error code.
11
U = 0.5-4.5 V
12
Checked by control
system, error shown
with error code.
13
14
Low level: U = 24 V
15
Water in fuel: U = 0 V
VDRT02.02GB
1 Engine Engine
1:5
Pos
Explanation
Signal description
Reference
16
Checked by control
system, error shown
with error code.
17
Checked by control
system, error shown
with error code.
18
19
20
U = 0.5-4.5 V
21
Checked by control
system, error shown
with error code.
22
23
Checked by control
system, error shown
with error code.
24
VDRT02.02GB
1:6
1 Engine Engine
0
P
bar
I
rp m
kph
II
III
1,3
D 1
D 8
D 3
D 7 9 0 -2
D 7 9 0 -1
4,14
17
D 795
D 7 9 7 -R
2,9,18
5,10,16
D 15
D 13
12
D 5
D 794
13,19
15
S E N S O R S
014171
H 2O
11
Pos
Explanation
Signal description
Reference
U = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
6
7
VDRT02.02GB
1 Engine Engine
1:7
Pos
Explanation
Signal description
Reference
U = 0.5-4.5 V
Checked by control
system, error shown
with error code.
10
11
12
13
Checked by control
system, error shown
with error code.
14
15
U = 0.5-4.5 V
16
Checked by control
system, error shown
with error code.
17
18
Checked by control
system, error shown
with error code.
19
VDRT02.02GB
1:8
1 Engine Engine
1
9
2
4
5
013904
6.
Connection radiator
2.
Turbocharger
7.
3.
8.
Radiator
4.
Oil filter
9.
Intercooler
5.
Connection intercooler
VDRT02.02GB
1 Engine Engine
1:9
5
4
3
2
1
7
8
9
10
11
15
14
013905
12
13
8.
Alternator
2.
9.
Coolant pump
3.
Thermostat housing
4.
5.
Expansion tank
6.
7.
Connection intercooler
VDRT02.02GB
1:10
1 Engine Engine
18
7
17
16
8
9
10
11
12
13
14
014167
15
Engine alternative Cummins, right-hand side (in the machine's direction of travel)
1.
Expansion tank
2.
3.
4.
5.
6.
7.
8.
Starter motor
9.
18. Intercooler
VDRT02.02GB
1 Engine Engine
1:11
6
7
3
2
1
10
11
12
13
14
19
18
17
014166
15
16
Engine alternative Cummins, left-hand side (in the machine's direction of travel)
1.
2.
Turbocharger
3.
4.
13. Alternator
5.
6.
Expansion tank
7.
8.
9.
VDRT02.02GB
1:12
1 Engine Engine
0
P
II
III
13
6
12
7
9
8
014137
10
11
1.
2.
3.
4.
5.
6.
7.
VDRT02.02GB
8.
9.
1 Engine Engine
1:13
NOTE
Drain and collect liquids before detaching hoses.
Remove the cover washer on the clutch housing so that the flex
plate's attaching bolts are accessible.
VDRT02.02GB
1:14
1 Engine Engine
Rotate the engine so that the bolts in the flex plate can be
removed.
NOTE
Do not lift the engine.
10 Remove the bolts between engine and transmission.
11 Loosen the engine and transmission brackets.
12 Withdraw the engine rearwards to separate it from the
transmission.
Assembly
13 Rotate the engine so that the holes in the flywheel are just in front
of the attachment points on the flex plate.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
14 Fit the bolts to the engine mounts and transmission brackets.
Tighten to a torque of:
Engine mount, 330 Nm.
Transmission bracket, 280 Nm.
15 Connect the engine to the transmission.
16 Fit the bolts between engine and transmission.
Tighten to a torque of:
M12: 100120 Nm.
M14: 140160 Nm.
17 Fit the flex plate's attaching bolts. Tighten to a torque of 40 Nm.
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
18 Fit the cover plate in front of the flywheel.
VDRT02.02GB
1 Engine Engine
1:15
VDRT02.02GB
1:16
1 Engine Engine
NOTE
Drain and collect liquids before detaching hoses.
VDRT02.02GB
1 Engine Engine
1:17
Rotate the engine for each bolt in the flex plate that has to be
removed.
Remove the screws for the flex plate through the hole under the
cover washer.
NOTE
Do not lift the engine.
Assembly
12 Rotate the engine so that the holes in the flywheel are just in front
of the attachment points on the flex plate.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
VDRT02.02GB
1:18
1 Engine Engine
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
VDRT02.02GB
1:19
No function.
Operating position.
Voltage to all electrical functions. The control units for engine
and transmission are now ready to be started.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.1.4 CAN/POWER, menu
4.
II
Preheating position.
The preheating is controlled automatically by Control unit,
engine (D794).
III
Start position.
Engagement of starter motor for engine start.
0
P
NOTE
II
000317
III
1.1.2 Accelerator
Accelerator pedal, replacement
1.
Brake pedal
2.
Accelerator
VDRT02.02GB
1:20
1.
2.
Fuel tank
3.
012926
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.3.7 CAB, menu 7.
014134
VDRT02.02GB
1:21
001357
Intake hose
2.
Filter indicator
3.
Air cleaner
4.
Intake
5.
Dust reservoir
WARNING
Hot exhaust system!
Risk of burn injuries!
1.
Heat protection
2.
End pipe
3.
Silencer
4.
Flex pipe
5.
Exhaust pipe
014158
VDRT02.02GB
1:22
1 Engine Intercooler
1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air-air intercooler in the upper part of
the cooler unit.
See also Cooling system, description, page 1:23.
5
4
3
1.
Intercooler
2.
Radiator, engine
3.
4.
5.
VDRT02.02GB
003215
1:23
Coolant pump
Expansion tank
Thermostat
Cooling fan
Radiator
Intercooler
Coolant filter
2.
3.
4.
VDRT02.02GB
1:24
Engine coolant.
Transmission oil (cooled in the lower part of the cooler unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
Charge air (cooled in the upper part of the cooler unit), see also
Intercooler, description, page 1:22.
5
4
3
1.
Intercooler
2.
Radiator, engine
3.
4.
5.
VDRT02.02GB
003215
1:25
Release the tension on the fan belt and release it from the belt
pulley on the belt tensioner.
Reset the cab to the rear position and secure the cab on both
sides with the locking catches.
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine.
Reset the cab to the rear position and secure the cab on both
sides with the locking catches.
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine.
VDRT02.02GB
1:26
1 Engine Coolant
1.7.7 Coolant
Coolant, changing (engine alternative Yuchai
YC6M360-30)
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
1
VDRT02.02GB
Once all the coolant has drained out, close drain cocks.
1 Engine Coolant
1:27
Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
CAUTION
013827
1.
2.
Filling point
3.
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine.
12 Check the level in the expansion tank, fill if necessary.
13 Reset the cab to the rear position and secure the cab on both
sides with the locking catches.
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine.
14 Check the coolant level again after 10 operating hours.
VDRT02.02GB
1:28
1 Engine Coolant
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
1
1.
2.
Coolant filter
3.
Oil filter
VDRT02.02GB
Once all the coolant has drained out, close drain cocks.
1 Engine Coolant
1:29
Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
CAUTION
013827
1.
2.
Filling point
3.
12 Reset the cab to the rear position and secure the cab on both
sides with the locking catches.
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine.
13 Check the coolant level again after 10 operating hours.
VDRT02.02GB
1:30
VDRT02.02GB
1 Engine Start/stop
1:31
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, engine (D797-R).
For more information, see supplier documentation, engine.
NOTE
The battery disconnector must not be used for emergency stop!
For more information, see supplier documentation, engine.
Automatic engine shutdown is available as an option. This means
that the engine shuts off automatically after 3-30 minutes (depending
on customer setting) if the machine is stationary at idle.
VDRT02.02GB
1:32
VDRT02.02GB
2:1
2 Transmission
Contents 2 Transmission
2
Transmission ......................................................................................................2:3
2.1
Controls and instruments .................................................................................2:9
2.1.1
Gear selector and multi-function lever.........................................................2:9
2.2
Torque converter/Clutch system ....................................................................2:10
2.2.1
Flex plates .................................................................................................2:10
2.6
Lubrication system .........................................................................................2:13
2.6.3
Oil cooler ...................................................................................................2:16
2.7
Cooling system ..............................................................................................2:18
2.7.3
Oil cooler ...................................................................................................2:18
2.8
Control system, transmission.........................................................................2:19
2.8.1
Transmission control unit ..........................................................................2:19
2.8.2
Break contact (opening switch) declutch...................................................2:19
2.8.3
Transmission cable harness......................................................................2:19
VDRT02.02GB
2:2
VDRT02.02GB
2 Transmission Transmission
2:3
2 Transmission
Transmission, general
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the transmission's components and systems, refer
to the relevant supplier documentation.
References to supplier documentation are only provided in exceptional
cases. If information about a component is not found, the component
supplier documentation should be used.
F
R
1
23
D 23
6,24
D 1
D 1
D 5
D 7 9 0 -1
D 7 9 0 -2
D 793
D 794
11,17,19,21,27
2,7
D 795
D 7 9 7 -F
22
20
26
D 10
D 12
D 8
8
P a
D 9
D 25
10
P a
25
4
16
15
14
18
013852
13
12
Pos
Explanation
Signal description
Reference
Forward, Conn. F: U = 24 V
Reverse, Conn. R: U = 24 V
VDRT02.02GB
2:4
2 Transmission Transmission
Pos
Explanation
Signal description
Reference
U = 0.5-4.5 V
10
11
12
13
14
15
16
18
19
20
21
VDRT02.02GB
2 Transmission Transmission
2:5
Pos
Explanation
Signal description
Reference
22
23
U = 24 V
24
25
Conn 1, U = 24 V
Conn 2, U = 24 V
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
26
27
Y6067-1
Y6069
Y6067-3
Gear 1
On
On
On
Gear 2
Off
On
On
Gear 3
Off
Off
On
Gear 4
Off
Off
Off
VDRT02.02GB
2:6
2 Transmission Transmission
P a
5
28
10
26
7
29
14
15
17
20
11
18
21
25
13
R ev
Fw d
12
1st
2nd
16
19
3 rd
22
Pos
Explanation
Signal description
Reference
Transmission, component
location, page 2:8
10
Transmission, component
location, page 2:8
11
12
13
VDRT02.02GB
4 th
23
013853
2 Transmission Transmission
2:7
Pos
Explanation
Signal description
Reference
14
Transmission, component
location, page 2:8
15
16
17
Transmission, component
location, page 2:8
18
19
20
Transmission, component
location, page 2:8
21
22
23
24
Transmission, component
location, page 2:8
25
Transmission, component
location, page 2:8
26
27
28
29
VDRT02.02GB
2:8
2 Transmission Transmission
5
3
4
2
1
7
8
9
10
14
11
16
17
18
13
1.
2.
3.
4.
5.
Thermostat
6.
Gearbox
7.
8.
9.
VDRT02.02GB
12
013906
15
2:9
11
6
10
9
013847
7
8
1.
7.
2.
8.
3.
9.
4.
5.
6.
F - Forward
N - Neutral
R - Reverse
The switch is supplied with voltage by, and sends signals to, Control
unit KIT (D790-2).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.7.2 TRANSM, menu 2.
VDRT02.02GB
2:10
Remove the cover plate and rotate the engine so that each bolt to
the flex plate can be removed.
10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.
VDRT02.02GB
2:11
Rotate the engine for each bolt to the flex plate that has to be
removed.
VDRT02.02GB
2:12
10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.
VDRT02.02GB
2:13
During operation of the engine, the oil pump draws oil from the
transmission's oil sump through a strainer, and it then pumps it through
two oil filters to a control valve.
The control valve supplies oil at the correct pressure to the
transmission's valve housing to activate the clutch plates for
FORWARD or REVERSE and gear 1, 2, 3 or 4. The clutch plates
require just a small amount of the oil flow supplied by the pump. The
remainder of the oil is pumped through the torque converter circuit to
the oil cooler and returns to the transmission for lubrication.
See also supplier documentation, transmission.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be over-filled!
1
Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
VDRT02.02GB
2:14
When the transmission oil has drained, fit the drain plug.
013846
Make sure that the washer for the oil plug is included.
Fill with new transmission oil through the oil filling orifice (position
B) to the mark for low level on the dipstick.
For volume and quality, see section F Technical data.
Start the engine and allow it to idle for at least two minutes.
Check the transmission oil level with the engine running at idle and
top up to the marking for low level.
013823
a
000356
VDRT02.02GB
2:15
NOTE
Read the safety instructions for oil before working, see section B
Safety.
The transmission's oil filler pipe and dipstick (position C) are located
under the service cover in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 85 C in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
NOTE
013823
NOTE
VDRT02.02GB
2:16
5
4
3
1.
Intercooler
2.
Radiator, engine
3.
4.
5.
VDRT02.02GB
003215
2:17
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Drain the oil from the transmission, see Oil and oil filter, changing,
page 2:13.
IMPORTANT
007447
Fill with transmission oil; see Oil and oil filter, changing, page 2:13.
Check the transmission oil level, see Oil level, checking, page
2:15.
VDRT02.02GB
2:18
VDRT02.02GB
2:19
10
2 on the distribution block for the brake system above the drive axle's
differential.
3 The sensor can be checked via the diagnostic menu. See section 8
4 Control system, group 8.4.7.1 TRANSM, menu 1.
3
5
5
6
000439
1.
2.
3.
4.
5.
6.
7.
8.
9.
VDRT02.02GB
2:20
VDRT02.02GB
3:1
3 Power transmission
VDRT02.02GB
3:2
VDRT02.02GB
3:3
3 Power transmission
3.2 Propeller shaft
Propeller shaft, description
The propeller shaft transfers engine power from the transmission to the
drive axle. The propeller shaft has two joints, which means that the
engine and drive axle can move in relation to each other.
VDRT02.02GB
3:4
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
VDRT02.02GB
Turn the start key to position 0 and switch off the system voltage.
3:5
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
004501
2
1.
Hydraulic hoses
2.
Cable harness
6
Loosen the lock nut (position 4) and screw in the screw (position
5), this compresses the brake spring. Screw until the brake pads
release from the brake disc. Refit the cover on the parking brake
(position 3).
004505
1.
NOTE
5
004506
1.
Lock nut
2.
Release screw
3.
VDRT02.02GB
3:6
Detach the propeller shaft from the drive axle. Secure the propeller
shaft, otherwise there is a risk that it will be pulled apart.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
Lifting machine
13 Remove the bolts that secure the drive axle in the frame.
14 Lift away the drive axle.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
15 Transfer parts from the old drive axle to the new one.
NOTE
Attaching bolts drive axle
VDRT02.02GB
3:7
18 Transfer the guide pins from the old axle to the new axle.
19 Lift the drive axle into place under the frame.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
20 Lower the frame toward the drive axle. Check that the guide pins
fit in the frame.
21 Fit the new bolts that secure the drive axle in the frame. Tighten
the bolts to a torque of 2820 Nm.
22 Install the drive wheels on the new axle.
23 Rustproof the bolts with suitable paint.
004501
VDRT02.02GB
3:8
VDRT02.02GB
4:1
4 Brakes
Contents 4 Brakes
4
Brakes..................................................................................................................4:3
4.1
Controls and instruments .................................................................................4:3
4.1.1
Brake pedal .................................................................................................4:3
4.3
Power-assisted brake system ..........................................................................4:5
4.3.1
Brake oil pump ............................................................................................4:6
4.3.2
Brake oil filter ............................................................................................4:10
4.3.3
Accumulator charging valve ...................................................................... 4:11
4.3.4
Accumulator ..............................................................................................4:14
4.3.5
Brake valve ...............................................................................................4:18
4.3.6
Drive axle block .........................................................................................4:22
4.3.7
Break contact (opening switch) brake oil pressure....................................4:23
4.3.8
Make-contact (closing switch) brake lights................................................4:25
4.3.9
Wheel brakes ............................................................................................4:26
4.3.10
Pipes and hoses........................................................................................4:29
4.5
Parking brake system ....................................................................................4:30
4.5.1
Brake oil pump ..........................................................................................4:31
4.5.2
Brake oil filter ............................................................................................4:31
4.5.3
Solenoid valve parking brake ....................................................................4:31
4.5.4
Parking brake unit .....................................................................................4:32
4.5.5
Break contact (opening switch) parking brake ..........................................4:36
4.5.6
Pipes and hoses........................................................................................4:36
4.8
Temperature control, cleaning and oil brake system......................................4:37
4.8.1
Brake oil tank ............................................................................................4:38
4.8.3
Brake oil pump ..........................................................................................4:38
4.8.4
Accumulator charging valve ......................................................................4:38
4.8.5
Drive axle block .........................................................................................4:38
4.8.6
Wheel brakes ............................................................................................4:38
4.8.7
Oil cooler ...................................................................................................4:39
4.8.8
Cooling fan ................................................................................................4:40
4.8.9
Thermal bypass valve ...............................................................................4:40
4.8.10
Sensor, oil temperature brake system.......................................................4:41
4.8.11
Breather filter.............................................................................................4:42
4.8.12
Brake oil filter ............................................................................................4:43
4.8.13
Pipes and hoses........................................................................................4:44
4.8.14
Oil, brake system ......................................................................................4:44
VDRT02.02GB
4:2
VDRT02.02GB
4 Brakes Brakes
4:3
4 Brakes
4.1 Controls and instruments
4.1.1 Brake pedal
Brake pedal, checking and adjustment
1
Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1-1.5 mm.
If necessary, adjust the brake pedal's stop screw to the correct
clearance.
Check that the rubber pad on the brake pedal is intact and that the
tread pattern is not worn away. Replace if necessary.
Check the brake valve; see Brake valve, checking, page 4:18.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Switch off the engine and switch off the system voltage.
VDRT02.02GB
4:4
NOTE
There is a variant available with adjustable steering wheel shaft.
9
Mounting of steering wheel shaft and steering valve in
pedal assembly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
15 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment, page 4:3.
VDRT02.02GB
4:5
13
D790-2
B
P
D10
10
D797-R
D797-F
9, 12
C3
11
C5
Pa
D8
D11
4
Pa
7
ACC
C1
3
P
1
013153
B
Pos
Explanation
Signal description
Reference
P = 20.51.0 MPa
VDRT02.02GB
4:6
Pos
Explanation
Signal description
Reference
Conn. 1, U = 24 V
Conn. 2, U = 24 V
Brake pressure below
0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
9
10
U = 24 V
11
Conn. 1, U = 24 V
Conn. 2, U = 24 V
Brake pressure below
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
12
13
013858
1.
VDRT02.02GB
NOTE
It is very important that the clearance between the gears and
between the gear and the housing is correct. Clearance that is too
small creates wear damage. Clearance that is too large reduces
the pump's power output.
4:7
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Operate and warm up the machine so that the oil in the brake
system reaches operating temperature, at least 50 C.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
11 Close the drain valve on the accumulator charging valve.
VDRT02.02GB
4:8
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
NOTE
Plug all connections immediately to protect the brake system
from impurities.
VDRT02.02GB
Remove the attaching bolts, pull the pump out backwards and
lift it away.
4:9
Remove the spacer ring from the brake oil pump or hydraulic oil
pump.
Clean the O-rings' contact surfaces on the spacer ring.
Check the O-rings and replace if necessary. Fit the O-rings on the
spacer ring. Brush sealing silicone onto the sealing face against
the brake oil pump, see section F Technical data.
NOTE
Only use silicone on the side facing the oil pump, brake system.
Brush sealing silicone onto the sealing face of the brake oil pump
against the spacer ring, see section F Technical data.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
VDRT02.02GB
4:10
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Switch on the system voltage and start the engine.
14 Check that the hose connections and seal between the hydraulic
oil pump and brake oil pump are sealed tightly.
Check the feed pressure from the brake oil pump, see Brake oil
pump, checking, page 4:7.
15 Check the oil level in the brake system, fill if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the brake system as well.
VDRT02.02GB
4:11
13
12
oil pump between pressure storage and cooling of the wheel brakes.
The accumulator charging valve is fitted on the beam in front of the
3 transmission in the engine compartment.
11
4 the accumulators. The wheel brakes are cooled by oil being directed
10
The drain valve (position 11) is used to relieve the pressure in the
accumulators to the tank. The valve opens a connection between the
accumulators and the wheel brake's cooling circuit. The oil is drained
through the wheel brake to the tank.
000431
1.
Safety valve
2.
3.
4.
5.
6.
7.
8.
9.
VDRT02.02GB
4:12
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
VDRT02.02GB
4:13
Detach and plug all hydraulic hoses from the accumulator charging
valve.
Remove the parking brake valve (C) for easier access.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
10 Fit the parking brake valve and break contact (opening switch)
parking brake.
11 Connect the cable harness to the accumulator charging valve.
VDRT02.02GB
4:14
4 Brakes Accumulator
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Switch on the system voltage and start the engine.
Check that the hydraulic connections are sealed tightly.
14 Check the charging and switching function, see Accumulator
charging, checking and adjustment, page 4:12.
4.3.4 Accumulator
Accumulator, description
The accumulators store pressure so that there is a pressure reserve
in the event of engine or brake system malfunction. The brake system
has four accumulators connected in parallel. These are fitted at the
front in the engine compartment, above the drive axle.
The accumulators are of the diaphragm type. Each accumulator
is divided into two compartments by a diaphragm. One side of
the diaphragm is pressurised by nitrogen gas. The other side is
pressurised by the hydraulic oil, which compresses the nitrogen gas.
013156
The accumulator has test outlets for checking the gas pressure on
the opposite side to the pressure connection.
Accumulator, checking
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
VDRT02.02GB
4 Brakes Accumulator
4:15
Remove the accumulators and test them with the test equipment
designed for the purpose.
The accumulators' gas pressure must match with the pressure
plate.
Continue with step 17.
013855
VDRT02.02GB
4:16
4 Brakes Accumulator
NOTE
Check that the seals are intact, clean and in the correct position.
18 Switch on the system voltage and start the engine.
19 Close the drain valve on the accumulator charging valve so that
the accumulators are charged.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
20 Check that the accumulators' connections are sealed tightly.
21 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must be
switched on.
Accumulator, replacement
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Switch off the engine and switch off the system voltage.
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
VDRT02.02GB
4 Brakes Accumulator
4:17
NOTE
Check that the seal is intact, clean and fitted in the correct
position.
8
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
10 Switch on the system voltage and start the engine.
11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking, page
4:14 steps 18-19.
VDRT02.02GB
4:18
1
2
013158
1.
2.
3.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
VDRT02.02GB
Operate and warm up the machine so that the brake system's oil
reaches operating temperature, at least 50 C.
Start the machine and run it at idle until the accumulators are
charged and the accumulator charging valve changes to cooling.
Press down the pedal completely and read off the pressure.
Compare with the pressure plate on the left-hand frame member.
4:19
Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for 15
seconds.
013856
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Slide the cab forward slightly so that the brake valve is accessible
under the cab.
Mark up and detach the hydraulic hoses from the brake valve.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
5
VDRT02.02GB
4:20
NOTE
Remember the spacer ring.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
11 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment, page 4:3.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
4:21
13 Secure the cab in the rearmost position with the cab locks.
WARNING
The cab has the manual sliding cab function. The cab
must ALWAYS be in the rear position while operating
the machine.
Lock pin
012760
VDRT02.02GB
4:22
1 and left-hand wheel brakes. The drive axle block is fitted on a bracket
10
The drive axle block has a measuring outlet for brake pressure and
5 the cooling circuit intake to the cooling circuit return if the resistance
7 There are two switches fitted on the drive axle block: Make-contact
in the axle becomes too great. This protects the wheel brake seals,
000439
1.
2.
3.
4.
5.
6.
7.
8.
9.
VDRT02.02GB
4:23
000435
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.4 HYD, menu 4.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Operate and warm up the machine until the oil reaches operating
temperature, at least 50 C.
VDRT02.02GB
4:24
Brake several times, stop when the warning lamp for low brake
pressure illuminates.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp illuminates at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
13 Depressurise the brake and hydraulic systems, see section B
Safety.
14 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
15 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
4:25
013160
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.4 HYD, menu 4.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Operate and warm up the machine until the brake system's oil
reaches operating temperature, at least 50 C.
VDRT02.02GB
4:26
000144
DIAG HYD
4(6)
PRESSURE SWITCHES
BRAKE PRESSURE
X
BRAKE LIGHT PRESS. X
DECLUTCH PRESSURE
X
Depress the brake pedal slowly until the brake light is switched on
or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status should change and the brake light should be switched
on when the pressure is approx. 0.2 MPa.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
013161
The wheel brake uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to efficient cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
VDRT02.02GB
The wheel brakes have two main sections - disc pack and brake
cylinder. The disc pack performs the braking. The brake cylinder
presses the discs in the disc pack together during braking.
000016
4:27
Disc pack
2.
Brake cylinder
VDRT02.02GB
4:28
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work which involves the brake system being
opened or after work on the wheel brake.
Brake cylinder
1
Start the machine and depress the brake pedal, keep the pedal
depressed.
Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is long.
So allow at least two litres of oil to pass through the bleed
nipple when bleeding to ensure that no air pockets remain in
the system.
Move the spanner and hose and repeat steps 1-4 on the other side.
Disc brake
NOTE
Disc brake ventilation is vital for the correct cooling of the discs.
1
Start the engine and run the engine at idle. Wait until the brake
accumulators are fully charged and the accumulating charging
valve has switched to brake cooling.
Remove the bleed screw for the disc brake and allow oil to flow
out of the hole until it is free of air bubbles. Refit the bleed screw.
VDRT02.02GB
4:29
000008
Disc pack
000007
Brake cylinder
VDRT02.02GB
4:30
D5
5
12
D790-2
D790-1
D797-F
7
D8
C3
D10
8
P a 10
ACC
C1
3
H
013162
11
Pos
Explanation
Signal description
Reference
P = 20.51.0 MPa
Switch activated:
Conn 1, U = 2228 V
Conn 7, U = 0 V
Checked by control
system, error shown with
error code.
U = 24 V
Pump pressure.
VDRT02.02GB
4:31
Pos
Explanation
Signal description
Reference
0 MPa
10
Conn. 1: U = 24 V
Conn. 2: U= 0 V
Checked by control
system, error shown with
error code.
12
Checked by control
system, error shown with
error code.
013163
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.5 HYD, menu 5.
VDRT02.02GB
4:32
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1
Start the engine and run the engine at idle until the warning lamp
for brake pressure goes out and the accumulator charging valve
changes to cooling.
Switch off the engine and turn the start key to position I.
Release the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper releases. The
brake caliper should be able to move.
Activate the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper is applied.
NOTE
013164
VDRT02.02GB
4:33
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1
Switch off the engine and turn the start key to position I.
Check that the parking brake caliper can move on the bracket.
Check that the brake disc is free from oil and dirt.
Turn back the adjusting screw so that the clearance between pad
and disc is 0.50.1 mm.
NOTE
To avoid turning the adjusting screw as well it must be held still
when tightening the lock nut.
11 Refit the cover to the caliper.
12 Test the function of the parking brake.
VDRT02.02GB
4:34
The brake caliper has a spring section and a hydraulic section. The
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises.
000020
1.
Brake pads
2.
Release cylinder
3.
Thrust spring
4.
Slackening screw
5.
Adjusting washer
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
VDRT02.02GB
4:35
Remove the split pin and undo the nut on one of the attaching
bolts holding the parking brake caliper in place.
Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7
VDRT02.02GB
4:36
NOTE
013165
VDRT02.02GB
4:37
D 793
D 795
D 7 9 0 -1
9
11
D 7 9 7 -F
D 8
D 10
C 4
C 1
3
P
5
1
7
10
012490
Pos
Explanation
Signal description
Reference
P = 20.51.0 MPa
approx. 50 C
R = 25 k at 20 C
Checked by control
system, error shown with
error code.
10
U = 24 V with activated
fan
Activates at 65 C
Deactivates at 55 C
VDRT02.02GB
4:38
Pos
Explanation
Signal description
Reference
11
Checked by control
system, error shown with
error code.
12
Checked by control
system, error shown with
error code.
013166
VDRT02.02GB
4:39
013167
The cooling fan is screwed onto the cooler. See Cooling fan,
description, page 4:40.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Drain the oil from the brake oil tank, see Oil, brake system,
changing, page 4:45.
Mark up and detach the hydraulic hoses from the cooler. Let the
oil in the cooler drain into the receptacle.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
1. Cooling fan
2. Connector
NOTE
Check that the O-rings are intact, clean and in the correct
position.
3. Cooler
VDRT02.02GB
4:40
10 Fill oil in the brake oil tank, see Oil, brake system, changing, page
4:45. The oil level should be visible in the sight glass.
013168
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.2 HYD, menu 2.
013169
VDRT02.02GB
4:41
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Drain the oil from the brake oil tank, see Oil, brake system,
changing, page 4:45.
NOTE
Note how the valve is fitted.
5
013170
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.2 HYD, menu 2.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Drain the oil from the brake oil tank, see Oil, brake system,
changing, page 4:45.
Disconnect the cable harness from the sensor for the brake
system's oil temperature.
VDRT02.02GB
4:42
NOTE
Check that the O-rings are intact, clean and in the correct
position.
5
Fill oil in the brake oil tank, see Oil, brake system, changing, page
4:45. The oil level should be visible in the sight glass.
013171
The breather filter is a paper insert filter. The filter cleans moisture
and dust from the air passing through the tank's breather.
NOTE
Take care that impurities do not enter the tank.
1.
2.
VDRT02.02GB
4:43
NOTE
013172
When the filter is clogged, the oil is directed past the filter without
cleaning. It is therefore very important to replace the filter at the
prescribed interval.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
The filter protects the brake system against impurities.
It is very important that new impurities do not enter the
brake system during filter replacement.
1
NOTE
Leave the valves open during replacement.
VDRT02.02GB
4:44
NOTE
The filter holder is heavy. Detach it carefully.
5
NOTE
Note the location of the O-rings.
6
Fit the O-rings on the filter insert and the filter holder. Lubricate
the O-rings with oil for the brake system.
10 Close the valves opened for draining the pressure in the hydraulic
system.
013173
11 Start the engine and check the filter holder for leaks.
VDRT02.02GB
4:45
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1.
2.
Remove the filler cap and drain the brake oil tank.
Remove the drain plug and allow the last of the fluid drain into
a receptacle.
Fill oil for the brake system until the oil level is in the middle of the
sight glass. For volume and grade, see section F Technical data.
VDRT02.02GB
4:46
VDRT02.02GB
5:1
5 Steering
Contents 5 Steering
5
Steering ...............................................................................................................5:3
5.2
Power assisted system ....................................................................................5:3
5.2.1
Hydraulic oil pump.......................................................................................5:4
5.2.2
Priority valve................................................................................................5:4
5.2.3
Steering valve .............................................................................................5:8
5.2.4
Steering cylinder ....................................................................................... 5:11
5.2.5
Steering axle cradle ..................................................................................5:13
5.2.6
Link arm ....................................................................................................5:14
5.2.7
Wheel spindle............................................................................................5:14
5.2.8
Wheel hub .................................................................................................5:14
5.2.13
Pipes and hoses........................................................................................5:14
5.2.21
Valve block servo pressure .......................................................................5:14
VDRT02.02GB
5:2
VDRT02.02GB
5 Steering Steering
5:3
5 Steering
5.2 Power assisted system
Power assisted system, function description
LS P 1
LS P 2
LS P 3
LS P 3X
LS P R
LS H Y
P T
LS M
8
LS
4
LS
P P
C F
T
L
3 C 2
C 1
7
2
013877
Pos
Explanation
Signal description
Reference
Checked by control
system, error shown
with error code.
VDRT02.02GB
5:4
013884
The priority valve has a built-in pressure limiter on the load signal.
The pressure limiter maximises the load signal's pressure.
VDRT02.02GB
5:5
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Start the engine and increase engine speed to approx. 1200 rpm.
Turn the steering wheel fully and read pump pressure during
steering wheel movement. Compare this to the control pressure
on the hydraulics plate. The max. pressure measured on the
pump should be 1.5 MPa more than the control pressure on the
hydraulics plate.
Turn the start key to position 0 and switch off the system voltage.
Remove the pressure gauge and fit the protective cap on the
measuring outlet.
000475
C
Operating menu, hydraulic oil temperature
1.
2.
3.
4.
013857
VDRT02.02GB
5:6
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Turn the start key to position 0 and switch off the system voltage.
Mark up and detach the hydraulic hoses from the priority valve.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
5
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9
CAUTION
Do not tighten the hydraulic connection between
priority valve and collection block before all other
connections and attaching bolts are fitted.
Stresses in the priority valve may result in incorrect
function.
10 Fit the priority valve's attaching bolts.
11 Connect the hydraulic hoses to the priority valve.
12 Check that the collection block is not pressing against the priority
valve.
13 Tighten the hydraulic connection between priority valve and
collection block.
VDRT02.02GB
5:7
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
013399
Check that the relief valve for top lift is closed before
starting the engine.
16 Start the engine and check that the hydraulic connections at the
priority valve are sealed tightly.
Relief valve for top lift, the figure shows an open valve.
17 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
18 Check the control pressure, see Control pressure, checking, page
5:5.
VDRT02.02GB
5:8
013177
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1.
Water valve
2.
Steering valve
VDRT02.02GB
Slide the cab forward so that the steering valve is accessible from
below.
Turn the start key to position 0 and switch off the system voltage.
5:9
Mark up and detach the hydraulic hoses from the steering valve.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
8
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
10 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
11 Connect the new steering valve to the brake pedal.
Position the steering valve and check that the steering wheel
shaft's splines enter straight in the steering valve's slot. Fit the
attaching bolts.
12 Lock the cab in its rearmost position with both locking catches.
WARNING
The cab has the manual sliding cab function. The cab
must ALWAYS be in the rear position while operating
the machine.
Lock pin
012760
Always make sure that the cab locks on both sides are
locked in their rear position before operating, and that
the locks are secured with the lock pins.
VDRT02.02GB
5:10
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
16 Check that the connections on the steering valve are sealed tightly.
17 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
18 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
5:11
The steering cylinder acts on the wheels via the link arms. The
steering cylinder is a double-acting hydraulic cylinder.
013885
1.
Wheel hub
2.
Wheel spindle
3.
Link arm
4.
Steering axle
5.
Front suspension
6.
Steering cylinder
7.
Rear suspension
8.
Counterweight
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
VDRT02.02GB
5:12
Mark up and detach the hydraulic hoses from the steering cylinder.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
1.
2.
Hydraulic connection
6
NOTE
The steering cylinder is heavy, use lifting equipment.
8
Support the new steering cylinder so that the holes in the attaching
bolts are lined up directly opposite the holes in the steering axle.
Fit and lubricate the steering cylinder attaching bolts. Tighten the
bolts crosswise in steps until 680 Nm is achieved.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
11 Fit the link arms to the steering cylinder.
12 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
VDRT02.02GB
5:13
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
16 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
5:14
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels
then they must be replaced.
013885
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
1.
Wheel hub
2.
Wheel spindle
3.
Link arm
4.
Steering axle
5.
Front suspension
6.
Steering cylinder
7.
Rear suspension
8.
Counterweight
VDRT02.02GB
6:1
6 Suspension
Contents 6 Suspension
6
Suspension .........................................................................................................6:3
6.2
Suspension ......................................................................................................6:3
6.2.1
Steering axle cradle ....................................................................................6:5
6.2.2
Wheel spindle..............................................................................................6:7
6.2.3
Wheel hub ................................................................................................. 6:11
6.3
Tyres and rims ...............................................................................................6:16
6.3.1
Tyres .........................................................................................................6:18
6.3.2
Rim ............................................................................................................6:19
6.3.3
Nut, washer and clamp .............................................................................6:20
VDRT02.02GB
6:2
VDRT02.02GB
6 Suspension Suspension
6:3
6 Suspension
6.2 Suspension
Bushing steering axle mounting, changing
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
1
Turn the start key to position 0 and switch off the system voltage.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine's
stability.
4
NOTE
Do not lift so much that the wheels are off the ground.
6
Lift the machine up so that the frame is lifted away from the axle.
NOTE
If necessary, disconnect the cable harness for the sensors on
the steering axle.
VDRT02.02GB
6:4
6 Suspension Suspension
CAUTION
The bearing halves must be mounted horizontally.
14 Fit the washers that hold the bushing in place. Use locking fluid
and tighten the bolts to a torque of 45 Nm.
15 Move the steering axle into place under the frame.
Bushing steering axle parts
1. Inner race
2. Bearing halves
NOTE
Make sure that all counterweights are refitted and that they are
fitted in the exact same location as before. The stability of the
machine is affected if the counterweights are changed.
VDRT02.02GB
6:5
013885
1.
Wheel hub
2.
Wheel spindle
3.
Link arm
4.
Steering axle
5.
Front suspension
6.
Steering cylinder
7.
Rear suspension
8.
Counterweight
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
1
Turn the start key to position 0 and switch off the system voltage.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine's
stability.
6
VDRT02.02GB
6:6
Tension the lifting equipment, do not lift so much that the wheels
are off the ground.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
10 Remove the pins holding the steering axle.
11 Lift the machine up so that the frame is lifted away from the axle.
12 Lift out the steering axle.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not roll away
uncontrollably.
13 Adjust the support so that the machine is secured in the new
position.
14 Lift the steering axle into place under the frame.
15 Remove the support under the frame.
16 Lower the rear section of the machine.
17 Fit the pins at the steering axle mountings.
18 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
19 Remove the lifting equipment from the machine.
20 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they are
fitted in the exact same location as before. The stability of the
machine is affected if the counterweights are changed.
VDRT02.02GB
6:7
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
013181
1.
Wheel spindle
2.
Spindle bolt
3.
Seal
4.
Cover
5.
6.
Thrust washer
7.
Thrust bearing
8.
Lock screw
VDRT02.02GB
6:8
3
1.
2.
Cover (upper)
3.
Cover (lower)
Remove the covers at the spindle bolt's upper and lower bearing.
004516
13 Press out the old bearing bushings. Note how the old bearing
bushings are fitted so that the new ones can be positioned the
same way with the space between in the same place.
14 Clean the surfaces inside the steering axle.
15 Press in the new bearing bushings. Make sure that the space
between is at the same location as before.
NOTE
004517
1.
VDRT02.02GB
6:9
16 Fit new thrust washers on the steering axle. Only fit three bolts
in the manner illustrated. The fourth bolt cannot be fitted until the
wheel spindle is in place. Only tighten the bolts slightly (5-10 Nm)
so that the thrust bearings are secured in position.
Thoroughly coat the bearing bushings with lubricating grease. For
grade, see section F Technical data.
NOTE
Make sure the nuts are positioned as illustrated.
011152
011163
20 Apply lubricating grease onto the wear surface of the upper wear
washer, and align the bearing between the wheel spindle and the
upper thrust washer. Use a rubber mallet to get the bearing into
the right position. Check that the bearing is centred in the wheel
spindle by looking in the spindle from above.
NOTE
Check that the spindle bolt is turned so that the holes for the
guide screws align with the holes in the wheel spindle. It is
important that the spindle bolt is perfectly seated before the
lock screws are fitted. It is not possible to "tighten" the spindle
bolt into place.
VDRT02.02GB
6:10
22 Fit the lock screws and tighten the lock nut. Tighten to a torque of
250 Nm (oiled screw).
23 Apply lubricating grease onto the space between the wheel spindle
and steering axle.
25 Fit the remaining bolts to the thrust bearings' wear washers. Fit
the bolts in the manner illustrated. Tighten to a torque of 25 Nm
(oiled screw).
004517
1.
27 Lubricate the upper and lower bearings of the spindle bolt with
lubricating grease.
28 Turn the wheel spindle back and forth a few times to even out the
grease. Check that resistance is uniform.
29 Connect the link arm to the wheel spindle.
Lubricate the link arm bearings with lubricating grease.
30 Fit the wheel.
3
1.
2.
Cover (upper)
3.
Cover (lower)
VDRT02.02GB
004516
6:11
The wheel hub holds the wheel in place and allows the wheel to rotate.
013182
1.
2.
3.
Hub
4.
5.
Seal
6.
Support ring
Wipe away grease from hub cover and hub nut. Handle it as
environmentally hazardous waste.
VDRT02.02GB
6:12
Bend up the locking washer's tabs, remove the lock nut and
locking washer.
VDRT02.02GB
6:13
NOTE
Fit the outer races with the larger diameter outward.
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the
seal does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.
17 Fit the inner bearing's inner race and rollers on the wheel spindle.
Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".
VDRT02.02GB
6:14
VDRT02.02GB
6:15
VDRT02.02GB
6:16
DANGER
Always block the wheels on the side of the axle that
is not going to be worked on before positioning the
jack. Always secure the jack to prevent it from sliding
out of position.
Fully deflate the tyre before removal. Otherwise the
conical ring and locking clips can loosen and shoot
out when the pressure is changed. With double wheel
fitting both tyres must be fully deflated!
The air must always be released via the valve. If this is
not possible - drill holes in the tread to release the air.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflating
or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.
Never fit damaged tyres or rims.
It is prohibited to repair rims with welding.
It is prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.
VDRT02.02GB
6:17
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace the
spacer rings, with crushing injuries as a result.
When fitting drive wheels, ensure that the clamps clamp
straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other approved
instructions when changing tyres.
Never use a steel hammer to fit or remove rim
components. Instead, use a lead, brass or plastic
mallet.
Keep the tyre pressures at the prescribed level.
Insufficient tyre pressure impairs stability and reduces
the machine's capacity.
Remove stuck objects such as crushed glass, pieces
of wood, metal filings, etc.
Check if tyre wear is abnormal. This could indicate a
mechanical fault. Rectify faults immediately and change
damaged tyres.
VDRT02.02GB
6:18
6 Suspension Tyres
6.3.1 Tyres
Tyres, description
The tyres are the point of contact between the machine and the
ground, and they absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each
tyre's rolling circumference differs, the stresses on the drive axle
increase. For this reason it is important that the tyres on the drive
axle have equal wear and correct air pressure.
002027
002026
Front wheels
Rear wheels
Tyres, changing
DANGER
Changing tyres is complicated and dangerous work.
EXTREME DANGER!
Leave tyre work to authorised personnel/tyre company.
The wheel rims must be checked when tyres are changed. See
Maintenance manual DRT 450 section 6 Suspension.
VDRT02.02GB
6 Suspension Rim
6:19
6.3.2 Rim
Rim, description
1
The rim is split to make it possible to fit a tyre. The rim consists of
the following parts.
Rim
Rim edge
Lock ring
Lock lugs
Hub plate
013183
1.
Lock ring
2.
Rim edge
3.
Tapered rim
4.
O-ring
5.
Rim
6.
Rim edge
7.
Wheel nut
8.
Wheel clamp
VDRT02.02GB
6:20
The rim is attached to the wheel hub with nuts and clamps.
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
013183
1.
Lock ring
2.
Rim edge
3.
Tapered rim
4.
O-ring
5.
Rim
6.
Rim edge
7.
Wheel nut
8.
Wheel clamp
VDRT02.02GB
Raise the machine with a jack positioned under the steering axle.
6:21
VDRT02.02GB
6:22
VDRT02.02GB
7:1
7 Load handling
VDRT02.02GB
7:2
7.6.9
7.6.11
7.6.12
7.6.14
7.9
7.9.1
7.10
7.10.2
7.10.3
7.10.4
VDRT02.02GB
7:3
7 Load handling
Position sensor, checking and adjustment
4.
Sensor twistlocks
2.
Sensor, alignment
5.
Sensor spreading
3.
6.
Check that the distance between the position sensor and indicator
is 41 mm. Adjust if necessary.
012352
41 mm
C-C
1.
41 mm
013889
VDRT02.02GB
7:4
The control lever (S815) is used to control the boom and attachment.
The lever sends voltage signals to Control unit, cab (D790-1).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.8.1 BOOM, menu 1.
Extension
013896
1.
Not used
2.
Not used
3.
Rotation (S815-P3)
4.
5.
6.
7.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.8.1 BOOM, menu 1.
Rotation
When the potentiometer (position 3) is pressed down on the left-hand
side rotation clockwise is activated, and when the right-hand side
is pressed down rotation anticlockwise is activated. See Rotation,
function description, page 7:67.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.1 ATTACH, menu 1.
VDRT02.02GB
7:5
Pistol trigger
The pistol trigger (position 8) activates weighing if the machine is
equipped with a weight indicator. See Weight indicator, description,
page 7:87.
The pistol trigger also changes the function of other buttons of the
control lever.
If side shift is activated at the same time as the pistol trigger is pressed
in, spreading is activated. See Spreading, function description, page
7:50.
If lift is activated at the same time as the pistol trigger is pressed
in, synchronised lift is activated if the machine is equipped with this
option. See Synchronised lift, function description, page 7:91.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.2 ATTACH, menu 2.
000443
The switch for lock twistlocks (S1001) controls locking the twistlocks.
The switch has three positions: two fixed and one rocker with the
following functions.
1.
2.
3.
Twistlocks are opened with the switch on the control lever, see Control
lever, description, page 7:4.
The switch is supplied voltage by and sends a voltage signal to
Control unit, cab (D790-1).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.3 ATTACH, menu 3.
VDRT02.02GB
7:6
Reference value
Reference
Control breaker
Disengaged
Twistlocks
Overload system
D24
D1
2, 4
D790-1
D797-R
D797-F
D794
25
24
3, 15, 20
D3
16
D15
D20
21
14
PSS
PS
19
PSL
A1
VA
C-M
LSP3X
C+M
11
LSPR
LSP3
C+
LS
13
A
17, 22
EF CF
Pa
19
C12
LSHY
PT
18, 23
C-
LSP2
Pa
B1
LSP1
D19
26
LSM
8, 12
10
C9
C9
10 C9
10
10
VDRT02.02GB
013890
C9
7:7
Pos
Explanation
Signal description
Reference
I = 380650 mA
10
11
12
13
14
15
U = 24 V
VDRT02.02GB
7:8
Pos
Explanation
Signal description
Reference
16
17
19
Regeneration
UB768-L1/1 = 5 V
UB768-L1/2 = 0 V
NOTE
Regeneration is not possible in the
proximity of end position or in the event
of overload.
20
UB768-L1/5 = 0.5-4.5 V
Regeneration is activated
when the pressure in the
lift cylinders is 8.5 MPa.
Regeneration is stopped if the
pressure reaches 18.5 MPa.
U = 24 V
21
22
23
24
Damping
25
26
VDRT02.02GB
7:9
DANGER
The lowering speed must be correct. If lowering speed
is too high there is a risk of rollover.
The machine must absolutely not be operated before
lowering speed is verified.
1
Operate the machine and hydraulics until the hydraulic oil reaches
the operating temperature of 50 C.
NOTE
It is important that the ground is level and without gradient.
4
Note the time for how long it takes to lower from the top position
until the container is about 20 cm from the ground.
Lowering should take 18-21 seconds.
013188
The filter insert is pressed against the upper section of the filter
housing by a spring. Rubber gaskets seal between the insert and
filter housing. If the back pressure through the filter is too great then
the insert is pressed down so that the oil passes by the insert. This
occurs if the oil is viscous (cold or incorrect viscosity) or if the filter
insert is clogged.
VDRT02.02GB
7:10
013892
NOTE
Read the safety instructions for oil before working, see section B
Safety.
VDRT02.02GB
7:11
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
013399
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows an open valve.
8
Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
7:12
The control valve controls the speed and direction of lift and extension.
The control valve is fitted on a bracket in the space between the lifting
1 beam and front axle.
The valve has two sections, one for the lift function and one for boom
9
8
4 This means that both volume and direction of the flow from the valve
can be adjusted and that the valve also sends a control signal to the
variable pumps.
013893
1.
2.
3.
The lift slide controls the direction and flow of the oil to the lift cylinder.
4.
5.
6.
7.
8.
Servo valve, lift controls servo pressure to the lift slide so that it
controls oil pressure for lifting. The valve is controlled electrically
with the Solenoid valve, lift (Y6005), which is activated by Control
unit, frame front (D797-F).
9.
Connection, piston side, extension cylinder (A1) The signals can be checked via the diagnostic menu. See section 8
Control system, group 8.4.8.4 BOOM, menu 4.
Lift slide
DANGER
The lowering speed must be correct. If lowering speed
is too high there is a risk of rollover.
The machine must absolutely not be operated before
lowering speed is verified.
After replacing Control valve lift, lower and extension, or parts of
the valve, lowering speed must be checked. See Lowering speed,
checking, page 7:9.
VDRT02.02GB
7:13
1 Valve block lift cylinder directs oil to the lift cylinder and is mounted
directly on the lower part of the lift cylinder. The valve block contains
the blocking valve, regeneration valve, non-return valve and shock
2
valve.
3 Blocking valve
4 The blocking valve prevents unwanted lowering and angling of the
lift cylinders. The blocking valve holds the load by ensuring that the
connection to the lift cylinder's piston side is closed. (The pressure
5
passes through a restriction as blocking pressure and holds the valve
slide closed.)
Servo valve blocking actuates the blocking valve. The servo valve is
013895
Regeneration valve
The regeneration valve directs oil from the rod side of the cylinder
back to the piston side. This allows the oil to be re-used during lifting.
For more information on regeneration, see Lifting/lowering, function
description, page 7:6. The regeneration valve is regulated by servo
valve regeneration.
5.
6.
Shock valve
7.
Shock valve
8.
9.
1.
2.
3.
4.
Non-return valve
The non-return valve prevents oil from flowing the wrong way during
regeneration.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Turn the start key to position 0 and switch off the system voltage.
VDRT02.02GB
7:14
Mark and disconnect the cable harness from the valve block.
Mark up and detach the hydraulic hoses from the valve block.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
NOTE
Transfer one part at a time so that the marking is not mixed up.
VDRT02.02GB
7:15
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
VDRT02.02GB
7:16
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the functions carefully and operate at the
lowest possible speed a couple of times to avoid
cavitation.
17 Check for leaks.
VDRT02.02GB
7:17
18 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
19 Check the lowering speed, see Lowering speed, checking, page
7:9.
013192
The lift cylinder is equipped with guide bearings both in the cylinder
end and the piston rod mounting. The piston rod mounting is threaded
in the piston rod and locked with a lock nut.
The lift cylinders are connected in parallel and are supplied from the
control valve for lift, lower and extension, see 7.2.5 Control valve lift,
lower and extension, page 7:12.
DANGER
A lift cylinder weighs approx. 2 tonnes.
Extreme danger!
Use wooden blocks as protection between cab and
lift cylinder when the lift cylinder is lowered or lifted.
Secure the lift cylinders with tensioning straps in
between them.
WARNING
The boom may move when the pins are removed.
Risk of personal injury!
Make sure that the pins are unloaded. Stand to the side
of the boom mounting so that it provides protection in
the event of any movement.
VDRT02.02GB
7:18
CAUTION
The boom may drop.
Be certain to compensate for the lift cylinder's support
of the boom by lifting the boom's leading edge with the
lifting equipment.
VDRT02.02GB
Turn the start key to position 0 and switch off the system voltage.
Lift the boom at the front edge so that the bearings on the lift
cylinders are unloaded.
Mark up and detach the hydraulic hoses from the lift cylinder.
7:19
NOTE
The bearings are only lubricated during replacement.
15 Lift the new lift cylinder into place.
16 Fit the pins for the lift cylinder.
17 Connect the hydraulic hoses to the lift cylinder.
18 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
7:20
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows a closed valve.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
22 Check for leaks.
23 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
24 Check the lowering speed, see Lowering speed, checking, page
7:9.
VDRT02.02GB
7:21
If the machine is equipped with the fixed scale option then an extra
pressure sensor is used, on the piston side for the right-hand lift
cylinder.
013891
1.
The sensors are supplied voltage by, and send a voltage signal
proportional to the hydraulic oil pressure, to Control unit, frame front
(D797-F).
The signals can be checked via the diagnostic menu. See section 8
Control system, group 8.4.10.3 OP, menu 3.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
VDRT02.02GB
7:22
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
5
NOTE
Check that the O-rings are intact, clean and in the correct
position.
6
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
7:23
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
12 Check that the hydraulic connections of the valve block are sealed
tightly and lifting/lowering works correctly.
13 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
14 Check the function of the sensor from the diagnostic menu. See
section 8 Control system, group 8.4.10.3 OP menu 3.
DIAG OP
3(x)
PRESENT INPUT SIGNAL
LIFT CYL LE
RI
CX.XXV X.XXV
C+
X.XXV X.XXV
Raise the boom and check that the sensor is sending values. The
value should be approximately the same as from the sensor on
the second lift cylinder (RI/LE).
C008213
C+
VDRT02.02GB
7:24
1.
Outer boom
6.
Extension cylinder
2.
Inner boom
7.
Lift cylinder
3.
8.
4.
Mounting attachment
9.
5.
001239
The lift boom lifts the load. The rear section of the boom is secured
into the frame with two bearing-mounted shafts. Fitted in the front edge
is the lift attachment and in the centre on each side of the boom are
lift cylinders which are secured with bearing-mounted shafts. The lift
cylinders angle the boom and raise the front section of the boom in
this way. The lift boom is available in several versions depending on
reach and load capacity.
The boom consists of outer boom and inner boom manufactured
in high-strength steel with a minimum number of welds to provide
maximum strength.
The inner boom runs in the outer boom and can be extended
longitudinally with the extension cylinder. There are slide plates
between inner boom and outer boom which reduce the friction between
them. The slide plates are fitted in the front edge of the outer boom
and the rear edge of the inner boom.
Running along the left-hand side is a cable chain for hydraulic hoses
and cables between outer and inner boom.
VDRT02.02GB
7:25
VDRT02.02GB
7:26
7.3 Extension
Extension, function description
Condition
Reference value
Reference
Control breaker
Disengaged
Overload system
D1
D28
2, 5
22
D794
D790-1
6
m
Pa
D797-F
3, 23
D22
D797-R
28
4, 18, 24, 29
D4
D7
17
PSS
PS
PSL
A1
LS
LSP3
LSHY
T
9, 12, 15
13
D24
21, 27
CC+
20, 26
14
LSPR
PT
LSP2
LSP3X
C10
25
VA
16
LSP1
19
VA
A1
B1
11
D18
D3
EF CF
P
C15
30
LSM
C10
13
13
13 C10
10
Pos
1
10
10
013903
C10
10
Explanation
Signal description
Reference
VDRT02.02GB
Pos
7:27
Explanation
Signal description
Reference
I = 380-650 mA
U = 24 V
12
13
14
15
16
17
18
U = 24 V
10
11
VDRT02.02GB
7:28
Pos
Explanation
Signal description
Reference
19
20
22
Regeneration
UB768-L1/1 = 5 V
UB768-L1/2 = 0 V
UB768-L1/3 = 0.54.5 V
NOTE
Regeneration is not possible in the
proximity of end position or in the
event of overload.
23
24
U = 24 V
25
26
27
28
Damping
30
VDRT02.02GB
7:29
The control valve has two sections: one for the lift function and one
for boom extension. The sections have many similarities, but are
1 described separately under the respective function.
For general information on the control valve, refer to 7.2.5 Control
Extension slide
The extension slide controls direction (in or out) and oil flow to valve
block extension cylinder.
Servo valve boom out, controls servo pressure to the extension slide
013893
1.
2.
3.
4.
5.
6.
7.
8.
9.
Servo valve boom in, controls servo pressure to the extension slide
so that it controls oil pressure for boom retraction.
Servo valve boom in is controlled electrically with Solenoid valve,
boom in (Y6007) which is activated by Control unit, frame front
(D797-F).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.8.6 BOOM, menu 6.
Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and rod side and tank if the pressure becomes too high.
VDRT02.02GB
7:30
1
7
Blocking valve
013894
Regeneration valve
1.
2.
Draining (D)
3.
4.
5.
6.
7.
The regeneration valve directs oil from the rod side back to the piston
side. This allows the oil to be re-used during extension. For more
information on regeneration, see Extension, function description, page
7:26. The regeneration valve is regulated by servo valve regeneration.
Solenoid valve, extension (Y6046) pressurises the regeneration
valve. Solenoid valve, extension (Y6046) which is activated by
Control unit, frame rear (D797-R).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.8.3 BOOM, menu 3.
VDRT02.02GB
7:31
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Removal
1
Operate the boom out until the inspection holes in the side of the
inner boom become accessible.
Remove the lock rings and press out the shaft for the front cylinder
mounting in the inner boom.
Remove the sensor for boom length from the boom, see section 8
Control systems, group 8.2.1.6 Sensor boom length.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
7
Mark and disconnect the cable harness from the valve block on
the extension cylinder.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
VDRT02.02GB
7:32
Remove the lock rings and press out the outer shafts for the rear
cylinder mountings in the outer boom.
013463
Installation
14 Clean and lubricate all bearing surfaces with lubricating grease.
15 Measure how far the old extension cylinder is extended and
extend the new cylinder to the same length.
NOTE
If this is not carried out then the front cylinder mounting will not
reach far enough forward.
16 Lift the extension cylinder into place.
CAUTION
Use the dual lifting devices to achieve balance during
the lifting. The front should be positioned behind the
support at the front edge of the cylinder so that it can
be slid into the boom.
17 Fit the shaft at the front cylinder mounting in the inner boom.
NOTE
Lubricate the shaft with lubricating grease before installation.
18 Fit the catches on the shaft.
VDRT02.02GB
7:33
NOTE
Lubricate the shaft with lubricating grease before installation.
20 Fit the catches on the shafts.
21 Fit the valve block on the extension cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
013463
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
VDRT02.02GB
7:34
27 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
28 Calibrate the sensor for boom length, see section 8 Control
system, group 8.5.2.1 Calibrate SCALE steps 9 - 12.
VDRT02.02GB
7:35
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom.
NOTE
The inner boom must be centred in the outer boom.
Position the boom to the lowest position with the inner boom
extended approx. 50 cm.
Remove the cover plate for the side-mounted slide plates and
remove the spacer plates and slid plate.
Check the clearance between the boom and slide plate, the
clearance should be 1 mm, adjust with spacer plates as required.
NOTE
The inner boom must be centred in the outer boom.
1.
2.
Remove the lock screws and the slide plates' brackets, and pull
out the upper slide plates and the spacer plates.
Unload the lower slide plates, lift the inner boom at the front edge
and use wooden shims.
WARNING
Risk of crushing!
Secure the inner boom relative to the outer boom with
wooden blocks.
7
Remove the lock screws, slide plates' brackets and pull out the
lower slide plates.
Transfer the nuts for the lock screws for the lower slide plates
to the new slide plates.
Fit the new lower slide plates, lock screws and brackets.
10 Remove the wooden blocks and ease down the inner boom so
that it rests on the lower slide plates.
11 Transfer the nuts for the lock screws for the upper slide plates
to the new slide plates.
12 Fit the new slide plates, spacer plates, lock screws and brackets.
13 Check the clearance between the boom and stop at the front
edge/top edge of the boom, the clearance must be max. 2 mm,
adjust the slide plates with spacer plates if necessary.
VDRT02.02GB
7:36
013197
Check both the dimensions with the boom fully retracted and fully
extended.
17 If necessary, adjust the lower slide plates so that the attachment
is straight.
WARNING
Risk of crushing!
Secure the inner boom relative to the outer boom with
wooden blocks.
1.
2.
3.
23 Remove the cover plates, spacer plates and the lower slide plates.
24 Fit new slide plates, spacer plates and cover plate.
25 Unload the upper slide plates, use wooden shims.
WARNING
Risk of crushing!
Secure the inner boom relative to the outer boom with
wooden blocks.
26 Remove the lock screws, the slide plates' brackets, and pull out
the upper slide plates and the spacer plates.
27 Transfer the nuts for the lock screws for the upper slide plates
to the new slide plates.
28 Fit the new slide plates, spacer plates, lock screws and brackets.
29 Check the clearance between the outer and inner boom, the
clearance should be max. 2 mm, adjust the slide plates with
spacer plates as required.
VDRT02.02GB
7:37
Lubrication
013198
VDRT02.02GB
7:38
Reference
value
Reference
Control breaker
Disengaged
D1
1
2
D790-1
3
D797-R
D791-1
8
D8
D3
C10
P1
11
4
T1
T
LSP2
LSPR
LSP3
LSHY
LSP3X
PT
10
LSM
C6
013907
LSP1
6
Pos
Explanation
Signal description
Reference
Left: US815-T1.1 = 24 V
Right: US815-T1.2 = 24 V
Checked by control
system, error shown with
error code.
U = 24 V
VDRT02.02GB
7:39
Pos
Explanation
Signal description
Reference
U = 24 V
10
11
VDRT02.02GB
7:40
21
20
19
18
17
16
15
14
13
12
10
013911
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
VDRT02.02GB
7:41
Side shift
Spreading (positioning)
Rotation
Twistlocks
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
VDRT02.02GB
7:42
Mark and disconnect the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
4
Mark and disconnect the cable harness from the control valve.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
7
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
7:43
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
16 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
000475
VDRT02.02GB
008226
7:44
Start the engine and run it at idle. Check the pressures in the
attachment's different functions by letting each function go to its
end-position and then reading off the pressure gauge.
Function
Pressure
Side shift
16,0 MPa
Spreading (positioning)
12,0 MPa
Rotation
15,0 MPa
Twistlocks
Remove the pressure gauge and fit the protective cap on the
measuring outlet.
1
10
9
8
2
3
1.
2.
3.
4.
Sensor, alignment
5.
Twistlock
6.
Sensor twistlocks
7.
8.
Spreading boom
9.
001500
VDRT02.02GB
7:45
The attachment is secured in the boom with the rotation yoke. The
side shift frame is fitted under the rotation yoke. The attachment's
main beam is fitted in the side shift frame. The main beam can be
extended laterally in relation to the side shift frame with two hydraulic
cylinders. Inside the main beam are two spreader beams which can
be extended in and out with a hydraulic motor.
000526
1.
Main beam
2.
Ring gear
3.
4.
Rotation bar
5.
6.
Undo the cover plate's attaching bolt and remove the cover plate.
VDRT02.02GB
7:46
Measure the distance between the edge of the cover plate and the
attachment's main beam slide surface on all slide plates.
VDRT02.02GB
7:47
Lubrication
013202
Switch off the engine and switch off the system voltage.
DANGER
Risk of crushing!
Place spacers between the crossmember and the
attachment's main boom for both crossmembers.
3
VDRT02.02GB
7:48
Lubrication
Lubricate the slide surfaces of the attachment with white lubricating
paste.
013202
The main beam attachment is fitted in the side shift frame. The main
beam contains equipment for spreading (spreader beams, hydraulic
motor, chains, slide plates and sensors). The control valves for the
attachment's hydraulic functions are also fitted on the attachment's
main beam.
000526
1.
Main beam
2.
Ring gear
3.
4.
Rotation bar
5.
6.
VDRT02.02GB
7:49
013400
VDRT02.02GB
7:50
Reference value
Reference
Control breaker
Disengaged
Twistlocks
Unlocked or bypass
activated
Passive
Overload system
D1
1
+
2
D790-1
D797-R
D3
D791-1
D14
8,14
D8
9, 15
C10
13
P1
12, 17
T1
T
LSP2
LSPR
LSP3
LSHY
LSP3X
PT
10, 16
11
LSM
C6
013908
LSP1
6
Pos
Explanation
Signal description
Spreading: US815-T4 = 24 V
Out: US815-T1.2 = 24 V
Reference
Checked by control
system, error shown
with error code.
U = 24 V
VDRT02.02GB
7:51
Pos
Explanation
Signal description
Reference
I = 350600 mA
10
11
12
13
16
17
14
15
VDRT02.02GB
7:52
Spreader slide
The valve slide controls the direction and speed of spreading. The
valve slide is controlled by a servo valve for spreading out and a servo
valve for spreading in.
VDRT02.02GB
7:53
II
001004
1
10
9
8
2
3
1.
2.
3.
4.
Sensor, alignment
5.
Twistlock
6.
Sensor twistlocks
7.
8.
Spreading boom
9.
001500
VDRT02.02GB
7:54
NOTE
Read the safety instructions for oil before working, see section B
Safety.
VDRT02.02GB
Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
Turn the start key to position 0 and switch off the system voltage.
Measure and note the chain tensioners' length to attain the correct
chain tension when refitting.
Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
7:55
10 Mark up and detach the hydraulic hoses from the valve block for
the spreader motor.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
13 Clean the contact surfaces between the planetary gear and the
attachment's main beam.
14 Fit the motor unit. Tighten the bolts crosswise in steps until 117
Nm is achieved.
15 Attach the hydraulic hoses to the valve block on the motor.
VDRT02.02GB
7:56
16 Connect the spreader chain to the chain tensioner. Check that the
chain runs straight in the chain wheel on the hydraulic motor.
17 Tension the spreader chain to the same degree as before.
18 Switch on the system voltage and start the engine.
19 Check that the hydraulic connections are sealed tightly.
20 Check that the spreading is working.
21 Fit the protective plate over the motor.
22 Brush the spreader chain with lubricating grease.
23 Fit the cover plates on the attachment's main beam.
24 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
013399
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows an open valve.
26 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
7:57
000472
20-foot position
2
Check that both spreader beams are against the 20-foot stop and
that the distance between the spreader beam and the spreader
motor mounting is at least 3 mm.
NOTE
Note the distance the stop was adjusted.
Run spreading out a little to make it possible to move the washers.
CAUTION
20-foot stop
VDRT02.02GB
7:58
NOTE
005105
40-foot position
8
Start the engine, run spreading out to the 40-foot position and
switch off the engine.
005106
40-foot stop
VDRT02.02GB
13 Use suspension scales and measure how far the chain moves
when pulled outward with a force of 100 N at 815 mm in from the
main beam's internal reinforcement collar as illustrated.
100 N
815m m
100 N
100 N
010486
0 N
815 m m
7:59
NOTE
Adjust max. 2 mm on the chain tightener at a time.
15 Repeat steps 1114 until the chains have the correct tension.
16 Brush the spreader chain with lubricating grease.
17 Fit the cover plates on the attachment's main beam.
VDRT02.02GB
Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
Switch off the engine and switch off the system voltage.
005105
7:60
NOTE
005105
NOTE
Note the location of the spacer ring.
If the chain wheel on the engine side must be removed, fist remove
the spreader motor. See Spreader motor, replacement, page 7:54.
VDRT02.02GB
7:61
Pull the chain out through the hole for the chain wheel so that the
chain runs along the spreader beam.
Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.
NOTE
Support the spreader beam to minimise breaks. If necessary,
remove the upper slide plates to reduce resistance.
VDRT02.02GB
7:62
12 Detach the cable rack from the attachment's main beam. Support
the cable rack so that it is not damaged.
13 Pull out the spreader beam until the chain mounting becomes
accessible.
14 Detach the chain from the spreader beam and cable rack.
15 Connect the new chain to the spreader beam.
16 Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
17 Brush the chain with lubricating grease.
18 Slide in the spreader beam so that the extension stop can be fitted.
19 Fit the extension stop.
20 Connect the cable rack to the attachment's main beam.
21 Fit the hydraulic hoses' clamping on the attachment's main beam.
22 Slide in the spreader beam until it is inserted the same amount
as the other one. This is important in order to facilitate the fitting
of the chains.
23 Detach the chain from the cable rack and insert it through the
chain wheel's hole.
VDRT02.02GB
7:63
24 Fit the chain wheel. The spacer ring must be fitted on the
underside of the chain wheel.
If the rotation motor has been removed, refit it. See Spreader
motor, replacement, page 7:54.
NOTE
Check that the chain runs straight in the chain wheels.
NOTE
005105
VDRT02.02GB
7:64
1
10
9
8
2
3
1.
2.
3.
4.
Sensor, alignment
5.
Twistlock
6.
Sensor twistlocks
7.
8.
Spreading boom
9.
001500
VDRT02.02GB
7:65
Pull out the slide plate with spacer plate and bracket.
Lubrication
Lubricate the slide surfaces of the attachment with white lubricating
paste.
013202
VDRT02.02GB
7:66
The end position sensor (B769) indicates the end position of 20 and
40-foot containers. The sensor detects the spreader beam end
positions via two indicator plates on the top of the spreader beams.
The sensor is used to activate damping.
The sensors are supplied power by and send a 24 V signal to Control
unit, attachment (D791-1) when the indicator plates pass the sensor.
Indicator plates on the spreader units are mounted so that the sensors
generate a signal when the spreader unit passes the sensor. The
indicator plates and the position of the sensors are designed so that
the distance between the spreaders becomes 20' (30') and 40'.
013912
The signals can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.5 ATTACH, menu 5.
1.
2.
3.
7:67
7.6 Rotation
Rotation, function description
Condition
Reference
value
Reference
Control breaker
Disengaged
Overload system
Passive
D1
1
2
D790-1
D797-R
D791-1
3
D3
D8
C10
P1
12, 13
T1
T
LSP2
LSPR
LSP3
LSHY
LSP3X
PT
10
11
LSM
C6
013909
LSP1
6
Pos
Explanation
Signal description
Reference
Anticlockwise: US815/P3 =
0.52.0 V
VDRT02.02GB
7:68
Pos
Explanation
Signal description
Reference
U = 24 V
I = 435650 mA
10
11
12
13
VDRT02.02GB
7:69
Rotation slide
The valve slide controls the direction and speed of rotation. The valve
slide is controlled by Servo valve, rotation clockwise and Servo valve,
rotation anticlockwise.
VDRT02.02GB
7:70
000530
1.
2.
Disc brake
3.
Planetary gear
4.
Gear wheel
5.
Rotation bar
6.
Ring gear
7.
VDRT02.02GB
7:71
1 The planetary gear reinforces the output in the motor and disc brake.
The planetary gear changes the motor's speed down so that motor
2 power is greater.
000530
1.
2.
Disc brake
3.
Planetary gear
4.
Gear wheel
5.
Rotation bar
6.
Ring gear
7.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
VDRT02.02GB
7:72
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
VDRT02.02GB
Lift away the rotation motor unit. Position the motor unit so that
the pinion and planetary gear are not damaged.
Clean the contact surfaces on the motor unit and rotation yoke.
Fit the motor unit. Tighten the bolts crosswise in steps until 117
Nm is achieved.
7:73
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
7:74
Using the rotation motors, which act on the ring gear, the remaining
parts of the attachment can be rotated in relation to the lift boom.
000526
1.
Main beam
2.
Ring gear
3.
4.
Rotation bar
5.
6.
VDRT02.02GB
7:75
Remove the plastic plugs and clean the threads and holes on the
new rotation yoke, clean the contact surface against the ring gear.
Grease cups
Mounting shafts
NOTE
Align the position against that of the ring gear so that the
lubrication lines can be fitted.
13 Brush the rotation yoke's mounting shafts with lubricating grease
and fit them in the rotation yoke.
NOTE
If necessary, rotate the rotation yoke slightly so that the rotation
motor's gear wheel aligns against the ring gear.
19 Connect the attachment to the boom.
20 Start the motor and check that the rotation is working.
21 Clean the attachment.
VDRT02.02GB
7:76
22 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The oil
level should be at the top of the sight glass. Top up if necessary.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
000530
1.
2.
Disc brake
3.
Planetary gear
4.
Gear wheel
5.
Rotation bar
6.
Ring gear
7.
VDRT02.02GB
7:77
NOTE
Note down the locations of the lubricating pipes to facilitate
refitting.
The illustration shows removed rotation yoke and ring
gear.
Remove the attaching bolts between the ring gear and the side
shift frame.
Clean the contact surfaces on the side shift frame and ring gear.
NOTE
Rotate it so that the connections for the lubricating pipes are in
the same positions as before.
7
Lubricate the inner attaching bolts with lubricating grease and fit
them. Tighten the bolts crosswise in steps until a torque of 331
Nm is achieved.
Fit the rotation yoke, see Rotation yoke, replacement, page 7:74.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
7:78
VDRT02.02GB
7:79
Reference value
Reference
Control breaker
Disengaged
Alignment
Full alignment or
bypass activated
Section 9 Frame, body, cab and accessories, group 9.1 Controls and
instruments
Section 8 Control system, group 8.2.2 Bypass
Passive
Overload system
D1
8
D2
7, 21
D790-1
D790-2
5, 22
D795
D19
D797-R
D791-1
4, 6, 14, 19, 20
D9
D14
C16
15
18
D18
D3
3
P1
10
17
T1
T
LSP2
LSPR
LSP3
LSHY
LSP3X
PT
13
11
16
LSM
C12
013910
LSP1
12
VDRT02.02GB
7:80
Pos
Explanation
Signal description
Reference
U = 24 V
US815/T2 = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
Checked by control
system, error shown
with error code.
U = 24 V
11
12
13
14
U = 24 V
10
15
VDRT02.02GB
7:81
Pos
Explanation
Signal description
Reference
16
17
18
19
U = 24 V
20
Checked by control
system, error shown
with error code.
21
22
VDRT02.02GB
7:82
013210
The lock cylinder activates the lock mechanism so that the twistlocks
are rotated. Two lock cylinders, one in the right and one in the left
spreader beam, activate the lock mechanism. The lock cylinders are
fitted in the centre of the spreader beam's longitudinal section.
013211
VDRT02.02GB
7:83
7.9.1.7 Twistlocks
Twistlocks, description
1
WARNING
Dropped load.
Extreme danger!
Twistlocks secure the load and are located out in the corners of the
spreader beam's longitudinal section.
013212
1.
Lock mechanism
2.
Sensor, alignment
3.
Alignment pin
4.
Lift pin
5.
Lock guide
Twistlock, replacement
1
Tap on the nut so that the lift pin releases from the wedge.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
VDRT02.02GB
7:84
Fit a new lift pin in the guide pin. Brush the lift pin with lubricating
grease.
Position the lift pin and guide pin in the extension beam. Position
the guide pin so that the grease cup is accessible through the
holes in the extension beam.
NOTE
Do not forget the washer between the extension beam and
guide pin.
013213
VDRT02.02GB
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.9.6 ATTACH, menu 6.
7:85
000360
Check that the indicator pins in the corner boxes can move up
and down freely. The indicator pins must spring down when they
are not loaded.
013214
VDRT02.02GB
7:86
VDRT02.02GB
7:87
The weight indicator shows the weight of the raised load. The dynamic
scale shows the load regardless of the position of the boom and
extension.
The weight indicator uses Sensor boom length (R777), Sensor boom
angle (R771) and Sensor hydraulic pressure, lift cylinder (B768),
to calculate the weight of the load. For more information about the
sensors see section 8 Control system, group 8.2.1 Overload System.
The pressure sensors can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.5.3 HYD, menu 3.
The dynamic scale weighs the load regardless of boom position. The
weight is calculated as a function of boom angle, boom length and
the pressure in the lift cylinders. The dynamic scale uses Sensor,
hydraulic pressure lift cylinder, Sensor, boom angle (analogue sensor)
and Sensor, boom length (analogue sensor).
Condition
Reference
value
Reference
Control breaker
Disengaged
OK
D6
D790-1
D795
D797-F
D797-R
D2
3, 5
D4
6
Pa
Pa
Pa
Pa
2m
<
013913
Pos
Explanation
Signal description
Reference
U = 0.5-4.5 V
Checked by control
system, error shown with
error code.
VDRT02.02GB
7:88
Pos
Explanation
Signal description
Reference
U = 0.5-4.5 V
Checked by control
system, error shown with
error code.
U = 0.5-4.5 V
Checked by control
system, error shown with
error code.
NOTE
The load curve is unique for each
machine.
8
VDRT02.02GB
7:89
Condition
Reference
value
Reference
Control breaker
Disengaged
1, 4, 7
D1
10
D790-1
D795
D797-R
D791-1
3, 6, 9
D2
5
006898
2, 8
D5
Pos
Explanation
Signal description
Reference
Sensor directly
opposite indicator
plate: U = 24 V
Checked by control
system, error shown
with error code.
Sensor directly
opposite indicator
plate: U = 24 V
Checked by control
system, error shown
with error code.
VDRT02.02GB
7:90
Pos
Explanation
Signal description
Reference
U=0V
Checked by control
system, error shown
with error code.
10
VDRT02.02GB
7:91
Reference value
Reference
Control breaker
Disengaged
1
D1
+
2, 6
D790-1
D795
D797-R
D797-F
D4
3m
<
013215
D3
Pos
Explanation
Signal description
Reference
U = 0.5-4.5 V
U = 0.5-4.5 V
VDRT02.02GB
7:92
VDRT02.02GB
8:1
8 Control system
VDRT02.02GB
8:2
VDRT02.02GB
8:3
8 Control system
Control system, general
In many cases, the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator
or limit the machine's functions in the event of certain dangerous
situations or if there are malfunctions in the machine.
The control system function is subdivided into the following functions:
Monitoring
Error codes
Diagnostics
Setup
Software
VDRT02.02GB
8:4
C
D
E
000389
E
000350
Stop
Indicates a serious malfunction that may jeopardise the operator's
safety or cause machine failure. The error code must be attended
to immediately. Stop working with the machine and contact
service immediately.
Warning
Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
contact service as soon as possible.
000351
C
E
000352
VDRT02.02GB
Information
Information to the operator that something should be rectified,
e.g. broken bulb. Take action to rectify the cause of the error
code as soon as possible.
The error code is stored in the error code list under operating
menu for service.
8:5
C
D
The control and monitoring system gives error codes from three
sub-systems:
000389
Machine:
Shown with error code number XXX on display.
Engine:
Shown with error code number XXX/YY on display.
X X X /Y Y
NOTE
If several error codes come from the engine, the error code level
is shown for the most serious error code.
013390
Transmission:
Shown with error code number XX/YY on display.
X X /Y Y
D
013391
1.
2.
3.
4.
5.
6.
7.
000396
VDRT02.02GB
8:6
10
11
12
1.
Attachment
2.
Rotation of attachment
3.
Side shift-attachment
4.
5.
Twistlocks
6.
Boom up/down
7.
8.
Overload system
9.
Boom in/out
13
14
13. Engine
15
14. Transmission
15. Control unit
16. Hardware-related error
16
17
18
17. Cab
18. Air conditioning
19. Fuel system
19
20
20. Headlights
21
23
014163
22
VDRT02.02GB
8:7
8.2 Monitoring
8.2.1 Overload system
Overload system, function description
D 795
D 4
D 3
D 7 9 7 -F
D 1
D 793
0 1 4 11 3
D 7 9 7 -R
5,8
Pos
Explanation
Signal description
Reference
UB768-XX/1 = 5 V
UB768-XX/2 = 0 V
UB768-XX/3 = 0.5 - 4.5 V
UB777/1 = 5 V
UB777/2 = 0 V
UB777/3 = 0.5 - 4.5 V
UB771/1 = 5 V
UB771/2 = 0 V
UB771/3 = 0.5 - 4.5 V
NOTE
The load curve is unique for each
machine.
If the load is high then Control unit,
frame front (D797-F) sends Overload
forward on the CAN bus.
6
VDRT02.02GB
8:8
Pos
Explanation
Signal description
Reference
001093
The signal can be checked via the diagnostic menu. See section8
Control system, group 8.4.10.4 OP, menu 4.
VDRT02.02GB
Switch on the system voltage and turn the start key to position I.
Check that the end position damping is working in both outer and
inner end positions.
8:9
000471
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.10.4 OP, menu 4.
Switch on the system voltage and turn the start key to position I.
Check that the end position damping is working in both the outer
and the inner end positions.
VDRT02.02GB
8:10
8.2.2 Bypass
Bypass, description
When the overload system engages and turns off the hydraulic
controls, it may take place in a situation where it is necessary to bypass
the safety system.
By-passing the safety system allows:
lift, lower and extension with active error in the overload system
DANGER
Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
Extreme hazard to personal health and risk of property
damage!
Only use the bypass of safety systems in emergency
situations.
VDRT02.02GB
8:11
8.4 Diagnostics
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
009268
VDRT02.02GB
8:12
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
Diagnostic tests show how the control units interpret input signals as
well as which signals that the control units send.
2(10)
2
11
0
1.
2.
Menu group
3.
Menu number
4.
5.
Signal value
6.
Variable
7.
Menu heading
004856
DIAG
Menu group
Menu number
Number of current menu. Every menu group consists of several menus in a loop.
Number of
menus
Variable
The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g. a switch.
OUTPUT: a digital output signal, e.g. feed to a motor.
INPUT: an analogue input signal, e.g. from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value
Measurement value or status for the signal for variable. On the same row there are different types
that are interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading
VDRT02.02GB
8:13
8.4.1 CAN/POWER
CAN/POWER, description
This group handles redundant voltage feed to control units and CAN
bus communication.
Confirm selections with function key for Enter.
009268
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CAN/POWER
1(20)
PRESENT REDCAN STATUS
COMMUNICATION MODE X
NUMBERS OF UNITS
X
SEGMENT ERROR
X
OK.
Segment check
Error.
DIAG CAN/POWER
1(20)
PRESENT REDCAN STATUS
COMMUNICATION MODE X
NUMBERS OF UNITS
X
SEGMENT ERROR
X
003177
VDRT02.02GB
8:14
DIAG CAN/POWER
1(20)
PRESENT REDCAN STATUS
COMMUNICATION MODE X
NUMBERS OF UNITS
X
SEGMENT ERROR
X
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Contact: Function: 11.6.2 Redundant CAN bus
Signal value:
0
No open circuits.
>0
DIAG CAN/POWER
2(20)
PRESENT REDCAN STATUS
RED.CON.CITIES
XYXYXYXY
1234ROFD
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Contact:
D790-1: K13:4, K13:5, K13:7 and K13:8
D795: K1:10, K1:11, K1:12 and K1:13
D797-F, D797-R, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.1 Control unit, cab, 11.5.3.2 Control unit, frame front,
11.5.3.3 Control unit, frame rear, 11.5.3.5 Control unit, attachment,
11.5.3.6, 11.5.3.12 Control unit KID, 11.6.2 Redundant CAN bus
Signal value:
1
VDRT02.02GB
8:15
DIAG CAN/POWER
3(20)
PRESENT DRIVE-TRAIN
CAN BUS STATUS
ENGINE
X
TRANSMISSION
X
Contact:
Yuchai YC6M360-30: CAN J1939 from D790-1/K13:1 and K13:2
to D794/1:34 and 1:35
Cummins QSM11
: CAN J1939 from D790-1/K13:1 and K13:2
to D794/46 and 37
Function: 11.6.3 CAN bus drive-train
Signal value:
1
NOTE
The cable harness for CAN bus drive-train is common to the
engine and transmission from the cab electronic box to the
frame electronic box. The cable branches in the frame electronic
box. If communication with both the engine and transmission
is cut off, start troubleshooting at the cable harness between
the cab electronic box and the frame electronic box. If there is
communication (either engine or transmission), this rules out a
fault in the cable harness between the cab electronic box and the
frame electronic box.
DIAG CAN/POWER
3(20)
PRESENT DRIVE-TRAIN
CAN BUS STATUS
ENGINE
X
TRANSMISSION
X
NOTE
The cable harness for CAN bus drive-train is common to the
engine and transmission from the cab electronic box to the
frame electronic box. The cable branches in the frame electronic
box. If communication with both the engine and transmission
is cut off, start troubleshooting at the cable harness between
the cab electronic box and the frame electronic box. If there is
communication (either engine or transmission), this rules out a
fault in the cable harness between the cab electronic box and the
frame electronic box.
VDRT02.02GB
8:16
4(X)
X
XY
XY
DIAG CAN/POWER
INGNITION
KEY IN
RELAY K315-1
RELAY K315-2
No signal.
4(X)
X
XY
XY
DIAG CAN/POWER
INGNITION
KEY IN
RELAY K315-1
RELAY K315-2
01
10
11
4(X)
X
XY
XY
DIAG CAN/POWER
INGNITION
KEY IN
RELAY K315-1
RELAY K315-2
01
10
11
VDRT02.02GB
8:17
DIAG CAN/POWER
5(X)
EMERGENCY STOP, SW X
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY
No signal.
DIAG CAN/POWER
5(X)
EMERGENCY STOP, SW X
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY
01
10
11
DIAG CAN/POWER
5(X)
EMERGENCY STOP, SW X
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY
No signal.
VDRT02.02GB
8:18
DIAG CAN/POWER
5(X)
EMERGENCY STOP, SW X
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY
01
10
11
000091
DIAG CAN/POWER
6(20)
790-1 CAB
POWER
XX.XXV
5V REF
X.XXV
DIAG CAN/POWER
6(20)
790-1 CAB
POWER
XX.XXV
5V REF
X.XXV
Contact:
1.
2.
3.
4.
VDRT02.02GB
8:19
003178
DIAG CAN/POWER
7(20)
790-1 CAB
24V SENSOR SUPPLY XY
24V SUPPLY,RPM>500 XY
1.
2.
3.
4.
Circuit Power group 11.5, Circuit Brake group 4.0, Circuit Bypass
group 8.2, Circuit Twistlocks group 7.9, Circuit Spreading Sensor
group 7.5
5.
Not used.
6.
7.
Not used.
8.
9.
2.
3.
4.
5.
Not used.
6.
7.
Not used.
8.
9.
2.
3.
4.
5.
Not used.
6.
7.
Not used.
8.
9.
VDRT02.02GB
8:20
Signal value:
01
10
11
003178
DIAG CAN/POWER
7(20)
790-1 CAB
24V SENSOR SUPPLY XY
24V SUPPLY,RPM>500 XY
01
10
11
000093
DIAG CAN/POWER
8(20)
797-F FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
VDRT02.02GB
8:21
DIAG CAN/POWER
8(20)
797-F FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
Feed active.
No feed.
DIAG CAN/POWER
8(20)
797-F FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
Feed active.
No feed.
DIAG CAN/POWER
9(20)
797-F FRAME
24V SENSOR SUPPLY XY
5V REF
X.XXV
01
10
11
VDRT02.02GB
8:22
DIAG CAN/POWER
9(20)
797-F FRAME
24V SENSOR SUPPLY XY
5V REF
X.XXV
000095
VDRT02.02GB
Feed active.
No feed.
8:23
01
10
11
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:24
RED.POWER
14(20)
Le X Ri X
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
Contact:
000099
DIAG CAN/POWER
795 DISPLAY
Feed active.
No feed.
VDRT02.02GB
8:25
00003179
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Contact:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1
Feed active.
No feed.
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:26
XXXXXXX
X(X)
008793
NOT USED
01
10
11
003180
VDRT02.02GB
003180
8:27
003180
SEGMENT ERROR
D791-2
CAN R
006861
DIAG CAN/POWER
21(X)
REDCAN STATUS CHECK
PRESS ENTER
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
D791-1
CAN L
CAN R
CAN L
Contact:
D790-1
1
CAN R
D790-2
D795
CAN L
CAN R
Signal value:
CAN L
CAN L
CAN R
D797-R
CAN L
CAN R
D797-F
013438
No errors.
>0
8.4.2 LIGHTS
LIGHTS, description
This group covers lighting.
Confirm selections with function key for Enter.
012083
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG LIGHTS
1(13)
WORKING LIGHT CAB
SWITCH
X
OUTPUT
LE XY RI XY
No signal.
VDRT02.02GB
8:28
DIAG LIGHTS
1(13)
WORKING LIGHT CAB
SWITCH
X
OUTPUT
LE XY RI XY
10
11
DIAG LIGHTS
2(13)
WORKING LIGHT ATTACH
SWITCH
X
OUTPUT
LE XY RI XY
OPT OUTPUT (2X)
XY
No signal.
DIAG LIGHTS
2(13)
WORKING LIGHT ATTACH
SWITCH
X
OUTPUT
LE XY RI XY
OPT OUTPUT (2X)
XY
01
10
11
VDRT02.02GB
8:29
DIAG LIGHTS
2(13)
WORKING LIGHT ATTACH
SWITCH
X
OUTPUT
LE XY RI XY
OPT OUTPUT (2X)
XY
01
10
11
DIAG LIGHTS
3(13)
WORKING LIGHT BOOM
SWITCH
X
OUTPUT
LE XY RI XY
OPTIONAL OUTPUT
XX
No signal.
VDRT02.02GB
8:30
DIAG LIGHTS
3(13)
WORKING LIGHT BOOM
SWITCH
X
OUTPUT
LE XY RI XY
OPTIONAL OUTPUT
XX
01
10
11
DIAG LIGHTS
3(13)
WORKING LIGHT BOOM
SWITCH
X
OUTPUT
LE XY RI XY
OPTIONAL OUTPUT
XX
01
10
11
VDRT02.02GB
8:31
4(13)
DIAG LIGHTS
MAIN LIGHT
SWITCH
No signal.
DIAG LIGHTS
5(13)
PRESENT OUTPUT SIGNAL
SIDE-F
LE XY RI XY
SIDE-R
LE XY RI XY
REAR
LE XY RI XY
01
10
11
VDRT02.02GB
8:32
DIAG LIGHTS
5(13)
PRESENT OUTPUT SIGNAL
SIDE-F
LE XY RI XY
SIDE-R
LE XY RI XY
REAR
LE XY RI XY
01
10
11
DIAG LIGHTS
5(13)
PRESENT OUTPUT SIGNAL
SIDE-F
LE XY RI XY
SIDE-R
LE XY RI XY
REAR
LE XY RI XY
01
10
11
VDRT02.02GB
8:33
DIAG LIGHTS
6(13)
HEAD LIGHTS
SWITCH
X
HEAD
LE XY RI XY
DIMMED
XY
No signal.
DIAG LIGHTS
6(13)
HEAD LIGHTS
SWITCH
X
HEAD
LE XY RI XY
DIMMED
XY
Circuit diagram: Circuit Lighting group 9.6 and Circuit Extra Wor.Li.
Frame group 9.6
Contact:
LE: digital out from D797-F/K1:1 to E402L
RI: digital out from D797-F/K1:15 to E402R
Function: 9.6.1 Headlights
Signal value:
00
01
10
11
VDRT02.02GB
8:34
DIAG LIGHTS
6(13)
HEAD LIGHTS
SWITCH
X
HEAD
LE XY RI XY
DIMMED
XY
01
10
11
DIAG LIGHTS
7(13)
PRESENT INPUT SIGNAL
HAZARD SWITCH
X
FLASH.SW.
LE X RI X
No signal.
DIAG LIGHTS
7(13)
PRESENT INPUT SIGNAL
HAZARD SWITCH
X
FLASH.SW.
LE X RI X
Contact:
LE: from S161/1 to digital in D790-2/K8:9
RI: from S161/6 to digital in D790-2/K8:8
Function: 9.6 Lighting system
Signal value:
VDRT02.02GB
No signal.
8:35
DIAG LIGHTS
8(13)
PRESENT OUTPUT SIGNAL
HAZARD/FLASHER
FRONT
LE XY RI XY
REAR
LE XY RI XY
Contact:
LE: digital out from D797-F/K1:9 to H422
RI: digital out from D797-F/K1:10 to H423
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
00
01
10
11
DIAG LIGHTS
8(13)
PRESENT OUTPUT SIGNAL
HAZARD/FLASHER
FRONT
LE XY RI XY
REAR
LE XY RI XY
Contact:
LE: digital out from D797-R/K1:29 to H426
RI: digital out from D797-R/K1:39 to H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
00
01
10
11
VDRT02.02GB
8:36
9(13)
X
XY
DIAG LIGHTS
ROTATION BEACON
SWITCH
OUTPUT
No signal.
9(13)
X
XY
DIAG LIGHTS
ROTATION BEACON
SWITCH
OUTPUT
10
11
DIAG LIGHTS
10(13)
PRESENT INPUT SIGNAL
BRAKE LIGHT SWITCH
X
REVERSE LIGHT SIGNAL X
VDRT02.02GB
No signal.
8:37
DIAG LIGHTS
10(13)
PRESENT INPUT SIGNAL
BRAKE LIGHT SWITCH
X
REVERSE LIGHT SIGNAL X
No signal.
DIAG LIGHTS
11(13)
PRESENT OUTPUT SIGNAL
BRAKE LIGHT LEXY RIXY
REVERSE LGT LEXY RIXY
REVERSE ALARM
XY
01
10
11
VDRT02.02GB
8:38
DIAG LIGHTS
11(13)
PRESENT OUTPUT SIGNAL
BRAKE LIGHT LEXY RIXY
REVERSE LGT LEXY RIXY
REVERSE ALARM
XY
01
10
11
DIAG LIGHTS
11(13)
PRESENT OUTPUT SIGNAL
BRAKE LIGHT LEXY RIXY
REVERSE LGT LEXY RIXY
REVERSE ALARM
XY
01
10
11
12(13)
X
X
XXX
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT
VDRT02.02GB
No signal.
8:39
12(13)
X
X
XXX
000118
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT
No signal.
12(13)
X
X
XXX
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT
OUTPUT
13(13)
Circuit diagram: -
XXX
000119
DIAG LIGHTS
SWITCH LIGHTS
Means 4-5 V.
170
Means 15-16 V.
VDRT02.02GB
8:40
8.4.3 CAB
CAB, description
This group covers functions in the cab.
Confirm selections with function key for Enter.
012086
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
1(X)
X
XY
XY
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR/ROOF
No signal.
WASHER, OUTPUT
Description: Voltage feed to motor, windscreen washing.
1(X)
X
XY
XY
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR/ROOF
10
11
VDRT02.02GB
8:41
1(X)
X
XY
XY
012087
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR/ROOF
01
10
11
2(10)
X
XY
X
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
Long interval.
Normal interval.
Continuous operation.
VDRT02.02GB
8:42
2(10)
X
XY
X
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
10
11
2(10)
X
XY
X
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
3(10)
X
XY
X
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK
VDRT02.02GB
No signal.
8:43
3(10)
X
XY
X
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK
10
11
3(10)
X
XY
X
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK
4(10)
X
XY
X
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK
No signal.
VDRT02.02GB
8:44
4(10)
X
XY
X
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK
01
10
11
4(10)
X
XY
X
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK
5(10)
Circuit diagram: Circuit Alarm, audible signals group 9.7
X
XY
X
DIAG CAB
HORN
SWITCH
OUTPUT
SWITCH JOYSTICK
VDRT02.02GB
No signal.
8:45
HORN, OUTPUT
Description: Voltage feed to horn.
5(10)
Circuit diagram: Circuit Alarm, audible signals group 9.7
X
XY
X
DIAG CAB
HORN
SWITCH
OUTPUT
SWITCH JOYSTICK
10
11
SWITCH JOYSTICK
Description: Signal from switch, open twistlocks on the control lever.
The signal is used to activate the horn when there is no alignment.
5(10)
X
XY
X
DIAG CAB
HORN
SWITCH
OUTPUT
SWITCH JOYSTICK
No signal.
6(10)
XY
X
X
X
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
01
10
11
VDRT02.02GB
8:46
SWITCH SEAT
Description: Signal from Sensor, operator-in-seat.
6(10)
XY
X
X
X
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
ALARM
6(10)
XY
X
X
X
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
OP
Description: Status for overload warning from the control system.
6(10)
XY
X
X
X
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
7(10)
XXXOHM
XXX
000127
DIAG CAB
FUEL
SENSOR VALUE
PROC
VDRT02.02GB
8:47
FUEL, PROC
Description: The control system's interpretation of the signal from
sensor, fuel tank.
7(10)
XXXOHM
XXX
DIAG CAB
FUEL
SENSOR VALUE
PROC
DIAG CAB
SEAT HEATER
SWITCH
OUTPUT
8(10)
Description: Signal from switch, seat heating.
Circuit diagram: Circuit Cab driver's seat group 9.3
000128
X
XY
No signal.
DIAG CAB
SEAT HEATER
SWITCH
OUTPUT
8(10)
Description: Control voltage to seat heating relay.
Circuit diagram: Circuit Cab driver's seat group 9.3
000128
X
XY
01
10
11
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:48
XXXXXXX
X(X)
008793
NOT USED
8.4.4 CLIMATE
CLIMATE, description
This group covers the cab's air conditioning.
Confirm selections with function key for Enter.
012088
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG CLIMATE
1(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
WATER VALVE FEEDB. XXX
DIAG CLIMATE
1(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
WATER VALVE FEEDB. XXX
DIAG CLIMATE
1(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
WATER VALVE FEEDB. XXX
VDRT02.02GB
8:49
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
Description: Temperature of the air out from the fan. The sensor is
fitted in the air distributor.
Circuit diagram: Circuit Climate system group 9.4
000133
DIAG
TEMP
TEMP
TEMP
TEMP
TEMP COOLANT
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
DIAG
TEMP
TEMP
TEMP
TEMP
TEMP AMBIENT
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
DIAG
TEMP
TEMP
TEMP
TEMP
TEMP DE-ICE
Description: Temperature in refrigerant circuit.
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
DIAG
TEMP
TEMP
TEMP
TEMP
VDRT02.02GB
8:50
DIAG CLIMATE
3(X)
PRESENT INPUT SIGNAL
PRESSURE SWITCH
X
OPT DOOR SWITCH
X
DIAG CLIMATE
3(X)
PRESENT INPUT SIGNAL
PRESSURE SWITCH
X
OPT DOOR SWITCH
X
006865
DIAG CLIMATE
4(8)
PRESENT INPUT SIGNAL
WATER VALVE
XX.XXV
DRAUGHT VALVE XX.XXV
DIAG CLIMATE
4(8)
PRESENT INPUT SIGNAL
WATER VALVE
XX.XXV
DRAUGHT VALVE XX.XXV
VDRT02.02GB
8:51
DIAG CLIMATE
5(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV
REQ. DRAUGHT
XX.XXV
REQ. FAN SPEED XX.XXV
DIAG CLIMATE
5(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV
REQ. DRAUGHT
XX.XXV
REQ. FAN SPEED XX.XXV
DIAG CLIMATE
5(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV
REQ. DRAUGHT
XX.XXV
REQ. FAN SPEED XX.XXV
DIAG CLIMATE
6(8)
PRESENT OUTPUT SIGNAL
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
VDRT02.02GB
8:52
DIAG CLIMATE
6(8)
PRESENT OUTPUT SIGNAL
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
10
11
DIAG CLIMATE
6(8)
PRESENT OUTPUT SIGNAL
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
01
10
11
VDRT02.02GB
8:53
DIAG CLIMATE
7(8)
OUTPUT WATER VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
24V
01
000138
0V
H-bridge
10
11
DIAG CLIMATE
7(8)
OUTPUT WATER VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
24V
H-bridge
00
01
000138
0V
10
11
VDRT02.02GB
8:54
DIAG CLIMATE
8(8)
OUTPUT DRAUGHT VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
24V
01
000139
0V
00
10
11
H-bridge
DIAG CLIMATE
8(8)
OUTPUT DRAUGHT VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
24V
01
000139
0V
00
H-bridge
10
11
8.4.5 HYD
HYD, description
This group covers the hydraulic functions.
VDRT02.02GB
009272
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8:55
1(6)
XXX
XY
DIAG HYD
HYDRAULIC OIL
TEMP
FAN
1(6)
XXX
XY
DIAG HYD
HYDRAULIC OIL
TEMP
FAN
10
11
DIAG HYD
2(6)
BRAKE COOLANT OIL
TEMP
XXX
FAN
XY
DIAG HYD
2(6)
BRAKE COOLANT OIL
TEMP
XXX
FAN
XY
10
11
VDRT02.02GB
8:56
DIAG HYD
3(6)
PRESSURE LIFTING CYL
Le
Ri
CXXX
XXX
C+
XXX
XXX
Description: Pressure on the lift cylinders' rod side (C-). For voltage
value, see OP, description, page 8:91.
Circuit diagram: Circuit OP + Scale group 8.2
Contact: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C-, page
8:92
Function: 8.2.1 Overload system
C-
NOTE
The sensors can be quickly tested by lifting max. and running the
lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure 0.1 MPa.
000143
C+
DIAG HYD
3(6)
PRESSURE LIFTING CYL
Le
Ri
CXXX
XXX
C+
XXX
XXX
C-
NOTE
000143
C+
The sensors can be quickly tested by lifting max. and running the
lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure 0.1 MPa.
VDRT02.02GB
8:57
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
BRAKE LIGHT PRESS. X
DECLUTCH PRESSURE
X
No signal.
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
BRAKE LIGHT PRESS. X
DECLUTCH PRESSURE
X
No signal.
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
BRAKE LIGHT PRESS. X
DECLUTCH PRESSURE
X
No signal.
5(X)
X/Y
X
XY
DIAG HYDRAULIC
P-BRAKE
SWITCH
FEEDBACK SWITCH
VALVE
0/1
VDRT02.02GB
8:58
5(X)
X/Y
X
XY
DIAG HYDRAULIC
P-BRAKE
SWITCH
FEEDBACK SWITCH
VALVE
No signal.
P-BRAKE, VALVE
Description: Voltage feed to Solenoid valve parking brake.
5(X)
X/Y
X
XY
DIAG HYDRAULIC
P-BRAKE
SWITCH
FEEDBACK SWITCH
VALVE
01
10
11
DIAG HYD
6(6)
PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM.
VALVE
XY
01
10
11
VDRT02.02GB
8:59
8.4.6 ENGINE
ENGINE, description
This group covers engine functions.
Confirm selections with function key for Enter.
012093
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG ENGINE
1(X)
PRESENT INPUT SIGNAL
ACCELERATOR
X.XXV
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX
Function: 1 Engine
Signal value: X.XXV = 0.50-4.50 V
DIAG ENGINE
1(X)
PRESENT INPUT SIGNAL
ACCELERATOR
X.XXV
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX
DIAG ENGINE
1(X)
PRESENT INPUT SIGNAL
ACCELERATOR
X.XXV
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX
DIAG ENGINE
2(X)
PRESENT INPUT SIGNAL
ENGINE SPEED EDC XXXX
014149
VDRT02.02GB
8:60
DIAG ENGINE
3(X)
PRESENT INPUT SIGNAL
PRESENT TORQUE
XXX
014150
009282
DIAG ENGINE
4(X)
PRESENT INPUT SIGNAL
PREHEAT SWITCH
X
CRANK ENGINE SWITCH X
D+
X
DIAG ENGINE
4(X)
PRESENT INPUT SIGNAL
PREHEAT SWITCH
X
CRANK ENGINE SWITCH X
D+
X
No signal.
DIAG ENGINE
4(X)
PRESENT INPUT SIGNAL
PREHEAT SWITCH
X
CRANK ENGINE SWITCH X
D+
X
VDRT02.02GB
No signal.
8:61
DIAG ENGINE
5(X)
PRESENT OUTPUT SIGNAL
PREHEAT
X
CRANK ENGINE
X
No output signal.
DIAG ENGINE
5(X)
PRESENT OUTPUT SIGNAL
PREHEAT
X
CRANK ENGINE
X
01
10
11
DIAG ENGINE
5(X)
PRESENT OUTPUT SIGNAL
PREHEAT
X
CRANK ENGINE
X
10
11
VDRT02.02GB
8:62
DIAG ENGINE
6(10)
PRESENT INPUT SIGNAL
OIL PRESSURE
XXX
BOOST PRESSURE
XXX
Contact:
Cummins QSM11
: signal from "Oil pressure/temperature
sensor" to Control unit, engine (D794) "Sensor connector" sleeve
44
Yuchai YC6M360-30: Function: 1.8 Lubrication system
Signal value: XXX = 10 corresponds to 100 kPa.
DIAG ENGINE
6(10)
PRESENT INPUT SIGNAL
OIL PRESSURE
XXX
BOOST PRESSURE
XXX
000153
DIAG ENGINE
7(X)
PRESENT INPUT SIGNAL
OIL TEMP
XXX
COOLANT TEMP
XXX
INTAKE MAIN.TEMP XXX
Contact:
Cummins QSM11
: signal from "Oil pressure/temperature
sensor" sleeve 4 to Control unit, engine (D794) "Sensor
connector" sleeve 42
Yuchai YC6M360-30: Function: 1.8 Lubrication system
Signal value: XXX = 200 corresponds to 20 C.
DIAG ENGINE
7(X)
PRESENT INPUT SIGNAL
OIL TEMP
XXX
COOLANT TEMP
XXX
INTAKE MAIN.TEMP XXX
Contact:
Cummins QSM11
: signal from "Coolant temperature sensor"
to Control unit, engine (D794) "Sensor connector" sleeve 02
Yuchai YC6M360-30: Function: 1.7 Cooling system
Signal value: XXX = 200 corresponds to 20 C.
VDRT02.02GB
8:63
DIAG ENGINE
7(X)
PRESENT INPUT SIGNAL
OIL TEMP
XXX
COOLANT TEMP
XXX
INTAKE MAIN.TEMP XXX
Contact:
Cummins QSM11
: signal from "Intake manifold /(Boost)
temperature sensor" to Control unit, engine (D794) "Sensor
connector" sleeve 38
Yuchai YC6M360-30: Function: 1.6 Air intake and exhaust outlet
Signal value: XXX = 200 corresponds to 20 C.
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
VDRT02.02GB
8:64
9(X)
Circuit diagram: -
XXX
Contact: 009280
DIAG ENGINE
FUEL CONSUMTION
MOMENTARILY l/h
DIAG ENGINE
10(X)
PRESENT INPUT SIGNAL
PRE-HEAT FEEDBACK
X
WATER IN FUEL SW.
X
COOLANT LEVEL SW.
X
No signal
DIAG ENGINE
10(X)
PRESENT INPUT SIGNAL
PRE-HEAT FEEDBACK
X
WATER IN FUEL SW.
X
COOLANT LEVEL SW.
X
No signal
DIAG ENGINE
10(X)
PRESENT INPUT SIGNAL
PRE-HEAT FEEDBACK
X
WATER IN FUEL SW.
X
COOLANT LEVEL SW.
X
VDRT02.02GB
No signal
8:65
8.4.7 TRANSM
TRANSM, description
This group covers the transmission function.
Confirm selections with function key for Enter.
009274
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG TRANSM.
1(15)
PRESENT INPUT SIGNAL
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
DECLUTCH PRESS SW. X
DIAG TRANSM.
1(15)
PRESENT INPUT SIGNAL
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
DECLUTCH PRESS SW. X
No signal.
DIAG TRANSM.
1(15)
PRESENT INPUT SIGNAL
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
DECLUTCH PRESS SW. X
No signal.
VDRT02.02GB
8:66
2(15)
X
X
X
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
Function: 2 Transmission
Signal value:
1
No signal.
SWITCHES, REVERSE
Description: Signal from gear and multi-function lever (reverse).
2(15)
X
X
X
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
Function: 2 Transmission
Signal value:
1
No signal.
2(15)
X
X
X
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
3(15)
X
X
X
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR
VDRT02.02GB
No output signal.
8:67
3(15)
X
X
X
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR
No output signal.
3(15)
X
X
X
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR
4(15)
X
X
X
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE
Automatic.
Manual.
4(15)
X
X
X
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE
Active error.
No errors.
VDRT02.02GB
8:68
4(15)
X
X
X
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE
Not used.
Not used.
Not used.
DIAG TRANSM.
5(15)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X
Shifting in progress.
No activity.
DIAG TRANSM.
5(15)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X
VDRT02.02GB
No error codes.
8:69
DIAG TRANSM.
5(15)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:70
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
DIAG TRANSM.
12(X)
006872
NOT USED
DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
NUMBER OF OCCU. XXXXX
TIME AGO
XXXXX
TYPE
Description: Indicates type of active error.
Circuit diagram: Contact: 000171
DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
NUMBER OF OCCU. XXXXX
TIME AGO
XXXXX
VDRT02.02GB
8:71
NUMBER OF OCCU.
Description: Number of times active errors have occurred.
Circuit diagram: Contact: 000171
DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
NUMBER OF OCCU. XXXXX
TIME AGO
XXXXX
TIME AGO
Description: When latest active error occurred.
Circuit diagram: Contact: 000171
DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
NUMBER OF OCCU. XXXXX
TIME AGO
XXXXX
DIAG TRANSM.
14(X)
MANUAL GEAR SHIFT
X
GEAR
(+/-)
VDRT02.02GB
8:72
8.4.8 BOOM
BOOM, description
This group covers the boom functions.
Confirm selections with function key for Enter.
009275
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
DIAG BOOM
1(8)
PRESENT INPUT SIGNALS
BOOM UP/DOWN
XX.XXV
BOOM IN/OUT
XX.XXV
DIAG BOOM
1(8)
PRESENT INPUT SIGNALS
BOOM UP/DOWN
XX.XXV
BOOM IN/OUT
XX.XXV
DIAG BOOM
2(8)
BLOCK VALVES
UP/DOWN
LE XY RI XY
IN
XY
RELIEVE PRESS. IN XY
01
10
11
VDRT02.02GB
8:73
DIAG BOOM
2(8)
BLOCK VALVES
UP/DOWN
LE XY RI XY
IN
XY
RELIEVE PRESS. IN XY
01
10
11
DIAG BOOM
2(8)
BLOCK VALVES
UP/DOWN
LE XY RI XY
IN
XY
RELIEVE PRESS. IN XY
01
10
11
VDRT02.02GB
8:74
DIAG BOOM
3(8)
BOOM HIGH SPEED
UP
LE XY RI XY
OUT
XY
01
10
11
DIAG BOOM
3(8)
BOOM HIGH SPEED
UP
LE XY RI XY
OUT
XY
01
10
11
VDRT02.02GB
8:75
4(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM UP
REFERENCE
REQUIRED VALUE
FEEDBACK
01
10
11
4(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM UP
REFERENCE
REQUIRED VALUE
FEEDBACK
4(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM UP
REFERENCE
REQUIRED VALUE
FEEDBACK
VDRT02.02GB
8:76
5(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM DOWN
REFERENCE
REQUIRED VALUE
FEEDBACK
01
10
11
5(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM DOWN
REFERENCE
REQUIRED VALUE
FEEDBACK
5(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM DOWN
REFERENCE
REQUIRED VALUE
FEEDBACK
VDRT02.02GB
8:77
6(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM IN
REFERENCE
REQUIRED VALUE
FEEDBACK
01
10
11
6(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM IN
REFERENCE
REQUIRED VALUE
FEEDBACK
6(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM IN
REFERENCE
REQUIRED VALUE
FEEDBACK
VDRT02.02GB
8:78
7(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM OUT
REFERENCE
REQUIRED VALUE
FEEDBACK
01
10
11
7(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM OUT
REFERENCE
REQUIRED VALUE
FEEDBACK
7(8)
XY
XXX
XXX
DIAG BOOM
OUTPUT BOOM OUT
REFERENCE
REQUIRED VALUE
FEEDBACK
VDRT02.02GB
8:79
DIAG BOOM
8(8)
PRESENT INPUT SIGNAL
BOOM LOW SPEED
UP/DOWN
X
IN/OUT
X/X
No signal.
DIAG BOOM
8(8)
PRESENT INPUT SIGNAL
BOOM LOW SPEED
UP/DOWN
X
IN/OUT
X/X
No signal.
8.4.9 ATTACH
ATTACH, description
This group covers attachment functions.
Confirm selections with function key for Enter.
009276
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
VDRT02.02GB
8:80
000184
Contact:
LE: from S815/14 to digital in D790-1/K7:14 (spreading in)
RI: from S815/16 to digital in D790-1/K7:13 (spreading out)
Function: 7.4 Side shift
Signal value:
1
No signal.
No signal.
VDRT02.02GB
000185
8:81
No signal.
No signal.
000186
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:82
DIAG ATTACHMENT
5(X)
PRESENT INPUT SIGNALS
LOW SPEED 20/40
X
30/35 STOP
X
No signal.
012122
DIAG ATTACHMENT
5(X)
PRESENT INPUT SIGNALS
LOW SPEED 20/40
X
30/35 STOP
X
000202
No signal.
000202
VDRT02.02GB
No signal.
8:83
001633
No signal.
001633
No signal.
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:84
01
10
11
01
10
11
VDRT02.02GB
8:85
01
10
11
01
10
11
VDRT02.02GB
8:86
01
10
11
01
10
11
VDRT02.02GB
8:87
01
10
11
VDRT02.02GB
8:88
01
10
11
VDRT02.02GB
8:89
01
10
11
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8:90
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
VDRT02.02GB
8 Control system OP
8:91
XXXXXXX
X(X)
008793
NOT USED
XXXXXXX
X(X)
008793
NOT USED
8.4.10 OP
OP, description
This group covers the overload system functions.
Confirm selections with function key for Enter.
009277
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
XXXXXXX
X(X)
008793
NOT USED
DIAG OP
2(5)
PRESENT INPUT SIGNAL
X
BY-PASS
No signal.
VDRT02.02GB
8:92
8 Control system OP
DIAG OP
3(5)
PRESENT INPUT SIGNAL
LIFT CYL LE
RI
CX.XXV X.XXV
C+
X.XXV X.XXV
1.
Pressure C-
2.
Pressure C+
000207
DIAG OP
3(5)
PRESENT INPUT SIGNAL
LIFT CYL LE
RI
CX.XXV X.XXV
C+
X.XXV X.XXV
1.
Pressure C-
2.
Pressure C+
VDRT02.02GB
000207
8 Control system OP
8:93
DIAG OP
4(5)
PRESENT INPUT SIGNAL
BOOM ANGLE
X.XXV
BOOM EXTENSION X.XXV
DIAG OP
4(5)
PRESENT INPUT SIGNAL
BOOM ANGLE
X.XXV
BOOM EXTENSION X.XXV
DIAG OP
5(X)
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg
LOAD STR.AXLE XXXXXkg
LOAD-CENTER
XX.XXm
PRESENT LOAD
Description: Calculated load.
Circuit diagram: Contact: 006879
DIAG OP
5(X)
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg
LOAD STR.AXLE XXXXXkg
LOAD-CENTER
XX.XXm
LOAD STR.AXLE
Description: Estimated load on the steering axle.
Circuit diagram: Contact: 006879
DIAG OP
5(X)
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg
LOAD STR.AXLE XXXXXkg
LOAD-CENTER
XX.XXm
VDRT02.02GB
8:94
8 Control system OP
LOAD-CENTRE
Description: Horizontal distance between centre drive axle and load
centre.
Circuit diagram: 006879
DIAG OP
5(X)
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg
LOAD STR.AXLE XXXXXkg
LOAD-CENTER
XX.XXm
6(X)
XXX
XXX
XXX
XXX
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE
BOOM EXTENSION
Description: Current boom extension.
6(X)
XXX
XXX
XXX
XXX
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE
BOOM HEIGHT
6(X)
XXX
XXX
XXX
XXX
Description: Status for boom height at the top edge of the boom,
the machine's total height.
Circuit diagram: 006880
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE
BOOM HEIGHT-NOSE
6(X)
XXX
XXX
XXX
XXX
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE
VDRT02.02GB
8:95
8.4.11 EXTRA
EXTRA, description
009278
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.13 RMI
RMI, description
007442
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
VDRT02.02GB
8:96
8.5 Setup
Setup, general
Settings are built-in functions to adapt the functions to the unique
machine individual. Settings are performed via menus in the display.
Settings are divided into initiation and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is carried out in order to compensate for mechanical and
electrical tolerances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after replacement of control units, and in certain cases, service
or replacement of components. Calibration is performed so that certain
functions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
2
9(10)
The settings influence the functions. Adjustments
may impair the function.
XXXmA
XXXmA
000058
INIT STEERING
START CURRENT
STEERING LEFT
STORED VALUE
PRESENT VALUE
DANGER
Menu group
2.
3.
Values
4.
Actual variable
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
In order that hydraulic functions shall work satisfactorily and safely,
certain values must be set to operate the machine, this is known as
initiation.
Initiation consists of several menus grouped according to functions.
Each individual menu sets a specific variable. The menus are similar
in structure and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Store the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.
START CURRENT
Specifies the start current to the solenoid valve for the selected function.
The start current is the lowest current that can be actuated. In practice,
it controls how slowly a function can be operated. On functions with
analogue control/activation (controllable), e.g. lift, this is the current
which is triggered when the lever leaves the zero position. On certain
functions with digital activation (off/on) which are soft-started, this is
the current which is triggered directly when the function is activated.
VDRT02.02GB
8:97
END CURRENT
Specifies the max. current to the solenoid valve for the selected
function. The max. current is the highest current that can be actuated.
In practice, it controls how quickly a function can be operated. On
functions with analogue control activation (controllable), e.g. lift, this is
the current which is triggered when the lever is in the end position. On
certain functions with digital activation (off/on) which are soft-started,
this is the current which is triggered after the ramp time when the
function is activated. The interval between START CURRENT and
END CURRENT is the active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during
damping. The interval is specified as 0-100% of the active range
between START CURRENT and END CURRENT.
Overview initiations
Function
Menu
Comment: The current value is for unladen machines. When loaded, the current
value is controlled by the limited lowering speed.
Comment: The current value is for unladen machines. When loaded, the current
value is controlled by the limited lowering speed.
VDRT02.02GB
8:98
Function
Menu
7.5 Spreading, in
000056
1 23
4 5
000060
NOTE
INITIATION BOOM
1(8)
START CURRENT
LIFT
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
VDRT02.02GB
Change the current value with the plus and minus keys.
NOTE
Current values can only be adjusted within specific limits.
Use the function key for Enter to store the desired current value
setting, "STORED".
000061
INITIATION BOOM
2(8)
END CURRENT
LIFT
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
Select group by scrolling with the arrow keys (1 and 2) and confirm
with Enter.
Each initiation consists of a sequence of a number of menus. The
first menu for the selected initiation opens in the display. Select
the desired menu with the arrow keys (1 and 2).
000057
INITIATION
BOOM ATTACHMENT
SLIDING-CAB STEERING
TIMES RETURN
8:99
8.5.1.1 BOOM
INIT BOOM
This function menu group handles initiation of the boom functions
lift, lower and extension.
BOOM ATTACHMENT
SLIDING-CAB STEERING
DRIVE-TRAIN
DANGER
000651
INITIATION
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
1(11)
Description: Start current for activation of Solenoid valve, lift (Y6005).
XXXmA
XXXmA
005042
INIT BOOM
START CURRENT
LIFT
STORED VALUE
PRESENT VALUE
PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, lift (Y6005)
Signal value: XXXmA = 0 - 999 mA
2(11)
Description: Control current at full lever actuation for the activation of
Solenoid valve, lift (Y6005).
XXXmA
XXXmA
005043
INIT BOOM
END CURRENT
LIFT
STORED VALUE
PRESENT VALUE
VDRT02.02GB
8:100
3(11)
Description: Start current for activation of Solenoid valve, lower
(Y6004).
XXXmA
XXXmA
005044
INIT BOOM
START CURRENT
LOWER
STORED VALUE
PRESENT VALUE
PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, lower (Y6004)
Signal value: XXXmA = 0 - 999 mA
4(11)
Description: Control current at full lever actuation for the activation of
Solenoid valve, lower (Y6004).
XXXmA
XXXmA
005045
INIT BOOM
END CURRENT
LOWER
STORED VALUE
PRESENT VALUE
5(11)
Description: Start current for activation of Solenoid valve, boom out
(Y6006).
XXXmA
XXXmA
005046
INIT BOOM
START CURRENT
BOOM OUT
STORED VALUE
PRESENT VALUE
PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, boom out (Y6006)
Signal value: XXXmA = 0 - 999 mA
VDRT02.02GB
8:101
6(11)
Description: Control current at full lever actuation for the activation of
Solenoid valve, boom out (Y6006).
XXXmA
XXXmA
005047
INIT BOOM
END CURRENT
BOOM OUT
STORED VALUE
PRESENT VALUE
7(11)
Description: Start current for activation of Solenoid valve, boom in
(Y6007).
XXXmA
XXXmA
005048
INIT BOOM
START CURRENT
BOOM IN
STORED VALUE
PRESENT VALUE
PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, boom in (Y6007)
Signal value: XXXmA = 0 - 999 mA
8(11)
Description: Control current at full lever actuation for the activation of
Solenoid valve, boom in (Y6007).
XXXmA
XXXmA
005049
INIT BOOM
END CURRENT
BOOM IN
STORED VALUE
PRESENT VALUE
VDRT02.02GB
8:102
INIT BOOM
9(11)
OUTPUT LIFT AT F/R
(PROC)
STORED VALUE
XXX
PRESENT VALUE
XXX
PRESENT VALUE: indicates the current value for the lift speed.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for lift speed.
Function: 7.2 Lift and lower
Component: Signal Value: XXX = lift speed as a percentage of max. value.
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
8.5.1.2 ATTACHMENT
INIT ATTACH
This function handles initiation of the attachment functions rotation,
controllable tilt and controllable levelling.
BOOM ATTACHMENT
SLIDING-CAB STEERING
DRIVE-TRAIN
DANGER
001157
INITIATION
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
VDRT02.02GB
8:103
1(14)
Description: tart current for activation of Solenoid valve, rotation
clockwise (Y6008).
XXXmA
XXXmA
005091
INIT ATTACH
START CURRENT
ROTATION CW
STORED VALUE
PRESENT VALUE
PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.6.3 Control valve attachment
Component: Solenoid valve rotation clockwise (Y6008)
Signal value: XXXmA = 0 - 999 mA
2(14)
Description: Control current at full lever actuation for the activation of
Solenoid valve, rotation anticlockwise (Y6009).
XXXmA
XXXmA
005092
INIT ATTACH
END CURRENT
ROTATION CW
STORED VALUE
PRESENT VALUE
3(14)
Description: tart current for activation of Solenoid valve, rotation
anticlockwise (Y6009).
XXXmA
XXXmA
005093
INIT ATTACH
START CURRENT
ROTATION CCW
STORED VALUE
PRESENT VALUE
PRESENT VALUE: indicates the current value for the start current.
Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.6.3 Control valve attachment
Component: Solenoid valve rotation anticlockwise (Y6009)
Signal value: XXXmA = 0 - 999 mA
XXXXXXX
NOT USED
X(X)
NOT USED
VDRT02.02GB
8:104
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
INIT ATTACH
9(X)
START CURRENT
SPREADER OUT, 20'-40'
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
I [mA]
1
2
t [s]
1.
2.
3.
VDRT02.02GB
005517
8:105
INIT ATTACH
10(X)
END CURRENT
SPREADER OUT, 20'-40'
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
I [mA]
1
2
t [s]
1.
2.
3.
005518
INIT ATTACH
11(X)
DAMP (PROC)
SPREADER OUT, 20'-40'
STORED VALUE
XX
PRESENT VALUE
XX
I [mA]
1
2
t [s]
1.
2.
3.
005519
INIT ATTACH
12(X)
START CURRENT
SPREADER IN, 40'-20'
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
I [mA]
1
2
t [s]
1.
2.
3.
005520
VDRT02.02GB
8:106
INIT ATTACH
13(X)
END CURRENT
SPREADER IN, 40'-20'
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
I [mA]
1
2
t [s]
1.
2.
3.
005521
INIT ATTACH
14(X)
DAMP (PROC)
SPREADER IN, 40'-20'
STORED VALUE
XX
PRESENT VALUE
XX
I [mA]
1
2
t [s]
1.
2.
3.
005522
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
VDRT02.02GB
8:107
8.5.1.3 SLIDING-CAB
INIT SLIDING-CAB
This menu is not used.
BOOM ATTACHMENT
SLIDING-CAB STEERING
DRIVE-TRAIN
001645
INITIATION
8.5.1.4 STEERING
INIT STEERING
This menu is not used.
BOOM ATTACHMENT
SLIDING-CAB STEERING
DRIVE-TRAIN
002954
INITIATION
8.5.1.5 DRIVE-TRAIN
INIT DRIVE-TRAIN
This function handles initialisation of the transmission.
INITIATION
NOTE
003140
BOOM ATTACHMENT
SLIDING-CAB STEERING
DRIVE-TRAIN
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.
After changes have been made, the ignition must be switched off
and then on for the changes to be saved and start to apply.
START IN 1:ST
1(X)
Description: Setting to get transmission to always start in 1st gear.
XXX
XXX
013915
INIT DRIVE-TRN
START IN 1:ST
1=YES 0=NO
STORED VALUE
PRESENT VALUE
VDRT02.02GB
8:108
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
XXXXXXX
NOT USED
X(X)
NOT USED
VDRT02.02GB
8:109
XXXXXXX
NOT USED
X(X)
NOT USED
INIT DRIVE-TRN
9(12)
OPTION SPEED LIMIT
(KM/H)
STORED VALUE
XXX
PRESENT VALUE
XXX
004936
INIT DRIVE-TRN
10(12)
OPTION HIGHETS GEAR
AT SPEED LIMIT
STORED VALUE
XXX
PRESENT VALUE
XXX
INIT DRIVE-TRN
11(12)
OPTION ENGINE SHUT
DOWN AT IDLE (sec)
STORED VALUE
XXX
PRESENT VALUE
XXX
VDRT02.02GB
8:110
004938
INIT DRIVE-TRN
12(12)
F-R WITHOUT ENGINE
SPEED REDUCTION
STORED VALUE
XXX
PRESENT VALUE
XXX
STORED VALUE
PRESENT VALUE
XXX
XXX
013918
INIT DRIVE-TRN
13(X)
OPT SPEED WARNING
Description: Speed warning, a warning is shown in the display at a
set speed.
PRESENT VALUE: indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: Signal value: XXX = speed (km/h)
8.5.2 Calibration
Calibration, description
Certain functions require calibration in order to operate correctly. The
control system has integrated calibrations for these functions.
VDRT02.02GB
SCALE
8:111
SCALE
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
IMPORTANT
Calibrate the weight indicator after replacing
components connected with lift, lower or extension.
If the weight indicator is not calibrated then the
overload system intervenes at a lower weight than
specified.
EL-STEERING
EL-STEERING
CALIBRATION
000074
SCALE STEERING
DRIVE-TRAIN RETURN
DRIVE-TRAIN
DRIVE-TRAIN
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
NOTE
Calibration does not need to be performed in one process but each
step can be performed separately, independently of other steps.
CALIBR SCALE
3(7)
BOOM FULLY RETRACTED
STORED VALUE
PRESENT VALUE
X.XXV
X.XXV
000063
1. Menu group
2. Sequence number (the total number of sequences is
indicated in brackets)
3. Signal value
4. STORED indicates stored value, PRESENT indicates
the current value of the signal to be calibrated
5. Heading of menu figure
Designation: Example
Description
VDRT02.02GB
8:112
000056
1 23
4 5
000060
NOTE
VDRT02.02GB
000062
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
8:113
NOTE
It is very important for accuracy that all steps are performed in the
given order.
Operate and warm the hydraulic oil to operating temperature, min.
40 C.
Park the machine on level ground without load and centre the
attachment.
000056
1 23
4 5
000060
NOTE
CALIBRATION
NOTE
Some options, such as height limitation and load centre
limitation, mean that bypass must be used to reach the boom's
end positions.
6
0 11 3 2 9
CALIBR SCALE
1(X)
MINIMUM BOOM ANGLE
X.XXV
X.XXV
000062
SCALE STEERING
DRIVE-TRAIN RETURN
STORED VALUE
PRESENT VALUE
CALIBR SCALE
2(x)
MAXIMUM BOOM ANGLE
X.XXV
X.XXV
0 11 3 3 0
STORED VALUE
PRESENT VALUE
CALIBR SCALE
3(X)
BOOM FULLY RETRACTED
X.XXV
X.XXV
0 11 3 3 1
STORED VALUE
PRESENT VALUE
VDRT02.02GB
8:114
CALIBR SCALE
4(X)
BOOM FULLY EXTENDED
X.XXV
X.XXV
011332
STORED VALUE
PRESENT VALUE
CALIBR SCALE
5(X)
LOAD SENSOR BOOM
RETRACTED
LE
RI
STORED
XXXX XXXX
PRESENT
XXXX XXXX
010454
CALIBR SCALE
6(X)
LOAD SENSOR BOOM
0t
EXTENDED
LE
RI
CALIBR
XXXX XXXX
PRESENT
XXXX XXXX
IMPORTANT
Check that the correct weight is shown in the menu
before the setting is saved. Incorrectly input weight
means that the scale indicates incorrectly.
Checking the calibration
27 Scroll to CALIBR SCALE, menu 7.
7(X)
XXXXXKg
XXXXXKg
XXXXXKg
XXX.XXm
28 Lift a reference load and check that the control system calculates
the correct weight of the load that the machine is lifting.
PRESENT LOAD = Reference load 450 kg. Weight is given in
kg.
006804
CALIBR SCALE
ALLOWED LOAD
PRESENT LOAD
LOAD STR.AXLE
LOAD-CENTER
NOTE
010455
VDRT02.02GB
30 Back out of calibration with the R-key. When the code menu
appears, press Enter.
8:115
DRIVE-TRAIN, menu 1
2
000079
DRIVE-TRAIN, menu 2
5
000080
Depress the accelerator pedal fully and keep it down until the
position is stored.
VDRT02.02GB
8:116
VDRT02.02GB
9:1
VDRT02.02GB
9:2
9.6.10
9.6.11
9.6.12
9.7
9.7.1
9.7.2
9.7.3
9.7.4
9.7.5
9.8
9.9
9.9.1
9.9.2
9.9.3
9.9.4
9.9.5
9.10
9.10.1
9.10.2
9.10.3
9.10.4
9.11
9.11.1
9.11.2
9.11.3
9.11.4
9.11.5
9.12
9.13
9.13.1
9.13.2
9.13.3
9.13.4
9.15
VDRT02.02GB
9 Frame, body, cab and accessories Frame, body, cab and accessories
9:3
Overview
11
10
15
13
12
6
010906
12
14
1.
2.
3.
4.
Steering wheel
5.
6.
7.
8.
9.
VDRT02.02GB
9:4
Instrument panel
Instrument panel
16. Switch for fan (S118)
17. Switch for heating (S139)
24..28
19..23
16
Instrument panel
010907
18
17
VDRT02.02GB
32
33
35
34
9:5
36
37..41
49
42..46
47 48
50
51
52
53
64
63
62
54
55
61
60
59 58 57
005073
56
VDRT02.02GB
9:6
65
66
67
68
65. Spare
66. Spare
67. Spare
68. Spare
6 9 ..7 2
73
72. Spare
74
73. Spare
76
74. Spare
014162
75
Panel for hydraulic functions
Operating menus, overview
75. Spare
76. Switch for bypassing of hydraulic functions (S1005)
O K
1.
2.
3.
4.
5.
6.
7.
8.
9.
VDRT02.02GB
014142
10
9:7
014143
5
1.
2.
3.
4.
5.
Switch, replacement
NOTE
The instruction applies to switches in general.
1
VDRT02.02GB
9:8
9 Frame, body, cab and accessories Gear selector and multi-function lever
2
3
1
0
000338
Movement
Function
Forward/Reverse
Inward,
handle
Rotation
Downward
000339
Upward
VDRT02.02GB
9:9
Remove the steering wheel and separate the steering wheel panel.
VDRT02.02GB
9:10
9.2.4 Buzzer
Seat buzzer, description
See Sensor, operator-in-seat, description (product alternative Hao
Bang), page 9:17.
VDRT02.02GB
9:11
9.3 Seat
Seat, general
There are three versions of driver's seat:
head rest
5
4
1.
Head rest
2.
3.
4.
5.
6.
7.
Front/rear adjustment
014151
VDRT02.02GB
9:12
6
7
006825
seat heating
head restraint
left armrest
The seat is equipped with a sensor that senses the spring deflection
of the seat. This is used to activate the buzzer if the operator leaves
the seat without applying the parking brake as well as without putting
the transmission in neutral position if leaving the seat.
Controls
1.
2.
3.
4.
5.
6.
7.
8.
Front/rear adjustment
VDRT02.02GB
9:13
2
3
6
7
2.
3.
4.
5.
6.
7.
8.
Front/rear adjustment
006826
seat heating
left armrest
head restraint
The seat is equipped with a sensor that senses the spring deflection
of the seat. This is used to activate the buzzer if the operator leaves
the seat without applying the parking brake as well as without putting
the transmission in neutral position if leaving the seat.
Slide back the seat to its rear position, remove the front attaching
bolts.
VDRT02.02GB
9:14
Slide the seat to its front position, remove the rear attaching bolts.
).
Unplug the connector for the heating coil before the padding is
removed.
NOTE
The seat's heating coil is glued to the padding. Exercise caution
if the padding is to be replaced but the heating coil is to be
re-used, or if only the coil is to be replaced.
3
5
006276
1.
2.
Upholstery
3.
Seat frame
4.
Padding
5.
Heating coil
VDRT02.02GB
9:15
).
3
4
Position the back rest on the seat and fit the attaching bolts
(position 1), do not tighten them. Then fit the attaching bolts for
the seat belt (position 2).
Tighten the attaching bolts for the seatbelt (position 2) with a
torque of 42 Nm, then tighten the attaching bolts (position 1) with
a torque of 33 Nm.
1
1.
2.
3.
4.
5.
Arm rest
6.
006278
The function of the heating coil is to warm the back rest and seat
cushions in the driver's seat. The heating coil is fitted under the
upholstery on the seat.
Workshop Manual DRT 450
VDRT02.02GB
9:16
9.3.4 Bumper
Bumper, description
The bumpers are integrated in the suspension unit in the seat's
frame and are self-adjusting, that is, they adjust automatically to the
operator's weight.
Remove the driver's seat from the frame and lift it out of the
machine. See Seat, replacement (product alternative BE-GE),
page 9:13.
3
1.
Bumper
2.
Attaching bolt
3.
Attaching bolt
006277
001621
9:17
014164
DANGER
Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
Extreme hazard to personal health and risk of property
damage!
Only use the bypass of safety systems in emergency
situations.
VDRT02.02GB
9:18
008220
DANGER
2.
Buzzer (H853)
VDRT02.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:19
The heating system controls heating and ventilation of the cab. The
cab can also be equipped with air conditioning.
2
4
E
The heating system uses heat from the engine's cooling system via a
heating coil to heat the ambient air. The fan forces the ambient air
through the heating coil on through ducts in the cab interior. It is then
directed to the windscreen (defroster) or the feet.
B
The climate control system (ECC) is responsible for heating,
ventilation, cooling and dehumidifying. The air is heated in the same
way as for the heating system (ECH).
1
000762
2.
3.
Fan
4.
Expansion valve
5.
Condenser
6.
Compressor
High-pressure gas
High-pressure fluid
Low-pressure fluid
Low-pressure gas
VDRT02.02GB
9:20
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
D1
26
D3 3
25
D15
D5
D9
D4
D23
D6
7
D790-1
15 D15
D797-R
D21
16
M
5
D790-2
D795
D794
12
22
14
M
M
D10
D14
13
D13
19
18
20 C
23
C
Pa
D17
21
24
17
D9
M
10
C
11
006416
Pos
Explanation
Signal description
Reference
Raise: U = 2.02.5 V
Unaffected: U = 0-0.5 V
Lower: U = 4.5-5.0 V
Raise: U = 2.02.5 V
Unaffected: U = 0-0.5 V
Lower: U = 4.5-5.0 V
R = 10 k at 25 C
R = 10 k at 25 C
VDRT02.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:21
Pos
Explanation
Signal description
Reference
R = 10 k at 25 C
Checked by control
system, error shown with
error code.
U = 0.5-4.5 V
Checked by control
system, error shown with
error code.
11
12
Checked by control
system, error shown with
error code.
13
Checked by control
system, error shown with
error code.
Checked by control
system, error shown with
error code.
U = 0.5-4.5 V
14
15
Section 1 Engine
D10: Diagnostic menu, see section 8 Control
system, group 8.4.4.2, CLIMATE menu 2
Checked by control
system, error shown with
error code.
17
U = 24 V
VDRT02.02GB
9:22
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
Pos
Explanation
Signal description
Reference
18
19
20
21
U = 24 V
22
23
R = 10 k at 25 C
24
25
Checked by control
system, error shown with
error code.
26
Checked by control
system, error shown with
error code.
000056
NOTE
000060
1 23
4 5
VDRT02.02GB
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
Select CLIMATE.
000131
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA HIST
9:23
Menu 1
5
000132
DIAG CLIMATE
1(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
WATER VALVE FEEDB. XXX
Menu 2
6
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
000133
DIAG
TEMP
TEMP
TEMP
TEMP
Menu 3
7
006865
DIAG CLIMATE
3(X)
PRESENT INPUT SIGNAL
PRESSURE SWITCH
X
OPT DOOR SWITCH
X
Menu 4
8
000135
DIAG CLIMATE
4(8)
PRESENT INPUT SIGNAL
WATER VALVE
XX.XXV
DRAUGHT VALVE XX.XXV
NOTE
Air to the round panel vents is not controlled by the air
conditioning.
VDRT02.02GB
9:24
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
Menu 5
9
000136
DIAG CLIMATE
5(8)
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV
REQ. DRAUGHT
XX.XXV
REQ. FAN SPEED XX.XXV
Menu 6
10 Checks Cab fan (M657), Fresh air and recirculation damper
(M612) and Electromagnetic clutch, compressor (M645)
DIAG CLIMATE
6(8)
PRESENT OUTPUT SIGNAL
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
NOTE
Compressor activation can only be tested when the engine is
running and the system is filled.
Menu 7
11 Checks the direction selector for Water valve (Y673).
DIAG CLIMATE
7(8)
OUTPUT WATER VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
24V
NOTE
The "ones" are only shown for a moment when the water valve
changes position, "zeros" are shown when the valve does not
change position. The water valve does not open if the engine
temperature is low, or if the outdoor temperature is high.
0V
VDRT02.02GB
000138
9 Frame, body, cab and accessories Heating, ventilation and air conditioning
9:25
Menu 8
DIAG CLIMATE
8(8)
OUTPUT DRAUGHT VALVE
CLOCKWISE
XY XY
ANTI-CLOCKWISE XY XY
24V
NOTE
The "ones" are only shown for a moment when the air distributor
changes position, "zeros" are shown when the air distributor
does not change position.
0V
000139
VDRT02.02GB
9:26
003208
2
1
Fresh air intake, cab
1.
2.
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab, in front of the cab fan.
VDRT02.02GB
9 Frame, body, cab and accessories Fresh air and recirculation damper
9:27
003208
2
1
Fresh air intake, cab
1.
2.
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
VDRT02.02GB
9:28
9 Frame, body, cab and accessories Fresh air and recirculation damper
VDRT02.02GB
Remove the nuts which hold the wiper motor in the protective plate.
9 Frame, body, cab and accessories Fresh air and recirculation damper
9:29
Remove the bolts which secure the arm and motor in the plate.
Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
VDRT02.02GB
9:30
003209
Cabin fan
VDRT02.02GB
9:31
Remove the bolts which hold the wiper motor in the protective
plate.
VDRT02.02GB
9:32
Remove the bolts which secure the plate and cab fan.
VDRT02.02GB
9:33
1, 2
003210
2.
3.
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
VDRT02.02GB
9:34
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
Remove the nuts which hold the wiper motor in the protective plate.
9:35
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
16 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:36
0 11 4 0 1
1.
Water valve
2.
Steering valve
Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
VDRT02.02GB
9:37
9.4.7 Compressor
Compressor, air conditioning, description (engine
alternative Yuchai YC6M360-30)
014126
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:38
Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
014126
1.
2.
Turnbuckle
VDRT02.02GB
9:39
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
1
Working on the air conditioning requires special
authorisation.
005000
1.
2.
Turnbuckle
Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:40
9.4.8 Condenser
Condenser, description
014125
VDRT02.02GB
9:41
Condenser, replacement
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
Working on the air conditioning requires special
authorisation.
1.
Radiator
2.
Condenser
Remove the bolts which secure the condenser at the top edge and
lift the condenser out in a suitable way.
Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:42
The receiver drier collects the liquid refrigerant, binds moisture, and
filters out impurities. The reservoir functions as an expansion tank in
the cooling circuit.
When the refrigerant has passed through the dryer in the bottom of
the fluid reservoir, it rises through a standpipe. Through a sight glass,
it is possible to check that there is flow without bubbles and that the
system is adequately filled with refrigerant.
014124
1.
2.
Pressure switch
014124
1.
2.
Pressure switch
VDRT02.02GB
9:43
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
Working on the air conditioning requires special
authorisation.
Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
014124
1.
2.
Pressure switch
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:44
The expansion valve is the part in the circuit that separates the
high-pressure side from the low-pressure side. The refrigerant arrives
at the expansion valve under high pressure and leaves it under low
pressure. After the expansion valve, the refrigerant converts to a
gaseous state and is transported to the compressor once again.
The amount of refrigerant that passes through the evaporator varies
depending on the heat load. The valve works from fully open to fully
closed and searches between these for an optimal evaporation point.
012368
1.
Expansion valve
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:45
Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special
authorisation.
2
1.
2.
3.
002226
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.
1
IMPORTANT
Working on the air conditioning requires special
authorisation.
3
VDRT02.02GB
9:46
Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special
authorisation.
VDRT02.02GB
9:47
Heat exchanger, cooling, consists of pipes and cooling fins. The cab
air is cooled as it passes through the heat exchanger, cooling. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
003210
2.
3.
VDRT02.02GB
9:48
002230
1.
Instrument panel
2.
3.
Detach the steering wheel shaft and angle it back against the
driver's seat.
Detach the air hoses from the air distributor and detach the
connector.
Air distributor
VDRT02.02GB
9:49
001839
Remove the bolts which hold the other part of the defroster nozzle
in the dashboard.
VDRT02.02GB
9:50
2
1.
2.
3.
002226
1.
Instrument panel
2.
3.
Detach the steering wheel shaft and angle it back against the
driver's seat.
VDRT02.02GB
9:51
2
1.
2.
3.
002226
VDRT02.02GB
9:52
VDRT02.02GB
9:53
013222
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.3.1 CAB, menu 1.
VDRT02.02GB
9:54
Remove the bolts which secure the fluid reservoir in the cab wall.
003619
Washer motors
VDRT02.02GB
Remove the nuts which hold the motor in the protective plate.
Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
9:55
Detach the washer hose and the connector to the wiper motor.
Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
VDRT02.02GB
9:56
VDRT02.02GB
Raise the plastic cover and remove the nut securing the wiper
arm. Detach the washer fluid hose.
Remove the screws securing the motor and the lock nut on the
motor.
Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
9:57
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
4
D 4
D 1
D 5
D 3
D 2
9
10
14
6
D 6
D 16
15
D 17
17
D 13
D 25
D 7 9 0 -1
7,12
24
D 7 9 7 -R
D 29
18 D 18
D 27
D 28
30 D 26
D 22
D 23
P a
D 21
D 20
25 26 27 28 29
D 7 9 0 -2
11
19
D 7 9 7 -F
31
D 7 9 1 -1
D 32
32
20 21 22 23
D 33
33
007417
D 30
D 10
13
16 M
D 9
D 8
Pos
Explanation
Signal description
Reference
Switch in on position: U
= 24 V
Switch in on position: U
= 24 V
Switch in on position: U
= 24 V
Switch in on position: U
= 24 V
VDRT02.02GB
9:58
Pos
Explanation
Signal description
Reference
Switch in on position: U
= 24 V
Door open: U = 24 V
Checked by control
system, error shown with
error code.
Left: US161/6 = 24 V
Right: US161/1 = 24 V
10
Checked by control
system, error shown with
error code.
11
Checked by control
system, error shown with
error code.
12
Checked by control
system, error shown with
error code.
13
Light on: U = 24 V
UK304/30 = 24 V
14
UK304/85 = 0 V
Working lights boom
switched on:
UK304/86 = 24 V
UK304/87 = 24 V
Working lights boom
switched off:
UK304/86 = 0 V
UK304/87 = 0 V
15
VDRT02.02GB
Light on: U = 24 V
9:59
Pos
Explanation
Signal description
Reference
16
Light on: U = 24 V
17
18
Light on: U = 24 V
19
Checked by control
system, error shown with
error code.
20
Light on: U = 24 V
Light on: U = 24 V
Light on: U = 24 V
Light on: U = 24 V
24
Checked by control
system, error shown with
error code.
25
Light on: U = 24 V
Light on: U = 24 V
Light on: U = 24 V
Light on: U = 24 V
21
22
23
26
27
28
VDRT02.02GB
9:60
Pos
Explanation
Signal description
Reference
29
Light on: U = 24 V
Light on: U = 24 V
31
Checked by control
system, error shown with
error code.
32
Light on: U = 24 V
Light on: U = 24 V
30
33
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
VDRT02.02GB
9:61
17
16
15
14
13
12
11,10,9
013840
1.
2.
Interior lighting
3.
4.
5.
6.
7.
8.
9.
9.6.1 Headlights
Headlights, description
Headlights are located in the front of the machine to give the
operator enhanced vision when operating in darkness, and to provide
surrounding traffic and the environment an indication of the machine's
position. Headlights have the options of high beam and low beam
(for meeting other traffic).
Switch between high and low beam with the gear and multi-function
lever. The signal travels to Control unit, cab (D790-1).
High and low beam signals can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.6 LIGHTS, menu 6.
VDRT02.02GB
9:62
VDRT02.02GB
9:63
VDRT02.02GB
9:64
DANGER
Xenon lights are activated with high voltage. Always
switch off the system voltage before working on
Xenon lights.
Handle the headlight with care since the light is under
gas pressure and may explode.
NOTE
The Xenon light is filled with different gases and metals. Replaced
Xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
).
VDRT02.02GB
9:65
).
VDRT02.02GB
9:66
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
3
D 2
D 3
D 1
16
D 6
D 16
D 17
D 14
15 M
17
14
D 7 9 0 -1 4
D 7 9 0 -2
D 7 9 7 -R
D 9
7
D 7 9 7 -F
D 10
9
10
D 11
11
D 13
D 795
18
12
13
014160
D 15
D 5
Pos
Description
Signal description
Reference
Switch in on position: U = 24
V
Switch in on position: U = 24
V
Switch in on position: U = 24
V
Left: US161/6 = 24 V
Right: US161/1 = 24 V
VDRT02.02GB
9:67
Pos
Description
Signal description
Reference
Light on: U = 24 V
Light on: U = 24 V
12
13
Light on: U = 24 V
Horn active: U = 24 V
Light on: U = 24 V
Operator in seat: U = 24 V
17
18
10
11
14
15
16
VDRT02.02GB
9:68
12
10,11
013841
13,14
1.
8.
Horn (H850)
2.
9.
3.
4.
5.
6.
7.
9.7.1 Horn
Horn, description
The horn is electromagnetic.
001247
The horn is activated from the gear and multi-function lever. The horn
can also be activated with the switch for open twistlocks on the control
lever, when the attachment does not have alignment with a container.
The horn is located under the cab.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.3.5 CAB, menu 5.
VDRT02.02GB
9:69
VDRT02.02GB
9:70
VDRT02.02GB
9:71
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
The windows are designed to both enclose the cab and provide the
operator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
glass, except the roof window which is made of polycarbonate plastic.
Side windows
Roof window
Rear window
001512
The rear view mirrors are of the convex mirror type. There is an
interior rear view mirror on all machines.
VDRT02.02GB
9:72
NOTE
The purpose of this instruction is to describe how silicone adhesive
923854.0100 should be handled in connection with replacement of
the windscreen and roof window on the Spirit Delta cab.
Fixing time:
10-20 minutes at 20 C
approx. 5 minutes at 60 C
Hardening time:
approx. 24 hours at 20 C
approx. 1 hour at 60 C
Full strength is obtained after 7 days.
9.9.1 Windscreen
Windscreen, description
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a decor strip and is glued to
the roof window with silicone adhesive. Front and side windows are
joined with silicone adhesive to give good all-round visibility from the
operator's station.
For location see, Glass/windows/mirrors, description, page 9:71.
VDRT02.02GB
9:73
Windscreen, replacement
NOTE
Read the handling advice for silicone adhesive before starting work.
See Silicone adhesive, handling advice, page 9:72.
1
NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane's lower front
edge.
If the roof window is to be replaced, then all bolts must be
removed before the silicone adhesive is cut away.
CAUTION
Acetone may not come into contact with a roof window
made of polycarbonate plastic. Acetone has a chemical
effect on the polycarbonate plastic which reduces the
roof window's strength.
Fit masking tape on the inside and outside of the window panes by
the surfaces that are to be glued.
VDRT02.02GB
9:74
006268
1,0
1
1.
Side window
2.
Rubber strip
3.
1,0
006269
Masking tape
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
9
006272
VDRT02.02GB
9:75
NOTE
The method describes a general procedure.
1
Remove the decor strip which runs around the whole window.
VDRT02.02GB
9:76
VDRT02.02GB
Thread the rubber strip around the whole window; use special
tools.
9:77
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!
VDRT02.02GB
9:78
A
A
External mirror
VDRT02.02GB
013225
The cab has a rear view mirror (position A) located in the cab as well
as rear view mirrors (position B) on left and right-hand front wing.
The function of the rear view mirror is to give the operator visibility
around the machine.
9:79
3
4
003206
Cab frame
2.
Door
3.
Cab suspension
4.
Cab substructure
002210
9.10.2 Doors
Doors, description
The cab has two doors, the left is the operator's door and the right is
the emergency exit. The door has:
hand rail
handle
key lock
Switches in the doors' locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.2.12 LIGHTS, menu 12.
VDRT02.02GB
9:80
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Extreme danger! Risk of crushing!
Secure the cab on both sides, with the locking catches
and pins before starting to operate the machine.
WARNING
It is important to that the locking catches are intact!
They should be checked regularly. However, it is not
included as part of the service schedule for preventive
maintenance!
VDRT02.02GB
9:81
VDRT02.02GB
9:82
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.
VDRT02.02GB
9:83
9.12 Chassis
Chassis, description
The frame is a modular construction and consists of front section, rear
section and a beam pair. This design provides advantages in terms of
rigidity and strength.
There are mounting points in the frame for engine, transmission, drive
axle, steering axle, fuel and hydraulic tanks, cab, boom and body parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The
counterweights are designed to allow as good visibility rearwards as
possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
4
6
2
1
013231
1.
2.
3.
4.
5.
Boom mounting
6.
7.
Beam pair
8.
VDRT02.02GB
9:84
3
1
013232
1.
Wings
2.
3.
Counterweight
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by
the wheels during operation. The design of the counterweight (see
Counterweights, description, page 9:85) acts as a mudguard for the
rear wheels.
VDRT02.02GB
9:85
9.13.4 Counterweights
Counterweights, description
The machine has counterweights to balance the machine's lift capacity
and these may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for
maximal leverage.
The machine has counterweights in the following locations:
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's operating characteristics are changed!
Never change the quantity of counterweights.
VDRT02.02GB
9:86
9.15 Paint/coatings
Paint/coatings, description
The machine is painted with an alkyd-based mono-component paint
that is applied with a brush or a spray. For paint codes (RAL), see
machine card.
Check the machine frequently for stone chips, dents and paint
scratches, rectify them at once to prevent corrosion on the underlying
metal. Only use touch-up paint for small stone chips and scratches.
More extensive paint damage should be repaired by a paint workshop.
NOTE
Before touching up, the surfaces to be touched up must be
thoroughly cleaned.
Please contact Cargotec for information about other surface treatment
and material colours.
VDRT02.02GB
10:1
10 Common hydraulics
VDRT02.02GB
10:2
VDRT02.02GB
10:3
10 Common hydraulics
10.2 Safety valves
10.2.1 Accumulator drain valve
Accumulator drain valve, description
013233
013400
The relief valve is fitted on valve block servo pressure. See Valve
block servo pressure, general, page 5:14.
VDRT02.02GB
10:4
013859
The pressure limiting valve is fitted on the supply to control valve lift
after the priority valve. The priority valve is fitted on the right-hand
side of the hydraulic plate in the engine compartment in front of the
transmission.
VDRT02.02GB
10:5
The hydraulic oil tank forms part of the side panel on the right-hand
side of the machine. The oil filters for the working hydraulics are
fitted inside the tank. These are accessible through hatches on top
of the tank.
Hydraulic oil is filled directly into the tank through the filler caps on
the filter manhole covers. For oil capacity and grade, see section
F Technical data. The whole filter unit can be removed to facilitate
access for cleaning. There is a drain plug located at the bottom of
the tank.
013128
The oil level is checked on the sight glass on the tank's side when all
hydraulic cylinders are in the bottom position.
1.
2.
3.
4.
5.
VDRT02.02GB
10:6
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
There are two gear pumps with fixed displacement. One supplies the
brake system with pressure, see section 4 Brakes, group 4.3.1 Brake
oil pump. The other gear pump (position 1) circulates hydraulic oil for
working hydraulics through the cooler and filter.
The gear pump pumps oil using two gear wheels that rotate opposite
each other. One is driven by the pump's input shaft and the other
rotates freely. The gear pump's flow is directly dependent on the
speed of the input shaft.
013860
The cooling pump is fitted on the right-hand main pump and is driven
by the main pump shaft from the transmission's power take-off. The
brake oil pump's speed is directly dependent on engine speed. Pump
flow increases and engine speed increases.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
VDRT02.02GB
Mark up and detach the hydraulic hoses from the gear pump.
10:7
Remove the spacer ring from the gear pump or axial piston pump.
Clean the O-rings' contact surfaces on the spacer ring.
Check the O-rings and replace if necessary. Fit the O-rings on the
spacer ring. Brush sealing silicone onto the sealing face against
the gear pump, see section F Technical data.
NOTE
Only use silicone on the side facing the gear pump.
VDRT02.02GB
10:8
Brush sealing silicone onto the sealing face of the gear pump
against the spacer ring, see section F Technical data.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
10:9
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
15 Check that the hose connections and seal between gear pump
and axial piston pump are sealed tightly.
16 Check the oil level in the brake or hydraulic system, depending on
which pump has been replaced, fill if necessary.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the brake system as well.
17 If the brake oil pump is replaced:
Check the brake pressure; see section 4 Brakes, group 4.3.1
Brake oil pump.
VDRT02.02GB
10:10
The hydraulic oil pumps are of the type variable axial piston pump,
and are controlled by load signals depending on the flow demand
from each function.
The hydraulic oil pumps are assembled in pairs with an inlet section
for the suction line. The inlet section leads oil to and from the pumps.
At the inlet section is a connection block containing test outlets for
checking pump pressure. On the connection block are non-return
valves that prevent the oil being pumped around between the pumps
instead of out into the hydraulic system.
One of the left-hand pumps' connection blocks also contains a
branching unit to the attachment hydraulics with a separate non-return
valve.
10
9
8
000528
2.
3.
4.
5.
6.
7.
8.
9.
VDRT02.02GB
10:11
34
D790-1
31
PS
C31
D797-R
P1
35
13, 26
D13
C35
18
LS
LS
P
D24
33
LSP2
CF
PP
P LS
LSPR
LSP3
LSP3X
EF
C2
A
LSP1
25
12, 24
14 27
LSHY
PT
LSM
7 30
9, 21
C8
6
C5
3, 16
No 1
No 2
No 3
5, 17, 29
8, 20
11, 23
10, 22
C10
No 4
013861
Pos
Explanation
Signal description
Reference
VDRT02.02GB
10:12
Pos
Explanation
Signal description
Reference
10
11
12
13
U = 24 V
14
15
16
1.8 MPa
17
2.1 MPa
18
19
20
21
22
23
24
25
26
U = 24 V
27
VDRT02.02GB
10:13
Pos
Explanation
Signal description
Reference
28
30
31
32
33
34
35
Opening pressure: 28
MPa
VDRT02.02GB
10:14
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Check the standby pressure for one pump at a time in the following
order:
Hydraulic oil pump 1: 1.8 MPa
Hydraulic oil pump 2: 2.1 MPa
Hydraulic oil pump 3: 2.9 MPa
Hydraulic oil pump 4: 3.1 MPa
1.
2.
3.
4.
Increase engine speed to approx. 1100 rpm and run the extension
function against end-position (overflow).
Run out the boom to max. and continue to request max. extension
with the control lever. This will cause the overflow of the extension
function.
Transfer the pressure gauge to the next pump and repeat steps
3-8 on all four pumps.
013863
NOTE
Read the safety instructions for oil before working, see section B
Safety.
VDRT02.02GB
10:15
Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump's suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained, see Hydraulic oil, changing, page 10:33.
2
Release the brake oil pump or cooling pump from the hydraulic oil
pump depending on the pump to be replaced.
Mark up and detach the hydraulic hoses from the axial piston
pump.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
VDRT02.02GB
10:16
CAUTION
Be careful and make sure that no gasket remains fall
down into the transmission.
Gasket remains may fall into the transmission and
cause product damage.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
12 Brush sealing silicone on the axial piston pump flange where it
makes contact with the gearbox, see section F Technical data.
13 Fit the axial piston pump.
Position the axial piston pump so that the pump shaft engages the
gearbox transmission. Fit the attaching bolts.
14 Connect the suction hose to the axial piston pump.
15 Fill the pump with oil through the connections on the top.
VDRT02.02GB
10:17
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Only use silicone on the side facing the gear pump.
VDRT02.02GB
10:18
20 Brush sealing silicone onto the sealing face of the gear pump
against the spacer ring, see section F Technical data.
CAUTION
Vent the axial piston pump before starting the engine.
The oil in the axial piston pump may cavitate and cause
product damage.
23 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
VDRT02.02GB
10:19
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
Check that the relief valve for top lift is closed before
starting the engine.
013399
Relief valve for top lift, the figure shows an open valve.
26 Check that the hose connections and seal between the axial
piston pump and gear pump are sealed tightly.
27 Check the pump pressures, see Hydraulic oil pump, checking,
page 10:14.
28 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the hydraulic system as well.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
10:20
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Loosen the hoses to the hydraulic system's feed from the axial
piston pump one at a time and let oil flow out. Tighten the
connections when oil free of air flows out.
Remove the compressed air from the tank and fit the breather filter.
Let the engine idle for at least one minute. Check that all the
connections are sealed tightly.
Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
VDRT02.02GB
10:21
2.
3.
4.
5.
Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6.
001015
C/L
NOTE
Hose length
Hose length is measured on a hose laid out between the sealing
surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. It is therefore very
important to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
Never re-use oil that has been drained from the machine.
If possible, filter the oil before pouring it into the machine. Oil
barrels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.
VDRT02.02GB
10:22
Valve block servo pressure controls load signals from the load
15
Valve block servo pressure is fitted to the right of the hydraulic plate in
14
13
7 The following are fitted on the valve block: Accumulator servo circuit,
11
10
013862
12
8
Pressure reducer
1.
2.
3.
4.
5.
6.
Shuttle valve
7.
8.
9.
The pressure reducer reduces the pressure from the hydraulic oil
pumps to servo pressure for the control valve.
10. Control signal hydraulic oil pump 3 and 4 [LSP1] Valve, pump unloading
11. Solenoid valve, top hydraulics (Y6003)
For boom in, only a small oil flow is required. Valve slide pump
12. Adjusting screw servo pressure
unloading drains the control signal for hydraulic oil pump 1 and 2, to
13. Solenoid valve, pump unloading (Y6062)
the tank. This results in only hydraulic oil pumps 3 and 4 building
up pressure, which reduces the use of engine power and thus fuel
14. Drain to hydraulic oil tank [EE]
consumption. If other functions are activated at the same time, the
15. Leakage line from control valve lift, lower and pressure signal will pass through the shuttle valves in valve block
extension [AA]
servo pressure. The valve slide is controlled by Solenoid valve, pump
unloading (Y6062), see 7 Load handling, group 7.3.9 Valve block
pump unloading.
Solenoid valve, pump unloading (Y6062) is supplied with voltage by
Control unit, frame rear (D797-R) on activation.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.8.2 BOOM, menu 2.
10:23
NOTE
Read the safety instructions for oil before working, see section B
Safety.
000475
VDRT02.02GB
10:24
Start the engine and check the servo pressure. Compare with
the pressure plate.
013864
NOTE
If the servo pressure is too high, a load handling function
must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be seen
on the pressure gauge. Sometimes the engine has to be shut
off between the checks.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
6
VDRT02.02GB
Remove the pressure gauge and fit the protective cap on the
measuring outlet.
10:25
D795
D3
D797-R
D4
The hydraulic oil pump pumps oil (from the tank) which is cooled in the
hydraulic oil cooler and cleaned by the oil filters in the tank. Some of
the oil is filtered by the fine filter. An electric cooling fan increases the
air flow through the cooler when the temperature needs to be lowered.
A bypass valve leads the hydraulic oil past the cooler directly to the
tank if the resistance through the cooler and filters is too high. The
temperature sensor controls fan activation and temperature display.
5
2
8
7
007414
C 3
Pos
Description
Signal value
Reference
U = 0.5-4.5 V
Checked by control
system, error shown with
error code.
VDRT02.02GB
10:26
013245
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Drain the oil from the hydraulic oil tank, see Hydraulic oil,
changing, page 10:33.
Mark up and detach the hydraulic hoses from the cooler. Let the
oil in the cooler drain into the receptacle.
NOTE
Plug all connections immediately to protect the hydraulic system
from impurities.
4
1.
Cooling fan
NOTE
2.
Connector
3.
Radiator
Check that the O-rings are intact, clean and in the correct
position.
VDRT02.02GB
10:27
10 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
013246
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.1 HYD, menu 1.
013247
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.5.1 HYD, menu 1.
VDRT02.02GB
10:28
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1
Drain the oil from the hydraulic oil tank, see Hydraulic oil,
changing, page 10:33.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
Connect the cable harness to the sensor.
Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
013187
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
7
1(6)
XXX
XY
000141
DIAG HYD
HYDRAULIC OIL
TEMP
FAN
Diagnostic menu Hyd, menu 1
VDRT02.02GB
10:29
013257
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in
the cooler becomes too high.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1
Depressurising removed.
Drain the oil from the hydraulic oil tank, see Hydraulic oil,
changing, page 10:33.
NOTE
Note how the bypass valve faces; the valve is marked with an
arrow.
Install the new bypass valve, turning the valve to face the same
way as the old one. Use Loctite when fitting the bypass valve.
013257
Bypass valve
VDRT02.02GB
10:30
Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
013248
VDRT02.02GB
10:31
013249
The oil in the hydraulic system is cleaned by two return filters fitted
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1
Switch off the engine and switch off the system voltage.
VDRT02.02GB
10:32
1.
2.
3.
4.
5.
Remove the cover plates (position 1) over the hydraulic oil filters.
Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
Separate the filter unit and remove the filter insert. Handle the
filter insert as environmentally hazardous waste. Note the position
of the parts.
Install the filter units and the covers. Tighten the screws crosswise.
Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
Magnetic rod
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
10:33
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1
Remove the filler cap and pump out the hydraulic oil into a
receptacle.
Fit the drain plug when the oil has drained out.
NOTE
Make sure that the seal washer for the drain plug is fitted as well.
Oil filter cover
2.
3.
4.
5.
Fill new hydraulic oil through the filler holes on the filters' covers.
This results in the filtering of the oil that is filled and protects the
hydraulic system from impurities.
Fill oil until the oil level is in the middle of the sight glass. For
volume and grade, see section F Technical data.
1.
VDRT02.02GB
10:34
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
Machine in service position, see section B Safety.
Lift up the filter insert and place it in the receptacle. Let the
hydraulic oil drain.
Fit the new filter insert and refit the cover over the fine filter.
Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the centre of the sight glass. Top up if
necessary, for grade see section F Technical data.
013131
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
VDRT02.02GB
10:35
10.7 Other
10.7.1 Hydraulic cylinders
Hydraulic cylinders, repairs
Fault tracing, leakage
1
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leakage
can be detected. High pressure causes the seals to
close tighter, which prevents detection of leaks.
Carefully check the source of the leakage before taking any action.
It may be possible to rectify the fault without disassembly.
2
1.
Piston rod
2.
Scraper
3.
Cylinder head
4.
5.
6.
Cylinder barrel
7.
Sleeve coupling
8.
9.
Piston
VDRT02.02GB
10:36
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod
is clean and free from all residual paint. Also check
that connections and couplings are free from burrs and
impact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.
1
Remove the cylinder from its mounting and undo the connections.
Inspection of surfaces
1
CAUTION
When fitting the cylinder head:
Get it absolutely straight. This is best done by hand.
Under no circumstances hit it with a mallet of any type.
If the cylinder head is fitted crooked, the sealing lip
of the piston rod seal could be damaged, making an
improper seal. This applies to all types of piston rod
seals.
VDRT02.02GB
10:37
The piston rod seal is the seal that sits in the groove in the cylinder
head and seals against the piston rod. This seal is very exposed to
wear since it is both a dynamic and a static seal, i.e. it seals against a
moving surface on the piston rod while the sealing surface with the
cylinder head is fixed. There are different types of piston rod seals:
001497
5
1.
Hydraulic pressure
2.
3.
4.
5.
6.
Screwdriver
Single V-seal
Compressible seal
The single V-seal has a V-shaped section with two lips that seal
in opposite directions. The hydraulic pressure acts in the V-shape,
pressing the sealing lips out towards the sealing surfaces on the
piston rod and in the cylinder barrel. Even minor damage to the
sealing lips can generate large leaks. Examine the sealing lips by
carefully using a fingernail to feel around the seal. To remove, use a
screwdriver to prise the seal outward and bend it up (see illustration).
It is extremely important that the screwdriver is always inserted in
the V-shape so that it cannot touch and thereby damage a sealing
surface. A mark from a screwdriver on a sealing surface can have a
devastating effect and cause major leakage.
VDRT02.02GB
10:38
2
1
001498
5
1.
Hydraulic pressure
2.
3.
4.
5.
6.
Screwdriver
7.
O-ring
The compressible piston rod seal consists of a solid rubber profile
and provides a larger contact face than the V-seals. To remove, use a
screwdriver to prise the seal outward and bend it up (see illustration).
With this type of seal with sealing surfaces that cover so much of
the seal groove, it is particularly important that marks are not made
with the screwdriver.
2
1
3
3
6
001499
5
1.
Hydraulic pressure
2.
3.
4.
5.
6.
Screwdriver
VDRT02.02GB
10:39
When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
1
1.
Hydraulic pressure
2.
O-ring
3.
Support ring
4.
001506
Scraper
Scraper
D+10
1
The purpose of the scraper is to scrape the piston rod clean and
prevent impurities from entering the cylinder barrel.
The scraper must be fitted with a special fitting tool. This tool must
have a greater outer diameter than the scraper so that the press force
against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal
capsule would be deformed (see lower illustration), which would
impair the function of the scraper.
3
D
5
001496
1.
2.
3.
Cylinder head
4.
5.
6.
Deformed scraper
VDRT02.02GB
10:40
1
2
CAUTION
No tool may be applied from the inside. This could
give rise to burrs on the cylinder head which could in
turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1.
Screwdriver
2.
Scraper
3.
Cylinder head
On the single-acting V-seal it is always the long side that seals
against the fixed surface and the short side that seals against the
moving surface.
002370
5
1.
Hydraulic pressure
2.
3.
4.
5.
6.
Screwdriver
VDRT02.02GB
10:41
002950
The double-acting seal functions with pressure from both sides, e.g.
in a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface
and it is therefore extremely important that it is completely free from
damage.
002951
2
1.
2.
3.
Guide ring
4.
Support ring
5.
Piston head
6.
Cylinder barrel
Exercise caution when fitting the piston in the cylinder barrel, making
sure that the seal is not damaged by the cylinder barrel threads.
Dismantling:
1
Move the seal body over to one side of the sealing groove.
Without damaging the surface of the piston - cut off the seal with
a knife.
Carefully examine the seal to find any damage that could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1
First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
VDRT02.02GB
10:42
002952
1.
Piston rod
2.
Chromium plating
3.
Impact mark
4.
Highly-polished hammer
VDRT02.02GB
10:43
Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
Rotate the piston rod while pulling the O-ring out through the hole.
002953
VDRT02.02GB
10:44
VDRT02.02GB
11:1
11 Common electrics
VDRT02.02GB
11:2
VDRT02.02GB
11:3
11 Common electrics
11.2 Electric protection
11.2.1 Battery disconnector
Battery disconnector, description
The positive terminals of the batteries connected in series are
connected to the machine's electrical system via the battery
disconnector. The battery disconnector cuts off all power from the
batteries to the machine's electrical system.
IMPORTANT
Never switch off the voltage with the battery
disconnector when the engine is running. This could
damage the alternator.
013250
11.2.2 Fuses
Fuses, changing
When checking and changing the main fuse:
1 Switch off the system voltage (battery disconnector).
2
3
VDRT02.02GB
11:4
11.3 Batteries
11.3.1 Start battery
Start battery, description
The machine's electrical system is supplied by two 12 V batteries
connected in series.
The negative terminal is connected to the frame. The positive terminal
is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description
(engine alternative Yuchai YC6M360-30), page 11:6 or Alternator,
description (engine alternative Cummins QSM11), page 11:6.
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
013251
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the
batteries. Sparks could ignite the hydrogen gas,
causing an explosion. Disconnect the battery with the
battery disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (chassis).
VDRT02.02GB
11:5
Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
NOTE
013251
VDRT02.02GB
11:6
11.4 Alternator
11.4.1 Alternator
Alternator, description (engine alternative Yuchai
YC6M360-30)
The alternator generates current during operation and supplies this
to the batteries. The alternator produces AC current and has an
integrated charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
013870
The signal can be checked via the diagnostic menu, section 8 Control
system, section 8.4.6.4 ENGINE, menu 4.
007444
The signal can be checked via the diagnostic menu, section 8 Control
system, section 8.4.6.4 ENGINE, menu 4.
Alternator, replacement
See supplier documentation, engine.
VDRT02.02GB
11:7
D1
4
D3
D2
D8
D10
D795
10
D790-1
5, 6
D797-R
8
D4
D7
D797-F
7
D794
013439
9
D791-1
D793
D9
Pos
Explanation
Signal description
Reference
U = 24 V
U = 24 V
U = 24 V
VDRT02.02GB
11:8
Pos
Explanation
Signal description
Reference
UK11:7 = 24 V
K11:8
= 24 V
UK11:9 = 24 V
UK11:10 = 24 V
UK2:7 = 24 V
UK2:8 = 24 V
UK2:7 = 24 V
UK2:8 = 24 V
UK2:7 = 24 V
UK2:8 = 24 V
10
VDRT02.02GB
UK2:7 = 24 V
UK2:8 = 24 V
11:9
Reference value
Reference
Battery disconnector
In position 1
Activated
Communication established
+
D4
1
D1
2
D2
D3
6
4, 5
D8
D795
D790-1
2, 8
D9
D10
D797-R
9
D797-F
10
D11
D793
11
7
D791-1
D794
013873
D790-2
Pos
Explanation
Signal description
Reference
U = 24 V
U = 24 V
U = 24 V
U = 24 V
U = 24 V
U = 24 V
VDRT02.02GB
11:10
Pos
Explanation
Signal description
Reference
Checked by control
system, error shown
with error code.
UK1:2 = 24 V
UK1:3 = 24 V
UK1:4 = 24 V
9
UK2:1 = 24 V
UK2:9 = 24 V
10
UK2:1 = 24 V
UK2:9 = 24 V
UK2:10 = 24 V
11
UA1 = 24 V
VDRT02.02GB
11:11
Reference
value
Reference
Redundant
voltage feed
Activated
Ignition voltage
Activated
Control breaker
Not activated
Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
3, 4
D4
D5
+
D2
D7
D795
D790-1
1, 2, 5
D797-R
8
D791-1
D797-F
7
D793
013426
D794
D8
Pos
Explanation
Signal description
Reference
Checked by control
system, error shown
with error code.
UK3009-1/86 = 24 V
UK3009-2/87 = 24 V
UK3009-1/87 = 24 V
UK3009-2/87= 0 V
UK3009-2/86 = 24 V
UK3009-2/87 = 24 V
VDRT02.02GB
11:12
Pos
Explanation
Signal description
Reference
Activate lift.
Press in the emergency stop switch and check that the lifting
movement stops.
000039
Control breaker
VDRT02.02GB
11:13
VDRT02.02GB
11:14
Circuit fuses
Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied
Connectors
Relays
Voltage converter 24 V to 12 V
NOTE
This connector is not fitted on the machine if the machine is
equipped with voltage converter.
2
3
4
5
014144
1.
2.
3.
4.
Fuse holder
5.
6.
Voltage converter
VDRT02.02GB
11:15
The electronic box is fitted on the side of the machine. Also located
there are:
1
4
8
5
6
Circuit fuses
Main fuses
014145
1.
Circuit fuses
2.
3.
Main fuses
4.
Main fuse
5.
6.
Relay (K315-2)
7.
8.
9.
VDRT02.02GB
11:16
1.
2.
3.
7.
8.
4.
9.
5.
6.
VDRT02.02GB
013869
11:17
5 6
000041
2
1.
2.
3.
4.
5.
Light 3, communication
6.
Control unit, cab has four indicator lights that indicate the control
unit's function (see illustration).
Lamp 1
Lamp 2
Lamp 3
Lamp 4
Check that the new control unit corresponds with the machine's
forklift number (Z-number).
Set the fresh air damper at fully closed and fully open, wait a
few seconds in each position so that the damper has time to go
to the end position.
VDRT02.02GB
11:18
2
3
Lamp 1
Lamp 2
000043
The control unit has four indicator lights that indicate the control unit's
function (see illustration).
1.
2.
3.
Light 3, communication
4.
5.
6.
Lamp 3
Lamp 4
Check that the new control unit corresponds with the machine's
forklift number (Z-number).
DANGER
The lowering speed must be correct. If lowering speed
is too high there is a risk of rollover.
The machine must absolutely not be operated before
lowering speed is verified.
VDRT02.02GB
11:19
2
3
Lamp 1
Lamp 2
000043
The control unit has four indicator lights that indicate the control unit's
function (see illustration).
1.
2.
3.
Light 3, communication
4.
5.
6.
Lamp 3
Lamp 4
Check that the new control unit corresponds with the machine's
forklift number (Z-number).
VDRT02.02GB
11:20
2
3
Lamp 1
Lamp 2
000043
The control unit has four indicator lights that indicate the control unit's
function (see illustration).
1.
2.
3.
Light 3, communication
4.
5.
6.
Lamp 3
Lamp 4
VDRT02.02GB
Check that the new control unit corresponds with the machine's
forklift number (Z-number).
11:21
013820
Check that the new control unit corresponds with the machine's
forklift number (Z-number).
Calibrate the new control unit; see section 8 Control system, group
8.5.2.3 Calibrate DRIVE-TRAIN and section 2 Transmission,
group 2.8 Control system, transmission.
013820
VDRT02.02GB
11:22
013872
engine speed
camshaft position
boost pressure
coolant temperature
oil pressure
oil temperature
oil level
crankcase pressure
water in fuel
fuel pressure
coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
VDRT02.02GB
11:23
3
Control unit, engine (D794) is part of the drive-train control and
handles engine function, fuel injection, etc.
Control unit, engine (D794) is connected via separate CAN bus
communication to the transmission, which is connected to Control
unit, cab (D790-1). In turn, Control unit, cab (D790-1) sends
drive-train information on to other units.
007423
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
system.
1.
Connector OEM
2.
Connector Actuator
3.
Connector Sensor
engine speed
boost pressure
coolant temperature
oil pressure
oil temperature
coolant level
water in fuel
air pressure
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
Control unit KIT (D790-2) handles functions for the gear selector
and multi-function lever, the direction indicator switch and start key
positions II and III. It also handles the key panel (B) for the control
system and its panel for warning and indicator lights (A).
Control unit KIT (D790-2) has several individual function keys and
indicator lights (see illustration).
000049
1.
2.
VDRT02.02GB
11:24
Remove the steering wheel and separate the steering wheel panel.
000051
See the operator's manual for detailed information about the display.
1.
LCD display
2.
VDRT02.02GB
Remove the steering wheel and separate the steering wheel panel.
11:25
Contact
Location
Function
X001
X002
Windscreen wipers
Cooling fan
Actuator motor, recirculation
X004
Air conditioning
X005
Switch, option
Switch flashing hazard lights (Hazard)
Air conditioning
Extra sensors
Accelerator
X006
X007
Control lever
X008
Control lever
Switch, bypass
Emergency stop switch
Switch parking brake
Switch, option
Switch, twistlocks
X009
Not used
X010
Water valve
Seat heat
Relay, working lights
Hour counter
Relay, compressor
Power supply relays K315-1, K3009-1, K3009-2 and K315-2
Windscreen washing
Windscreen wiper, roof
VDRT02.02GB
11:26
Contact
Location
Function
X011
X012
X013
CAN bus
RS232
X015
CAN bus
Power supply and ground connection Control unit KIT (D790-2)
X016
X017
Ignition
Control, windscreen wipers
Control, gear
Control, high and low beams
X018
X020
CAN bus
RS232 Printer
Power supply and ground connection Control unit KID (D795)
X033
Air conditioning
Control, fan
Control, temperature
Control, air distribution
X034
Air conditioning
Heater fan
Water valve
X035
Air conditioning
X036
Air conditioning
X038
Accelerator
Declutch pedal
X039
Hour counter
Relay, compressor air-suspension seat
Switch flashing hazard lights (Hazard)
Break contact (opening switch), cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
X048
Termination resistor
X049
CAN bus
VDRT02.02GB
Contact
Location
Function
X050
D-sub
11:27
X052
CAN bus
Control relays K315-1, K3009-1, K3009-2 and K315-2
X054
Interior lighting
Working lights
Flashing hazard lights
X055
X056
X057
X058
X059
CAN bus
Power supply, control units
X060
CAN bus
Interior lighting
X060A
Extension X060
CAN bus
Interior lighting
X061
X061A
Extension X061
X062
Horn
Map lighting
Cigarette lighter 12V
X063
Seat heater
Compressed-air damped seat
X071-1
X071-2
X072
Current outlet
X073
VDRT02.02GB
11:28
Contact
Location
Function
X080
X081
X082
X168
X200
Boom mounting
CAN bus
Redundant power supply, control units
X201
X202
Boom mounting
X203
Termination resistor
X205
CAN bus
Control unit, transmission (D793)
X206
Boom mounting
X209A
CAN bus
Power supply, control units
X210
X211
X212
Power supply and ground connection, Control unit, frame front (D797-F)
CAN bus, Control unit, frame front (D797-F)
Temperature oil, brake system
Control breaker
X221
X222
X246
AC compressor
X251
VDRT02.02GB
Contact
Location
Function
X253
Transmission
11:29
X259
Transmission
X260
X261
X264
X270
X271
Back-up lights
Tail lights
Brake light
Direction indicators
Side marker lights
X273
Back-up lights
Tail lights
Brake light
Direction indicators
Side marker lights
X276
X278
X279
Engine
X281
X286
Engine
X287
Engine
X301
Boom mounting
X400
Boom nose
VDRT02.02GB
11:30
Contact
Location
Function
X401
Boom nose
X403A
X403B
X404
X405
Boom nose
X406
Not used
X411
X412
X428
Boom
Revolving beacon
X759
Engine
X901
X905
Cab panel
Explanation
Application area
Temperature
There are two different resistance curves, one for Control unit, cab
(D790-1) and one for the frame and attachment control units.
Accuracy is 0.5 in the interval 0-100 C (sensor's measurement
inaccuracy not included). Outside of the interval 0-100 C, accuracy is
2 C.
Voltage
Hydraulics, e.g.
lifting/lowering of the
boom.
Analogue outputs
Current feedback
voltage out, PWM
VDRT02.02GB
11:31
Signal type
Explanation
Application area
Voltage out,
reversed polarity,
NPN PWM
Max. load 10 A
Logical one (1) generates voltage out, U >= 22.5 V or grounded output,
U=0V
Max. load 0.5 A
VDRT02.02GB
11:32
11.6 Communication
11.6.1 CAN bus
CAN bus, description
Communication between the control units takes place using so-called
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A
simple technology that is highly reliable (low error frequency), which is
a requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
CAN specifies:
Message
Message
F G
t [S]
Messages are sequential and signal is high (voltage
high) or low (voltage low).
000027
Length message
Start bit
Identity field/Priority
Data segment
Acknowledge bit
Does not indicate address to control unit. CAN does not work with
addressing. All control units receive messages and send them on.
Acknowledge (G)
The transmitting control unit sets a bit to logical one (1) when the
message is sent. The first control unit to receive the message sends it
on and sets the bit to logical zero (0).
VDRT02.02GB
Communication
11:33
Communication
The CAN network consists of control units and segments. The
segment (bus) is a twisted pair cable that leads CAN + and CAN signal levels from control unit to control unit.
U [V]
3,5 V
Each control unit measures the potential difference of its two inputs.
The potential difference generates logical zero and logical one. The
illustration depicts an approved interval according to the standard for
potential levels. CAN + has a recommended value of 3.5 V and CAN
- has 1.5 V. As a worst case scenario, the potential difference can be
only 0.5 V and still be approved. In practice, a potential difference of
2 V is recommended for reliable communication.
0,5 V
1,5 V
000028
t [S]
flow control
VDRT02.02GB
11:34
D791-1
CAN R
CAN L
D790-2
CAN L
CAN R
D797-R
D795
CAN R
CAN L
CAN L
CAN R
D797-F
013424
D790-1
CAN R
CAN L
Redundant CAN bus means that the control units are connected into a
network that communicates via a CAN bus (see CAN bus, description,
page 11:32) and that there are double communication routes on the
network. The network is divided into control units and segments
(segments are the cables between the control units). The number of
active segments depends on the number of control units the machine
has, which depends on the machine's equipment level (options).
VDRT02.02GB
11:35
Reference
value
Reference
Battery disconnector
In position 1
Activated.
S2
D791-1
22
6
S1
D790-2
D790-1
D795
S5
1, 7
D797-R
S4
5
D797-F
S3
013875
Pos
Explanation
Signal description
Reference
Checked by control
system, error shown
with error code.
A clicking sound is
audible when then
termination resistor is
activated.
A clicking sound is
audible when then
termination resistor is
activated.
A clicking sound is
audible when then
termination resistor is
activated.
A clicking sound is
audible when then
termination resistor is
activated.
VDRT02.02GB
11:36
Pos
Explanation
Signal description
Reference
A clicking sound is
audible when then
termination resistor is
activated.
Checked by control
system, error shown
with error code.
The drive-train CAN bus is based on the SAE J1939 standard where
selected messages are used to control engine and transmission.
D790-1
Control units for engine and transmission come from the respective
transmission and engine supplier. The control units use the same
standard of communication and therefore the messages for each
engine are constructed using the same structure.
Communication with Control unit, engine (D794) and Control unit,
transmission (D793) are separate from the redundant CAN bus.
1
1.
2.
3.
4.
Engine
5.
6.
Transmission
VDRT02.02GB
000033
The signals can be checked via the diagnostic menu. See section 8
Control system, group 8.4.1.3 CAN/POWER, menu 3.
11:37
Sockets for CAN bus drive-train in electronic box cab (position 2) are
used for communicating with the engine and transmission via CAN
bus.
014146
3
1.
2.
3.
VDRT02.02GB
11:38
VDRT02.02GB
D:1
D Error codes
VDRT02.02GB
D:2
VDRT02.02GB
D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
E
000389
VDRT02.02GB
D:4
C
D
E
000389
000350
C
D
Stop
Warning
Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
contact service as soon as possible.
E
000351
C
E
000352
VDRT02.02GB
Information
The error code is stored in the error code list under operating
menu for service.
D:5
C
D
The control and monitoring system gives error codes from three
sub-systems:
000389
Machine:
Shown with error code number XXX on display.
Engine:
Shown with error code number XX/YY on display.
XX/YY
NOTE
If several error codes come from the engine, the error code level
is shown for the most serious error code.
001343
XX/YY
Transmission:
Shown with error code number XX/YY on display.
D
014173
1.
2.
3.
4.
5.
6.
7.
000396
VDRT02.02GB
D:6
10
11
12
1.
Attachment
2.
Rotation of attachment
3.
4.
5.
Twistlocks
6.
Boom up/down
7.
8.
9.
Boom in/out
13
14
13. Engine
15
14. Transmission
15. Control unit
16. Hardware-related error
16
17
18
17. Cab
18. Air conditioning
19. Fuel system
19
20
20. Headlights
21
23
014163
22
VDRT02.02GB
D:7
WARNING
Risk of machine damage.
In the event of error codes of level "WARNING" and
"STOP", serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error code
has been identified or repaired.
Navigate to the service menu and press Enter.
The error code list is shown on the display. An active error code is
shown on display where field C shows error code number together
with X(Y). X shows sequence number for displayed error code and
(Y) shows total number of active error codes.
000056
000060
1 23
4 5
001998
VDRT02.02GB
D:8
C
E
000389
Use the error code tables to find more information about the error
code.
After the remedial action, check that no active error codes remain
for the function in question.
Engine
Error codes engine, general
When contacting engine suppliers, use the supplier code.
The supplier code indicates the error code in accordance with the
engine manufacturer's specification.
FMI
Description
SAE-text
Incorrect data.
Electrical problem.
Electrical problem.
Electrical problem.
Electrical problem.
Mechanical problem.
Abnormal frequency.
Communication error.
10
11
Unknown malfunction.
Non-identifiable malfunction.
12
Component error.
13
Incorrect calibration.
14
Unknown malfunction.
Special instructions.
15
Unknown malfunction.
VDRT02.02GB
D:9
Display
29/2
Supplier
code
P2135
Connections
and
components
Description
Limitation
Action
Signal from
accelerator pedal,
signal 2 and 1 do not
correspond.
Reduced engine
power.
D794/1:7
9
Diagnostic
menu
D794/1:8
0
29/3
P0223
Accelerator pedal,
short circuit to voltage.
Reduced engine
power.
D794/1:8
0
29/4
P0222
Accelerator pedal,
short circuit to ground.
Reduced engine
power.
D794/1:8
0
84/0
P0501
Engine speed is
limited.
84/2
P0501
Speed signal
unreasonable.
Machine speed
does not correspond
with values from fuel
injection and engine
speed.
Engine speed is
limited.
D794/1:7
1
ENGINE,
menu 1
Engine speed is
limited.
Engine speed is
limited.
ENGINE,
menu 1
D794/1:7
9
84/11
84/12
P0510
P0500
91/2
P2135
Signal from
accelerator pedal,
signal 1 and 2 do not
correspond.
Reduced engine
power.
D794/1:8
0
91/3
P0123
Accelerator pedal,
short circuit to voltage.
Reduced engine
power.
D794/1:7
9
91/4
P0122
Accelerator pedal,
short circuit to ground.
Reduced engine
power.
D794/1:7
9
91/7
P2299
Signal from
accelerator pedal
and brake pedal not
consistent.
No limitation.
D794/1:7
9
No limitation.
D794/1:8
1
95/2
P1017
D794/1:8
0
-
VDRT02.02GB
D:10
Display
95/3
Supplier
code
P1015
Description
Limitation
Action
No limitation.
Connections
and
components
Diagnostic
menu
D794/1:8
1
D794/1:8
1
P1016
No limitation.
95/7
P1018
No limitation.
97/3
P2267
Water-in-fuel sensor
(B760), short circuit to
voltage.
No limitation.
D794/
1:43
B760/1
ENGINE,
menu 10
D794/
1:43
B760/1
ENGINE,
menu 10
P2266
Water-in-fuel sensor
(B760), short circuit to
ground.
No limitation.
97/11
P2269
Water in fuel.
No limitation.
D794/
1:43
B760/1
ENGINE,
menu 10
98/2
P250B
No limitation.
98/3
P250D
No limitation.
98/4
P250C
No limitation.
98/12
P250A
No limitation.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
P0521
Sensor engine
oil pressure,
unreasonable signal.
No limitation.
VDRT02.02GB
D794/1:3
5
ENGINE,
menu 6
Display
100/3
Supplier
code
P0523
Description
Limitation
Action
No limitation.
D:11
Connections
and
components
Diagnostic
menu
ENGINE,
menu 6
ENGINE,
menu 6
D794/1:3
4
CAN/POWER,
menu 3
P0522
No limitation.
100/12
P0520
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
100/17
P0524
Reduced engine
power.
D794/1:3
5
ENGINE,
menu 6
D794/2:3
2 36
ENGINE,
menu 6
D794/2:3
4
ENGINE,
menu 6
D794/2:3
4
ENGINE,
menu 6
D794/1:3
4
CAN/POWER,
menu 3
102/3
P0236
P0238
Sensor boost
pressure and
sensor air pressure,
unreasonable signal
combination.
Reduced engine
power.
Sensor boost
pressure, short circuit
to voltage.
Reduced engine
power.
102/4
P0237
Sensor boost
pressure, short circuit
to ground.
Reduced engine
power.
102/12
P0235
Sensor boost
pressure, incorrect
signal via CAN bus.
Reduced engine
power.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
D794/1:3
5
VDRT02.02GB
D:12
Display
105/3
Supplier
code
P0098
Description
Limitation
Action
Sensor intake
temperature, incorrect
signal. Short circuit to
voltage.
No limitation.
Connections
and
components
Diagnostic
menu
D794/2:3
6
ENGINE,
menu 7
D794/2:3
6
ENGINE,
menu 7
D794/1:3
4
CAN/POWER,
menu 3
P0097
Sensor intake
temperature, short
circuit to ground.
No limitation.
105/12
P0099
Sensor intake
temperature, incorrect
signal via CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
108/2
108/3
P2227
P2229
Reduced engine
power.
Reduced engine
power.
D794/1:3
5
D794/2:3
2 2:36
ENGINE,
menu 6
D794/1:3
4
CAN/POWER,
menu 3
108/4
P2228
Reduced engine
power.
108/12
P0000
Reduced engine
power.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
110/2
110/3
P0116
P0118
Coolant temperature
sensor, the
temperature is
unreasonable in
relation to the oil
temperature.
Reduced engine
power.
Sensor coolant
temperature, short
circuit to voltage.
Reduced engine
power.
D794/2:1
5
ENGINE,
menu 7
D794/2:1
5
ENGINE,
menu 7
VDRT02.02GB
D794/1:3
5
Display
110/4
Supplier
code
P0117
Description
Limitation
Action
Sensor coolant
temperature, short
circuit to ground.
Reduced engine
power.
D:13
Connections
and
components
Diagnostic
menu
D794/2:1
5
ENGINE,
menu 7
D794/1:3
4
CAN/POWER,
menu 3
P0115
Sensor coolant
temperature, incorrect
signal via CAN bus.
Reduced engine
power.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
110/15
P0217
Coolant temperature
too high
No limitation.
D794/1:3
5
D794/2:1
5
P2557
No limitation.
ENGINE,
menu 10
111/3
P2559
No limitation.
ENGINE,
menu 10
111/4
P2558
No limitation.
ENGINE,
menu 10
111/12
P2556
No limitation.
ENGINE,
menu 10
132/3
P0101
No limitation.
132/3
P0103
No limitation.
132/4
P0101
No limitation.
132/4
P0102
No limitation.
VDRT02.02GB
D:14
Display
157/3
Supplier
code
P0193
Description
Limitation
Action
Reduced engine
power.
Connections
and
components
Diagnostic
menu
D794/2:1
4
D794/2:1
4
D794/2:1
4
D794/2:1
4
P0192
Reduced engine
power.
157/15
P0191
Reduced engine
power.
157/17
P0191
Reduced engine
power.
158/12
P2533
No limitation.
D794/1:4
0
168/3
P0563
No limitation.
D794/1:2
D794/1:2
If equipment for
assisted start is
connected, disconnect
it.
168/4
P0562
171/3
P0073
Sensor outdoor
temperature, short
circuit to voltage.
No limitation.
171/4
P0072
Sensor outdoor
temperature, short
circuit to ground.
No limitation.
171/12
P0071
Sensor outdoor
temperature, incorrect
signal via CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
VDRT02.02GB
D794/1:3
5
Display
172/3
Supplier
code
P0113
Description
Limitation
Action
Sensor intake
temperature, high
signal.
No limitation.
D:15
Connections
and
components
Diagnostic
menu
D794/2:3
6
ENGINE,
menu 7
D794/2:3
6
ENGINE,
menu 7
ENGINE,
menu 7
ENGINE,
menu 7
D794/1:3
4
CAN/POWER,
menu 3
P0112
Sensor intake
temperature, low
signal.
No limitation.
174/3
P0183
Sensor fuel
temperature, short
circuit to voltage.
No limitation.
174/4
P0182
Sensor fuel
temperature, short
circuit to ground.
No limitation.
175/3
P0198
No limitation.
175/4
P0197
No limitation.
175/12
P0195
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
175/17
P0196
No limitation.
D794/1:3
5
ENGINE,
menu 7
D794/2:0
9
Check coolant
temperature and level.
190/7
P0016
No limitation.
D794/2:2
3
P0336
The engine is
extremely difficult
to start and runs
unevenly or stops.
Reduced engine
power.
D794/2:2
3
ENGINE,
menu 2
VDRT02.02GB
D:16
Display
190/12
Supplier
code
P0008
Description
Limitation
Action
Sensor camshaft
rotation speed, signal
error.
No limitation.
Connections
and
components
Diagnostic
menu
D794/2:0
9
D794/2:2
3
D794/1:3
4
CAN/POWER,
menu 3
P0335
520/11
UD13A
520/12
UD13B
CAN bus,
communication error.
The engine is
extremely difficult
to start and runs
unevenly or stops.
Reduced engine
power.
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
533/15
P0219
No limitation.
D794/1:3
5
D794/2:0
9
D794/2:2
3
Engine,
menu 2
Check sensor
camshaft rotation
speed and sensor
crankshaft.
596/2
P0564
No limitation.
D794/1:3
1
D794/1:6
4
D794/1:7
4
D794/1:4
6
597/2
P0504
No limitation.
597/12
P0571
No limitation.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
VDRT02.02GB
P0704
Sensor clutch,
unreasonable signal.
No limitation.
D794/1:3
5
Display
598/12
Supplier
code
P0704
Description
Limitation
Action
Sensor clutch,
incorrect signal via
CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
D:17
Connections
and
components
D794/1:3
4
D794/1:3
5
Diagnostic
menu
CAN/POWER,
menu 3
624/2
P1626
No limitation.
624/2
P162A
No limitation.
624/2
P162E
No limitation.
624/2
P161C
No limitation.
624/2
P1632
No limitation.
624/3
P1623
No limitation.
624/3
P1627
No limitation.
624/3
P162B
No limitation.
624/3
P1619
No limitation.
624/3
P162F
No limitation.
624/4
P1624
No limitation.
624/4
P1628
No limitation.
624/4
P162C
No limitation.
624/4
P161A
No limitation.
624/4
P1630
No limitation.
VDRT02.02GB
D:18
Display
Supplier
code
Description
Limitation
Action
Connections
and
components
Diagnostic
menu
624/12
P1625
No limitation.
624/12
P1629
No limitation.
624/12
P162D
No limitation.
624/12
P161B
No limitation.
624/12
P1631
No limitation.
630/2
P062F
No limitation.
P062F
Contact Yuchai
service.
630/4
630/12
P062F
636/11
P0341
D794/2:0
9
D794/2:0
9
No limitation.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
636/12
639/12
P0340
UC029
P1511
Sensor machine
speed, incorrect signal
form.
Engine speed is
limited.
D794/1:3
5
D794/1:7
1
ENGINE,
menu 2
D794/1:7
1
ENGINE,
menu 2
D794/1:7
1
ENGINE,
menu 2
P1512
Sensor machine
speed, incorrect signal
form.
Engine speed is
limited.
645/12
P1513
Sensor machine
speed, incorrect signal
form.
Engine speed is
limited.
VDRT02.02GB
Display
651/3
Supplier
code
P0262
Description
Limitation
Action
Injector cylinder 1,
short circuit to ground.
D:19
Connections
and
components
D794/3:0
4
Diagnostic
menu
D794/3:1
3
P0261
Injector cylinder 1,
short circuit between
cables.
D794/3:0
4
D794/3:1
3
P0263
Injector cylinder 1,
installation-dependent
error.
D794/3:0
4
D794/3:1
3
P0263
Injector cylinder 1,
indefinable error.
D794/3:0
4
D794/3:1
3
P1213
Injector cylinder 1,
installation-dependent
error.
No limitation.
D794/3:0
4
D794/3:1
3
P1214
Injector cylinder 1,
installation-dependent
error.
No limitation.
D794/3:0
4
D794/3:1
3
P1215
Injector cylinder 1,
installation-dependent
error.
No limitation.
D794/3:0
4
D794/3:1
3
P0201
Injector cylinder 1,
open circuit.
No limitation.
D794/3:0
4
D794/3:1
3
P0265
Injector cylinder 2,
short circuit to ground.
D794/3:0
6
D794/3:11
P0264
Injector cylinder 2,
short circuit between
cables.
D794/3:0
6
D794/3:11
VDRT02.02GB
D:20
Display
652/11
Supplier
code
P0266
Description
Limitation
Action
Injector cylinder 2,
installation-dependent
error.
Connections
and
components
D794/3:0
6
Diagnostic
menu
D794/3:11
P0266
Injector cylinder 2,
indefinable error.
D794/3:0
6
D794/3:11
P1216
Injector cylinder 2,
installation-dependent
error.
No limitation.
D794/3:0
6
D794/3:11
P1217
Injector cylinder 2,
installation-dependent
error.
No limitation.
D794/3:0
6
D794/3:11
P1218
Injector cylinder 2,
installation-dependent
error.
No limitation.
D794/3:0
6
D794/3:11
P0202
Injector cylinder 2,
open circuit.
No limitation.
D794/3:0
6
D794/3:11
P0268
Injector cylinder 3,
short circuit to ground.
D794/3:0
5
D794/3:1
2
P0267
Injector cylinder 3,
short circuit between
cables.
D794/3:0
5
D794/3:1
2
P0269
Injector cylinder 3,
installation-dependent
error.
D794/3:0
5
D794/3:1
2
P0269
Injector cylinder 3,
indefinable error.
VDRT02.02GB
D794/3:0
5
D794/3:1
2
Display
653/11
Supplier
code
P1219
Description
Limitation
Action
Injector cylinder 3,
installation-dependent
error.
No limitation.
D:21
Connections
and
components
D794/3:0
5
Diagnostic
menu
D794/3:1
2
P121A
Injector cylinder 3,
installation-dependent
error.
No limitation.
D794/3:0
5
D794/3:1
2
P121B
Injector cylinder 3,
installation-dependent
error.
No limitation.
D794/3:0
5
D794/3:1
2
P0203
Injector cylinder 3,
open circuit.
No limitation.
D794/3:0
5
D794/3:1
2
P0271
Injector cylinder 4,
short circuit to ground.
D794/3:0
3
D794/3:1
4
P0270
Injector cylinder 4,
short circuit between
cables.
D794/3:0
3
D794/3:1
4
P0272
Injector cylinder 4,
installation-dependent
error.
D794/3:0
3
D794/3:1
4
P0272
Injector cylinder 4,
indefinable error.
D794/3:0
3
D794/3:1
4
P121C
Injector cylinder 4,
installation-dependent
error.
No limitation.
D794/3:0
3
D794/3:1
4
P121D
Injector cylinder 4,
installation-dependent
error.
No limitation.
D794/3:0
3
D794/3:1
4
VDRT02.02GB
D:22
Display
654/11
Supplier
code
P121E
Description
Limitation
Action
Injector cylinder 4,
installation-dependent
error.
No limitation.
Connections
and
components
D794/3:0
3
Diagnostic
menu
D794/3:1
4
P0204
Injector cylinder 4,
open circuit.
No limitation.
D794/3:0
3
D794/3:1
4
P0274
Injector cylinder 5,
short circuit to ground.
D794/3:0
1
D794/3:1
6
P0273
Injector cylinder 5,
short circuit between
cables.
D794/3:0
1
D794/3:1
6
P0275
Injector cylinder 5,
installation-dependent
error.
D794/3:0
1
D794/3:1
6
P0275
Injector cylinder 5,
indefinable error.
D794/3:0
1
D794/3:1
6
P121F
Injector cylinder 5,
installation-dependent
error.
No limitation.
D794/3:0
1
D794/3:1
6
P1220
Injector cylinder 5,
installation-dependent
error.
No limitation.
D794/3:0
1
D794/3:1
6
P1221
Injector cylinder 5,
installation-dependent
error.
No limitation.
D794/3:0
1
D794/3:1
6
P0205
Injector cylinder 5,
open circuit.
No limitation.
VDRT02.02GB
D794/3:0
1
D794/3:1
6
Display
656/3
Supplier
code
P0277
Description
Limitation
Action
Injector cylinder 6,
short circuit to ground.
D:23
Connections
and
components
D794/3:0
2
Diagnostic
menu
D794/3:1
5
P0276
Injector cylinder 6,
short circuit between
cables.
D794/3:0
2
D794/3:1
5
P0278
Injector cylinder 6,
installation-dependent
error.
D794/3:0
2
D794/3:1
5
P0278
Injector cylinder 6,
indefinable error.
D794/3:0
2
D794/3:1
5
P1222
Injector cylinder 6,
installation-dependent
error.
No limitation.
D794/3:0
2
D794/3:1
5
P1223
Injector cylinder 6,
installation-dependent
error.
No limitation.
D794/3:0
2
D794/3:1
5
P1224
Injector cylinder 6,
installation-dependent
error.
No limitation.
D794/3:0
2
D794/3:1
5
P0206
Injector cylinder 6,
open circuit.
No limitation.
D794/3:0
2
D794/3:1
5
P0540
Relay, preheating
(K312), signal error.
Preheating not
working.
677/3
P0617
P1638
No limitation.
D794/
1:55
K312/86
ENGINE,
menu 5
D794/
1:59
K312/85
D794/1:3
7
D794/1:5
1
VDRT02.02GB
D:24
Display
677/4
Supplier
code
P0616
P1639
677/5
729/3
P163A
P0541
Description
Limitation
Action
No limitation.
D794/1:3
7
D794/1:3
7
D794/
1:55
K312/86
Relay preheating
(K312), short circuit to
ground.
No limitation.
No limitation.
P0542
Relay preheating
(K312), short circuit to
voltage.
No limitation.
729/3
P1020
Relay preheating
(K312), high signal.
No limitation.
729/4
P1021
Relay preheating
(K312), active too
short time.
No limitation.
730/3
P1022
Relay preheating
(K312), high signal.
No limitation.
730/4
P1023
Relay preheating
(K312), low signal.
No limitation.
898/11
UD10E
898/12
UD10F
CAN bus,
communication error.
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
VDRT02.02GB
Connections
and
components
Diagnostic
menu
D794/1:5
1
-
D794/1:5
1
ENGINE,
menu 5
D794/
1:59
K312/85
D794/
1:55
K312/86
ENGINE,
menu 5
D794/
1:59
K312/85
D794/
1:55
K312/86
ENGINE,
menu 5
D794/
1:59
K312/85
D794/
1:55
K312/86
ENGINE,
menu 5
D794/
1:59
K312/85
D794/
1:55
K312/86
ENGINE,
menu 5
D794/
1:59
K312/85
D794/
1:55
K312/86
ENGINE,
menu 5
D794/
1:59
K312/85
D794/1:3
4
D794/1:3
5
CAN/POWER,
menu 3
Display
970/3
Supplier
code
P1617
Description
Limitation
Action
Voltage error at
shut-off, high battery
voltage.
Reduced engine
power.
D:25
Connections
and
components
Diagnostic
menu
D794/1:0
2
D794/1:0
2
D794/1:0
2
D794/1:3
4
CAN/POWER,
menu 3
P1618
Voltage error at
shut-off, low battery
voltage.
Reduced engine
power.
970/12
P1616
Voltage error at
shut-off, monitoring
switched off.
Reduced engine
power.
985/2
P2519
985/12
P2519
AC compressor,
incorrect CAN
message.
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
D794/1:3
5
1041/7
P2530
No limitation.
D794/1:6
1
1041/8
P2530
No limitation.
D794/1:6
1
1071/2
P0483
No limitation.
D794/1:1
3
D794/1:1
3
1071/3
P0692
No limitation.
D794/1:5
8
-
D794/1:5
8
1071/3
P0694
No limitation.
1071/4
P0691
No limitation.
D794/1:1
3
D794/1:5
8
1071/4
P0693
No limitation.
1071/12
P0480
No limitation.
D794/1:1
3
1072/3
P0080
No limitation.
D794/1:5
8
-
VDRT02.02GB
D:26
Display
Supplier
code
Description
Limitation
Action
Connections
and
components
Diagnostic
menu
1072/4
P0079
No limitation.
1072/255
P1633
No limitation.
1072/255
P1634
No limitation.
D794/3:0
8
1074/2
P0476
No limitation.
D794/3:0
8
1074/3
P0478
No limitation.
D794/3:0
8
1074/4
P0477
No limitation.
D794/3:0
8
1074/12
P0476
No limitation.
D794/3:0
8
1079/3
P0643
Reduced engine
power.
1079/4
P0642
No limitation.
1080/3
P0653
Reduced engine
power.
1080/4
P0652
No limitation.
1081/2
P1638
No limitation.
D794/1:3
8 D797F/K1:26
ENGINE,
menu 10
D794/1:3
8 D797F/K1:26
ENGINE,
menu 10
D794/1:3
8 D797F/K1:26
ENGINE,
menu 10
P1635
No limitation.
1081/4
P1636
No limitation.
VDRT02.02GB
Display
1081/12
Supplier
code
P1637
Description
Limitation
Action
No limitation.
D:27
Connections
and
components
Diagnostic
menu
D794/1:3
8 D797F/K1:26
ENGINE,
menu 10
D794/2:0
9
ENGINE,
menu 2
P1613
No limitation.
D794/2:2
3
Check sensor
camshaft rotation
speed and sensor
crankshaft.
Check the fuel
pressure.
1192/2
P0046
No limitation.
D794/2:0
1
1192/3
P0048
No limitation.
D794/2:0
1
1192/3
P1000
No limitation.
D794/2:0
1
1192/4
P0047
No limitation.
D794/2:0
1
1192/4
P1001
No limitation.
D794/2:0
1
1192/12
P0045
No limitation.
D794/2:0
1
1192/12
P1002
No limitation.
D794/2:0
1
1213/2
P0650
No limitation.
1213/3
P0650
No limitation.
1213/4
P0650
No limitation.
1213/12
P0650
No limitation.
VDRT02.02GB
D:28
Display
Supplier
code
1231/12
UC038
1235/12
UC047
Description
Limitation
Action
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
Connections
and
components
D794/1:3
4
D794/1:3
5
Diagnostic
menu
CAN/POWER,
menu 3
1322/3
P0300
Misfiring on multiple
cylinders.
Reduced engine
power.
Contact Yuchai
service.
1323/3
P0301
Misfiring cylinder 1.
Reduced engine
power.
Contact Yuchai
service.
1324/3
P0302
Misfiring cylinder 2.
Reduced engine
power.
Contact Yuchai
service.
1325/3
P0303
Misfiring cylinder 3.
Reduced engine
power.
Contact Yuchai
service.
1326/3
P0304
Misfiring cylinder 4.
Reduced engine
power.
Contact Yuchai
service.
1327/3
P0305
Misfiring cylinder 5.
Reduced engine
power.
Contact Yuchai
service.
1328/3
P0306
Misfiring cylinder 6.
Reduced engine
power.
Contact Yuchai
service.
1351/2
P0645
Drive circuit
AC compressor,
overheated.
No limitation.
D794/2:11
1351/3
P0647
Drive circuit AC
compressor, short
circuit to voltage.
No limitation.
D794/2:11
1351/4
P0646
Drive circuit AC
compressor, short
circuit to ground.
No limitation.
D794/2:11
1351/12
P0645
Drive circuit AC
compressor, open
circuit.
No limitation.
D794/2:11
1485/3
P0687
No limitation.
1485/4
P0686
No limitation.
1624/3
P2158
Sensor machine
speed, speed too
high.
Engine speed is
limited.
D794/1:7
1
1624/4
P2160
Sensor machine
speed, speed too
low.
Engine speed is
limited.
D794/1:7
1
VDRT02.02GB
Display
1624/12
Supplier
code
P2157
Description
Limitation
Action
Sensor machine
speed, speed
message via CAN
bus incorrect.
Engine speed is
limited.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
D:29
Connections
and
components
D794/1:3
4
D794/1:3
5
Diagnostic
menu
CAN/POWER,
menu 3
1624/255
P2159
Sensor machine
speed, unreasonable
speed.
Engine speed is
limited.
D794/1:7
1
1639/3
P0526
No limitation.
D794/1:6
8
D794/1:6
8
1639/4
P0527
No limitation.
D794/1:6
9
-
D794/1:6
9
2634/3
P160E
No limitation.
2634/4
P160F
No limitation.
2791/2
P0403
No limitation.
2791/3
P0490
No limitation.
2791/4
P0489
No limitation.
2791/5
P0404
No limitation.
520192/2
P063B
P060B
520192/4
P061B
VDRT02.02GB
D:30
Display
520192
/11
Supplier
code
P062B
Description
Limitation
Action
Connections
and
components
Diagnostic
menu
P0103
No limitation.
520193/4
P0102
No limitation.
520194/2
P0649
No limitation.
520194/3
P0649
No limitation.
520194/4
P0649
No limitation.
520194/5
P0649
No limitation.
520195
/15
P0402
No limitation.
520196
/17
P0401
No limitation.
520197/3
P022C
No limitation.
520197/4
P022B
No limitation.
520197
/12
P022A
No limitation.
520198/2
P0116
Sensor coolant
temperature,
unreasonable signal.
No limitation.
D794/2:1
5
ENGINE,
menu 7
D794/2:1
5
ENGINE,
menu 7
P0116
Sensor coolant
temperature,
unreasonable signal.
No limitation.
520199/2
VDRT02.02GB
P0856
DCS, unreasonable
signal.
No limitation.
Display
Supplier
code
Description
Limitation
Action
D:31
Connections
and
components
Diagnostic
menu
520200
/20
P161F
Incorrect compression
test.
No limitation.
contact Yuchai
service.
520201/3
P1505
Sensor outdoor
temperature (BET),
signal too high.
No limitation.
520201/4
P1506
Sensor outdoor
temperature (BET),
signal too low.
No limitation.
520202/3
P1507
Sensor outdoor
temperature (ClgZn),
signal too high.
No limitation.
520202/4
P1508
Sensor outdoor
temperature (ClgZn),
signal too low.
No limitation.
520203/3
P1509
Sensor intake
temperature, signal
too high.
No limitation.
D794/2:3
6
D794/2:3
6
P150A
Sensor intake
temperature, signal
too low.
No limitation.
520204/2
P1635
No limitation.
D794/2:2
9
520205/3
P245D
No limitation.
520205/4
P245C
No limitation.
520205
/12
P245A
No limitation.
520206/2
P0470
Exhaust back
pressure sensor,
unreasonable signal.
No limitation.
520206/3
P0473
No limitation.
520206/4
P0472
No limitation.
520207/3
P1008
No limitation.
D794/2:0
4
D794/2:0
5
VDRT02.02GB
D:32
Display
520207/4
Supplier
code
P1009
Connections
and
components
Description
Limitation
Action
No limitation.
D794/2:0
4
Diagnostic
menu
D794/2:0
5
520208/2
P0409
No limitation.
520208/3
P0406
No limitation.
520208/4
P0405
No limitation.
520208
/12
P0409
No limitation.
520209/2
P040B
Sensor exhaust
temperature,
unreasonable signal.
No limitation.
520209/3
P040D
Sensor exhaust
temperature, short
circuit to voltage.
No limitation.
520209/4
P040C
Sensor exhaust
temperature, short
circuit to ground.
No limitation.
520209
/12
P040A
Sensor exhaust
temperature, open
circuit.
No limitation.
520210/3
or/255
UC158
Communication error,
display.
No limitation.
VDRT02.02GB
Display
Supplier
code
520211
/12
P0000
520212/3
UD100
520213
/12
UC103
520214
/12
UC113
520215/3
UD101
520216/3
UC156
520217/3
UD103
520218/3
UD10C
520218/4
UD10D
520218
/12
UD104
520219/3
UD110
520219
/12
UD111
520220/3
UD112
520220
/12
UD113
520222
/14
P0607
520222
/14
P0607
520222
/14
P0607
520223
/20
Description
Limitation
Action
Communication error,
CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
D:33
Connections
and
components
D794/1:3
4
D794/1:3
5
Diagnostic
menu
CAN/POWER,
menu 3
Engine switched
off: engine cannot
be started. Engine
running: engine
misfires.
Contact Yuchai
service.
P160C
No limitation.
Contact Yuchai
service.
520224/3
P150B
No limitation.
520224/4
P150C
No limitation.
520225
/11
P1302
Injection error,
software error.
No limitation.
520225
/15
P1301
No limitation.
520225
/16
P1300
No limitation.
520226
/12
P1225
Pressure fault on
multiple injectors.
The engine is
switched off.
VDRT02.02GB
D:34
Display
Supplier
code
Description
Limitation
Action
Connections
and
components
Diagnostic
menu
520227/2
P154C
Multi-function lever,
unreasonable
position.
No limitation.
D794/1:6
2
520227/3
P154A
Multi-function lever,
short circuit to voltage.
No limitation.
D794/1:6
2
520227/4
23/04
Multi-function lever,
short circuit to ground.
No limitation.
D794/1:6
2
520228
/15
P1614
No limitation.
D794/2:2
3
ENGINE,
menu 2
D794/23:
09
P2263
Intake pressure
difference too high.
No limitation.
520230
/17
P2263
Intake pressure
difference too low.
No limitation.
520231/2
P062A
Feed pump,
overheated.
No limitation.
D794/23:
10
P0629
No limitation.
D794/23:
09
D794/23:
10
P0628
No limitation.
D794/23:
09
D794/23:
10
P0627
No limitation.
D794/23:
09
D794/23:
10
P1615
520233
/20
P1621
VDRT02.02GB
Test mode.
No limitation.
Contact Yuchai
service.
Display
520234/2
520234/3
520234/4
520234
/12
Supplier
code
P0488
P2142
P2141
P0487
D:35
Connections
and
components
Description
Limitation
Action
Throttle, overheated.
No limitation.
D794/1:7
9
D794/1:7
9
D794/1:7
9
D794/1:7
9
No limitation.
The engine is
running at idle.
No limitation.
Diagnostic
menu
D794/1:8
0
-
D794/1:8
0
-
D794/1:8
0
-
D794/1:8
0
520235/3
P1636
Reference voltage 12
V, signal too high.
No limitation.
520235/4
P1637
Reference voltage 12
V, signal too high.
No limitation.
520236/2
P1007
No limitation.
Contact Yuchai
service
520237/3
UD114
No limitation.
520238
/12
UD115
Communication error,
CAN bus.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
520239/2
P161E
520239
/11
P161D
523218
/12
UC104
523222
/12
UC157
D794/1:3
5
No limitation.
Contact Yuchai
service.
Communication error,
CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
D794/1:3
5
VDRT02.02GB
D:36
Display
523350/3
Supplier
code
P1203
Description
Limitation
Action
Connections
and
components
D794/3:0
4
Diagnostic
menu
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
523350/4
P1204
D794/3:0
4
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
523350
/11
P1205
Injector bank 1,
installation-dependent
error.
D794/3:0
4
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
523350
/11
P1206
Injector bank 1,
electrical problem.
D794/3:0
4
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
VDRT02.02GB
Display
523351
/11
Supplier
code
P1207
Description
Limitation
Action
Injector bank 1,
installation-dependent
error.
D:37
Connections
and
components
D794/3:0
4
Diagnostic
menu
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
523351
/11
P1208
Injector bank 1,
installation-dependent
error.
D794/3:0
4
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
523351
/11
P120A
Injector bank 1,
installation-dependent
error.
D794/3:0
4
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
523351
/12
P1209
D794/3:0
4
D794/3:1
3
D794/3:0
6
D794/3:11
D794/3:0
5
D794/3:1
2
VDRT02.02GB
D:38
Display
523352/3
Supplier
code
P120B
Description
Limitation
Action
Connections
and
components
D794/3:0
3
Diagnostic
menu
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
523352/4
P120C
D794/3:0
3
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
523352
/11
P120D
Injector bank 2,
installation-dependent
error.
D794/3:0
3
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
523352
/11
P120E
Injector bank 2,
electrical problem.
D794/3:0
3
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
VDRT02.02GB
Display
523353
/11
Supplier
code
P120F
Description
Limitation
Action
Injector bank 2,
installation-dependent
error.
D:39
Connections
and
components
D794/3:0
3
Diagnostic
menu
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
523353
/11
P1210
Injector bank 2,
installation-dependent
error.
D794/3:0
3
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
523353
/11
P1212
Injector bank 2,
installation-dependent
error.
D794/3:0
3
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
523352
/12
P1211
D794/3:0
3
D794/3:1
4
D794/3:0
1
D794/3:1
6
D794/3:0
2
D794/3:1
5
VDRT02.02GB
D:40
Display
Supplier
code
Connections
and
components
Diagnostic
menu
Description
Limitation
Action
The engine is
switched off.
Contact Yuchai
service.
523354/2
P062B
523354/3
P062B
523354/4
P062B
523354
/12
P062B
523355/2
P062B
523355/3
P062B
523355/4
P062B
523355
/12
P062B
523420/2
P060C
523470/0
P100E
Reduced engine
power.
D794/2:1
4
523470/7
P1010
Reduced engine
power.
D794/2:1
4
523470
/11
P100F
Reduced engine
power.
D794/2:1
4
523500
/12
UC001
Communication error,
CAN bus.
No limitation.
D794/1:3
4
523550/2
P0607
Use diagnostic
menu to check
communication.
CAN/POWER,
menu 3
523600
/12
P0607
No limitation.
Contact Yuchai
service.
523601/3
P0699
Reduced engine
power.
523601/4
P0698
VDRT02.02GB
D794/1:3
5
Display
Supplier
code
Description
Limitation
Action
Communication error,
CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
523604
/12
UD1102
523605
/11
UD1104
523605
/12
UD1105
523606
/11
UD1106
523606
/12
UD1107
523607
/11
UD1108
523608
/11
UD110A
523608
/12
UD110B
523612/3
P1607
523612/4
P1608
523613/2
P1014
Unreasonable fuel
pressure.
D:41
Connections
and
components
D794/1:3
4
D794/1:3
5
Diagnostic
menu
CAN/POWER,
menu 3
No limitation.
Contact Yuchai
service.
Reduced engine
power.
D794/2:1
4
D794/2:1
4
D794/2:1
4
D794/2:1
4
D794/2:1
4
P0088
Reduced engine
power.
523613/4
P0087
Reduced engine
power.
523613/5
P1019
Reduced engine
power.
523613/7
P1018
Reduced engine
power.
VDRT02.02GB
D:42
Display
523613
/15
Supplier
code
P1012
Description
Limitation
Action
Connections
and
components
Reduced engine
power.
D794/2:1
4
Diagnostic
menu
P1011
Reduced engine
power.
D794/2:1
4
523613
/17
P1013
Reduced engine
power.
D794/2:1
4
D794/2:1
4
P101A
Reduced engine
power.
523615/2
P0252
No limitation.
523615/3
P0254
No limitation.
523615/4
P0253
No limitation.
523615/5
P0251
No limitation.
523615
/16
P025C
No limitation.
523615
/18
P025D
No limitation.
523617
/11
P060A
Communication error,
CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
D794/1:3
4
CAN/POWER,
menu 3
VDRT02.02GB
D794/1:3
5
D:43
Code
84/2
84/10
91/3
91/4
91/8
Description
Limitation
Action
Connections and
components
Diagnostic menu
Engine speed
limited to maximum
speed without
gear.
Electrical error,
speed sensor,
signal manipulation
detected.
Engine speed
limited to maximum
speed without
gear.
Electrical error,
accelerator pedal,
cable short circuit to
voltage.
Electrical error,
accelerator pedal,
cable short circuit to
ground.
Electrical error,
accelerator pedal,
frequency too low.
J1587
PID084/2
PID084/1
0
PID091/3
PID091/4
PID091/8
91/8
PID091/8
Electrical error,
accelerator pedal,
frequency too high.
91/19
SID091/2
Communication error
with Control unit, cab
(D790-1), electrical
error, accelerator
pedal.
Engine only
running at idle.
CAN/POWER,
menu 3
97/3
PID097/3
Electrical error,
water-in-fuel sensor,
cable short circuit to
voltage.
No limitation.
D794/Sensor:09
Electrical error,
water-in-fuel sensor,
cable short circuit to
ground.
No limitation.
D794/Sensor:09
97/4
PID097/4
97/15
PID097/1
5
Water in fuel.
Risk of white
exhaust smoke
and reduced
engine output.
100/1
PID100/1
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
ENGINE,
menu 6
100/2
PID100/2
No warning of
low engine oil
pressure.
D794/Sensor:44
ENGINE,
menu 6
VDRT02.02GB
D:44
Code
100/3
Description
Limitation
Action
Connections and
components
Diagnostic menu
No warning of
low engine oil
pressure.
D794/Sensor:44
ENGINE,
menu 6
D794/Black:14
ENGINE,
menu 6
ENGINE,
menu 6
D794/Sensor:39
ENGINE,
menu 7
D794/Sensor:39
ENGINE,
menu 7
D794/Black:3
ENGINE,
menu 7
J1587
PID100/3
PID100/4
No warning of
low engine oil
pressure.
100/18
PID100/1
No limitation.
102/2
102/3
102/4
PID102/2
PID102/3
PID102/4
Sensor boost
pressure indicates
high boost pressure,
but other engine
data indicates that
pressure should be
normal.
Reduced engine
power.
Sensor, boost
pressure, cable
short-circuited to
voltage.
Reduced engine
power.
Sensor boost
pressure, cable short
circuit to ground or
open circuit.
Reduced engine
power.
103/16
PID103/0
Over-rev protection,
turbo.
Reduced engine
power.
105/0
PID105/0
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
ENGINE,
menu 7
D794/Sensor:38
ENGINE,
menu 7
105/3
PID105/3
Risk of white
exhaust smoke.
No warning of
high coolant
temperature.
VDRT02.02GB
Code
105/4
Description
Limitation
Action
Connections and
components
Diagnostic menu
Risk of white
exhaust smoke.
No warning of
high coolant
temperature.
D794/Sensor:38
ENGINE,
menu 7
J1587
PID105/4
D:45
108/2
PID108/2
Reduced engine
power.
108/3
PID108/3
Reduced engine
power.
D794/Sensor:06
Reduced engine
power.
D794/Sensor:06
High coolant
temperature.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
ENGINE,
menu 7
108/4
110/0
PID108/4
PID110/0
110/3
PID110/3
Sensor coolant
temperature, cable
short-circuited to
voltage or open
circuit.
No indication
of engine
temperature.
D794/Sensor:02
ENGINE,
menu 7
110/4
PID110/4
Sensor coolant
temperature, cable
short circuit to
ground.
No indication
of engine
temperature.
D794/Sensor:02
ENGINE,
menu 7
D794/Sensor:09
111/1
111/2
PID111/1
PID111/2
Electrical error,
sensor coolant level,
data error.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
No warning of low
coolant level.
PID116/2
Output imbalance
between cylinders.
Rough idle.
VDRT02.02GB
D:46
Code
Description
Limitation
Action
Connections and
components
Diagnostic menu
J1587
167/1
PID167/1
Warning active
until voltage is
correct.
D794/OEM:7, 8, 17,
18, 28
167/16
PID167/0
Warning active
until voltage is
correct.
D794/OEM:7, 8, 17,
18, 28
167/18
PID167/1
Warning active
until voltage is
correct. The
engine runs at
raised idle in
order to increase
voltage.
D794/OEM:7, 8, 17,
18, 28
168/16
PID168/0
No limitation.
D794/OEM:7, 8, 17,
18, 28
168/18
PID168/1
Rough idle.
D794/OEM:7, 8, 17,
18, 28
175/0
PID175/0
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
ENGINE,
menu 7
D794/Sensor:42
ENGINE,
menu 7
D794/Sensor:42
ENGINE,
menu 7
175/3
175/4
188/4
PID175/3
PID175/4
SID032/4
Sensor, oil
temperature, cable
short-circuited to
voltage or open
circuit.
No indication
of engine oil
temperature.
Sensor oil
temperature, cable
short circuit to
ground.
No indication
of engine oil
temperature.
Electrical error,
wastegate solenoid
valve 1 short circuit
to ground.
Reduced engine
power.
D794/Actuator:24
190/0
PID190/0
Fuel supply
restricted until
engine speed is
below permitted
value.
190/2
PID190/2
Electrical error,
sensor rotation
speed/ignition mode;
no signal from any
sensors.
D794/Sensor:47, 50
Electrical error,
sensor rotation
speed/ignition mode,
one of two signals
missing.
No limitation.
D794/Sensor:47, 50
190/10
VDRT02.02GB
PID190/1
0
Code
D:47
Description
Limitation
Action
Connections and
components
Diagnostic menu
J1587
191/16
PID191/0
Speed limitation
activated.
Speed is reduced.
Reduce throttle
application.
191/18
PID191/1
Engine only
running at idle.
Increase throttle
application.
251/2
PID251/2
441/3
PID441/3
Extra temperature
sensor, short circuit
to ground.
No warning of
high temperature,
Control unit,
engine (D794).
D794/Sensor:12
No warning of
high temperature,
Control unit,
engine (D794).
Electrical error,
sensor accelerator
pedal, idle contact,
data error.
No limitation.
Electrical error,
sensor accelerator
pedal, idle contact,
cable short circuit to
ground.
Electrical error,
sensor accelerator
pedal, idle contact,
calibration error.
Engine only
running at idle.
441/4
558/2
558/4
558/13
PID441/4
SID230/2
SID230/4
SID230/1
3
Extra temperature
sensor, short circuit
to voltage.
D794/OEM:03, 13
D794/OEM:13
Check component.
Check cable between
control unit and
component.
Check component.
Check cable between
control unit and
component.
Check component.
608/2
SID250/2
Communication error
with Control unit,
engine (D794).
No limitation.
D794/OEM:26, 27,
36, 37, 46
608/9
SID250/9
Communication error
with Control unit,
engine (D794).
No limitation.
D794/OEM:26, 27,
36, 37, 46
620/3
SID232/3
Electrical error,
reference voltage
to sensor short circuit
to voltage.
Reduced engine
power. No warning
of low oil pressure
or low coolant
level.
D794/Sensor:18, 25,
45
Electrical error,
reference voltage
to sensor short circuit
to ground.
Reduced engine
power. No warning
of low oil pressure
or low coolant
level.
D794/Sensor:18, 25,
45
Electrical error to
control of relay
preheating.
Preheating not
working. Risk of
white smoke.
D794/Actuator:34
ENGINE,
menu 5
D794/OEM:7, 8, 17,
18, 28
1080/3
620/4
SID232/4
1081/4
626/11
SID237/1
1
629/12
SID251/2
SID254/1
2
Voltage feed
to control unit
disappears but
ignition not off.
Reduced engine
power. Engine
difficult to start or
dies.
Check fuses.
VDRT02.02GB
D:48
Code
Description
Limitation
Action
Connections and
components
Diagnostic menu
J1587
629/12
SID254/1
2
No limitation.
630/2
SID253/2
Software error
Control unit, engine
(D794).
Reduced engine
power. Engine
difficult to start or
dies.
632/3
SID017/3
No limitation.
D794/Actuator:33
The engine is
switched off.
D794/Actuator:33
632/4
SID017/4
639/2
SID231/2
Communication error
with Control unit,
engine (D794).
CAN/POWER,
menu 2
639/9
SID231/9
Communication error
with Control unit,
engine (D794).
CAN/POWER,
menu 2
639/9
SID231/9
Communication
error with Control
unit, engine (D794),
timeout error.
CAN/POWER,
menu 2
639/13
SID231/1
3
Communication
error with Control
unit, engine (D794),
configuration error.
CAN/POWER,
menu 2
644/2
SID030/2
Electrical error,
accelerator pedal,
signal not within valid
interval.
The engine is
switched off.
D794/Actuator:10,
Actuator:9
Electrical error,
injector cylinder 1,
open circuit on cable.
D794/Actuator:10,
Actuator:9
Electrical error,
injector cylinder 1,
cable short circuit to
ground.
D794/Actuator:10,
Actuator:9
Electrical error,
injector cylinder 2,
open circuit on cable.
D794/Actuator:7, 8
647/4
651/5
651/6
652/5
VDRT02.02GB
SID033/4
SID001/5
SID001/7
SID002/5
Code
652/6
653/5
653/6
654/5
654/6
655/5
655/6
656/5
656/6
702/3
SID003/5
SID003/6
SID004/5
SID004/6
SID005/5
SID005/6
SID006/5
SID006/6
SID040/3
PID154/3
703/3
974/3
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error,
injector cylinder 2,
cable short circuit to
ground.
D794/Actuator:7, 8
Electrical error,
injector cylinder 3,
open circuit on cable.
D794/Actuator:6, 16
Electrical error,
injector cylinder 3,
cable short circuit to
ground.
D794/Actuator:6, 16
Electrical error,
injector cylinder 4,
open circuit on cable.
D794/Actuator:26, 36
Electrical error,
injector cylinder 4,
cable short circuit to
ground.
D794/Actuator:26, 36
Electrical error,
injector cylinder 5,
open circuit on cable.
D794/Actuator:3, 4
Electrical error,
injector cylinder 5,
cable short circuit to
ground.
D794/Actuator:3, 4
Electrical error,
injector cylinder 6,
open circuit on cable.
D794/Actuator:1, 2
Electrical error,
injector cylinder 6,
cable short circuit to
ground.
D794/Actuator:1, 2
Electrical error,
auxiliary output 2,
cable short circuit to
voltage.
No limitation.
D794/Actuator:14
Electrical error,
auxiliary output 2,
cable short circuit to
voltage.
No limitation.
D794/Actuator:45
D794/OEM:21
J1587
SID002/6
SID051/3
SID029/3
D:49
Check component.
Check component.
Check component.
VDRT02.02GB
D:50
Code
974/4
Description
Limitation
Action
Connections and
components
Diagnostic menu
D794/OEM:21
J1587
SID029/4
974/19
SID029/2
Communication error
with Control unit, cab
(D790-1), electrical
error, accelerator
pedal.
CAN/POWER,
menu 2
1043/3
PID221/3
Electrical error,
accelerator pedal
reference voltage,
cable short circuit to
voltage.
Engine only
running at idle.
D794/OEM:48
Electrical error,
accelerator pedal
reference voltage,
cable short circuit to
ground.
Engine only
running at idle.
D794/OEM:48
Electrical error,
solenoid valve engine
brake 2.
Engine brake
1 cannot be
activated.
D794/Actuator: 44
D794/Actuator:44
D794/Sensor:17, 37
D794/Sensor:17, 37
D794/Actuator:24
1043/4
1072/11
PID221/4
SID070/1
1
1073/11
SID029/1
1
Electrical error,
solenoid valve engine
brake 2.
Engine brake
2 cannot be
activated.
1079/3
1079/4
1188/3
1189/3
1189/4
1265/4
VDRT02.02GB
SID232/3
SID232/4
SID032/3
SID088/3
SID88/4
SID085/4
Electrical error,
reference voltage
to sensor short circuit
to voltage.
Reduced engine
power.
Electrical error,
reference voltage
to sensor short circuit
to ground.
Reduced engine
power.
Electrical error,
solenoid valve
wastegate 1 short
circuit to voltage.
Reduced engine
power.
Electrical error,
solenoid valve
wastegate 2 short
circuit to voltage.
Reduced engine
power.
Electrical error,
wastegate solenoid
valve 2 short circuit
to ground.
Reduced engine
power.
Electrical error,
oil-burn solenoid
valve, cable short
circuit to ground.
No limitation.
D794/Actuator:23
D794/Actuator:23
Code
1319/2
Description
Limitation
Action
Connections and
components
Diagnostic menu
Reduced engine
power.
D794/Sensor:9
J1587
PID102/2
D:51
PID017/1
No limitation.
1383/31
SID151/1
1
No limitation.
1384/31
SID029/1
4
No limitation.
1387/3
PID223/3
No pressure guard
(customer-specific
option).
D794/Sensor:19
No pressure guard
(customer-specific
option).
D794/Sensor:19
No limitation.
1387/4
1484/31
PID223/4
SID216/1
1
VDRT02.02GB
D:52
Transmission
Error codes transmission
Control unit transmission can generate two states with reduced
functionality to protect the transmission in the event of serious
malfunctions:
Limp home
In this condition only gear 1-2 in each direction can be used. If
the error occurs in a higher gear then downshifting to gear 1 or 2
must take place manually.
Shut down
In this mode the transmission is permanently in neutral as there
is no oil pressure to enable gear selection.
Table Error codes Dana HR36000
Code
00/31
01/31
02/31
03/31
04/31
05/31
VDRT02.02GB
Description
Limitation
Action
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
Digital input 4,
active error. The
transmission control
unit activates Shut
down or Limp home
depending on speed.
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
SPN/FMI
520192
/31
520193
/31
520194
/31
520195
/31
520196
/31
520197
/31
Connections
and
components
Diagnostic
menu
D793/59
D793/58
D793/57
D793/56
D793/55
D793/54
Code
06/31
07/31
16/03
Description
Limitation
Action
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
No limitation.
SPN/FMI
520198
/31
520199
/31
520208/3
Analogue input 0,
short circuit to voltage.
D:53
Connections
and
components
Diagnostic
menu
D793/53
D793/52
D793/24
D793/25
520208/4
Analogue input 0,
short circuit to ground.
No limitation.
D793/24
D793/25
520208
/16
No limitation.
D793/24
D793/25
520208
/18
No limitation.
D793/24
D793/25
17/03
520208
/31
520209/3
Analogue input 0,
active error.
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
520209/4
No limitation.
D793/24
D793/25
D793/26
B766/1
TRANSM,
menu 10
D793/27
B766/2
D793/26
B766/1
TRANSM,
menu 10
D793/27
B766/2
VDRT02.02GB
D:54
Code
17/18
Description
Limitation
Action
No limitation.
SPN/FMI
520209
/18
Connections
and
components
Diagnostic
menu
D793/26
B766/1
TRANSM,
menu 10
D793/27
B766/2
520209
/16
No limitation.
D793/26
B766/1
TRANSM,
menu 10
D793/27
B766/2
520209
/13
No limitation.
D793/26
B766/1
TRANSM,
menu 10
D793/27
B766/2
520209
/31
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
18/03
520210/3
No limitation.
D793/26
B766/1
TRANSM,
menu 10
D793/27
B766/2
D793/28
B765/A
TRANSM,
menu 10
D793/29
B765/B
520210/4
No limitation.
D793/28
B765/A
TRANSM,
menu 10
D793/29
B765/B
520210
/16
No limitation.
D793/28
B765/A
TRANSM,
menu 10
D793/29
B765/B
520210
/18
No limitation.
D793/28
B765/A
TRANSM,
menu 10
D793/29
B765/B
520210
/13
No limitation.
D793/28
B765/A
TRANSM,
menu 10
D793/29
B765/B
520210
/31
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
VDRT02.02GB
D793/28
B765/A
D793/29
B765/B
TRANSM,
menu 10
Code
19/03
19/04
19/16
19/18
19/13
19/31
D:55
Connections
and
components
Diagnostic
menu
-
Description
Limitation
Action
Analogue input 3,
short circuit to voltage.
No limitation.
D793/13
Analogue input 3,
short circuit to ground.
No limitation.
D793/13
520211
/16
No limitation.
D793/13
520211
/18
No limitation.
D793/13 -
520211
/13
Analogue input 3,
incorrectly calibrated
No limitation.
D793/13
520211
/31
Analogue input 3,
active error.
No limitation or Shut
down while error is
active.
D793/13
D793/09
D793/09
D793/09
D793/09
D793/11
B751/2
SPN/FMI
520211/3
520211/4
D793/14
-
D793/14
-
D793/14
-
D793/14
-
D793/14
-
D793/14
520218/5
No limitation or Shut
down while error is
active.
D793/10
520218/6
No limitation or Shut
down while error is
active.
D793/10
520218
/10
No limitation or Shut
down while error is
active.
D793/10
27/05
520218
/31
520219/5
Speed input 0,
active error. The
transmission control
unit activates Shut
down or Limp home
depending on speed.
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
D793/10
TRANSM,
menu
D793/12
B751/1
VDRT02.02GB
D:56
Code
27/06
Description
Limitation
Action
No limitation or Shut
down while error is
active.
SPN/FMI
520219/6
520219
/10
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
27/31
520219
/31
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
32/03
552022
4/3
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
32/04
520224/4
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
32/05
32/31
520224/5
520224
/31
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
33/03
520225/3
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
33/04
520225/4
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
VDRT02.02GB
Connections
and
components
Diagnostic
menu
D793/11
B751/2
TRANSM,
menu
D793/12
B751/1
D793/11
B751/2
TRANSM,
menu
D793/12
B751/1
D793/11
B751/2
TRANSM,
menu
D793/12
B751/1
D793/33
Y630/1
TRANSM,
menu
D793/34
Y630/2
D793/33
Y630/1
TRANSM,
menu
D793/34
Y630/2
D793/33
Y630/1
TRANSM,
menu
D793/34
Y630/2
D793/33
Y630/1
TRANSM,
menu
D793/34
Y630/2
D793/31
Y631/1
TRANSM,
menu
D793/32
Y631/2
D793/31
Y631/1
D793/32
Y631/2
TRANSM,
menu
Code
33/05
33/31
Description
Limitation
Action
No limitation or Shut
down while error is
active.
SPN/FMI
520225/5
520225
/31
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
34/03
520226/3
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
34/04
520226/4
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
34/05
34/31
520226/5
520226
/31
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
35/03
520227/3
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
35/05
35/31
520227/5
520227
/31
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
D:57
Connections
and
components
Diagnostic
menu
D793/31
Y631/1
TRANSM,
menu
D793/32
Y631/2
D793/31
Y631/1
TRANSM,
menu
D793/32
Y631/2
D793/48
Y60671/1
TRANSM,
menu
D793/49
Y60672/2
D793/48
Y60671/1
TRANSM,
menu
D793/49
Y60672/2
D793/48
Y60671/1
TRANSM,
menu
D793/49
Y60672/2
D793/48
Y60671/1
TRANSM,
menu
D793/49
Y60672/2
D793/18
Y6069/1
TRANSM,
menu
D793/19
Y6069/2
D793/18
Y6069/1
TRANSM,
menu
D793/19
Y6069/2
D793/18
Y6069/1
TRANSM,
menu
D793/19
Y6069/2
VDRT02.02GB
D:58
Code
36/03
Description
Limitation
Action
No limitation or Shut
down while error is
active.
SPN/FMI
520228/3
520228/4
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
36/05
36/31
520228/5
520228
/31
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
No limitation or Shut
down while error is
active.
For inactive error
code, Limp home until
ignition is switched off.
37/03
520229/3
Connections
and
components
D793/46
Y60673/1
TRANSM,
menu
D793/47
Y60673/2
D793/46
Y60673/1
TRANSM,
menu
D793/47
Y60673/2
D793/46
Y60673/1
TRANSM,
menu
D793/47
Y60673/2
D793/46
Y60673/1
TRANSM,
menu
D793/47
Y60673/2
D793/17
D793/17
D793/17
No limitation or Shut
down while error is
active.
D793/17
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
Diagnostic
menu
D793/18
520229/4
No limitation or Shut
down while error is
active.
D793/18
520229/5
No limitation or Shut
down while error is
active.
D793/18
38/03
520229
/31
520230/3
VDRT02.02GB
D793/18
D793/35
D793/50
Code
38/04
Connections
and
components
Diagnostic
menu
-
Description
Limitation
Action
No limitation or Shut
down while error is
active.
D793/35
D793/35
No limitation or Shut
down while error is
active.
D793/35
No limitation or Shut
down while error is
active.
D793/01
D793/01
D793/01
D793/01
No limitation or Shut
down while error is
active.
D793/01
No limitation or Shut
down while error is
active.
SPN/FMI
520230/4
D:59
D793/50
520230/5
No limitation or Shut
down while error is
active.
D793/50
39/03
520230
/31
520231/3
D793/50
D793/02
520231/4
No limitation or Shut
down while error is
active.
D793/02
520231/5
No limitation or Shut
down while error is
active.
D793/02
520231/6
No limitation or Shut
down while error is
active.
D793/02
40/03
520231
/31
520232/3
D793/02
D793/03
D793/04
VDRT02.02GB
D:60
Code
40/04
Diagnostic
menu
-
Description
Limitation
Action
No limitation or Shut
down while error is
active.
D793/03
D793/03
D793/03
No limitation or Shut
down while error is
active.
D793/03
Declutch of
transmission with
declutch pedal does
not work.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Declutch of
transmission with
declutch pedal does
not work.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Declutch of
transmission with
declutch pedal does
not work.
SPN/FMI
520232/4
Connections
and
components
D793/04
520232/5
No limitation or Shut
down while error is
active.
D793/04
520232/6
No limitation or Shut
down while error is
active.
D793/04
48/09
48/19
48/31
VDRT02.02GB
520230
/31
520240/9
520240
/19
520240
/31
Incorrect declutch
signal via the CAN
bus.
Incorrect declutch
signal via the CAN
bus.
Incorrect declutch
signal via the CAN
bus.
D793/04
CAN/POWER,
menu 3
CAN/POWER,
menu 3
Code
49/09
49/19
49/31
50/09
50/19
50/31
Description
Limitation
Action
Connections
and
components
Incorrect gear
programme selection
via the CAN bus.
Transmission control
unit does not allow
change of gear range,
however, operation of
machine is possible.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Transmission control
unit does not allow
change of gear range,
however, operation of
machine is possible.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
SPN/FMI
520241/9
520241
/19
520241
/31
520242/9
520242
/19
520242
/31
D:61
Incorrect gear
programme selection
via the CAN bus.
Incorrect gear
programme selection
via the CAN bus.
Incorrect kickdown
signal via the CAN
bus.
Incorrect kickdown
signal via the CAN
bus.
Incorrect kickdown
signal via the CAN
bus.
Transmission control
unit does not allow
change of gear range,
however, operation of
machine is possible.
Diagnostic
menu
CAN/POWER,
menu 3
CAN/POWER,
menu 3
CAN/POWER,
menu 3
520243/9
Incorrect neutral
position signal via
the CAN bus.
The transmission
is locked in neutral
position.
VDRT02.02GB
D:62
Code
51/19
51/31
Description
Limitation
Action
Connections
and
components
Incorrect neutral
position signal via
the CAN bus.
The transmission
is locked in neutral
position.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
SPN/FMI
520243
/19
520243
/31
Incorrect neutral
position signal via
the CAN bus.
The transmission
is locked in neutral
position.
Diagnostic
menu
CAN/POWER,
menu 3
52/09
52/19
52/31
520244/2
520244/9
520244
/19
520244
/31
No limitation.
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
CAN/POWER,
menu 3
VDRT02.02GB
520245/2
No limitation.
Code
53/09
53/19
53/31
Description
Limitation
Action
Connections
and
components
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
SPN/FMI
520245/9
520245
/19
520245
/31
D:63
No limitation.
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
CAN/POWER,
menu 3
57/19
57/31
520249/9
520249
/19
520249
/31
Incorrect parking
brake signal via the
CAN bus.
Incorrect parking
brake signal via the
CAN bus.
Incorrect parking
brake signal via the
CAN bus.
The transmission
is locked in neutral
position.
The transmission
is locked in neutral
position.
The transmission
is locked in neutral
position.
CAN/POWER,
menu 3
520250/9
No limitation.
VDRT02.02GB
D:64
Code
58/19
58/31
Description
Limitation
Action
Connections
and
components
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
SPN/FMI
520250
/19
520250
/31
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
59/19
59/31
60/09
60/19
VDRT02.02GB
520251/9
520251
/19
520251
/31
520252/9
520252
/19
No limitation.
No limitation.
No limitation.
Incorrect high/low
gear signal via the
CAN bus.
No limitation.
Incorrect high/low
gear signal via the
CAN bus.
CAN/POWER,
menu 3
No limitation.
CAN/POWER,
menu 3
Code
60/31
Connections
and
components
Diagnostic
menu
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Description
Limitation
Action
Incorrect high/low
gear signal via the
CAN bus.
No limitation.
SPN/FMI
250252
/31
D:65
61/19
61/31
520253/9
520253
/19
520253
/31
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
520254/1
Risk of slipping
clutches.
Check the
transmission oil level.
Check the sensor.
62/09
62/19
520254/9
520254
/19
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
D:66
Code
62/31
Connections
and
components
Diagnostic
menu
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Description
Limitation
Action
No limitation.
SPN/FMI
520254
/31
63/19
63/31
520255/9
520255
/19
520255
/31
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
64/19
64/31
520256/9
520256
/19
520256
/31
No limitation.
No limitation.
No limitation.
VDRT02.02GB
CAN/POWER,
menu 3
Code
65/09
65/19
65/31
Description
Limitation
Action
Connections
and
components
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
SPN/FMI
520257/9
520257
/19
520257
/31
D:67
No limitation.
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
CAN/POWER,
menu 3
66/19
66/31
520258/9
520258
/19
520258
/31
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
520260/0
Check the
transmission oil cooler,
clean if necessary.
Check the thermostat
in the transmission oil
cooler.
VDRT02.02GB
D:68
Code
68/09
68/19
68/31
Description
Limitation
Action
Connections
and
components
Incorrect transmission
oil temperature via the
CAN bus.
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
SPN/FMI
520260/9
520260
/19
520260
/31
Incorrect transmission
oil temperature via the
CAN bus.
Transmission oil
temperature, active
error.
No limitation.
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
CAN/POWER,
menu 3
69/19
68/31
520261/9
520261
/19
520261
/31
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
520262/9
No limitation.
Code
70/19
70/31
Description
Limitation
Action
Connections
and
components
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
SPN/FMI
520262
/19
520262
/31
D:69
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
71/19
71/31
520263/9
520263
/19
520263
/31
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
72/19
520264/9
520264
/19
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
D:70
Code
72/31
Description
Limitation
Action
No limitation.
SPN/FMI
520264
/31
Connections
and
components
Diagnostic
menu
520276/2
No limitation.
84/09
520276/9
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
84/19
84/31
520276
/19
520276
/31
No limitation.
No limitation.
CAN/POWER,
menu 3
85/19
VDRT02.02GB
520277/9
520277
/19
No limitation.
No limitation.
CAN/POWER,
menu 3
Code
85/31
Connections
and
components
Diagnostic
menu
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Description
Limitation
Action
Signal customer
function 1, active
error.
No limitation.
SPN/FMI
520277
/31
D:71
86/19
86/31
520278/9
520278
/19
520278
/31
Signal customer
function 2, active
error.
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
87/19
87/31
520279/9
520279
/19
520279
/31
Signal customer
function 3, active
error.
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
D:72
Code
88/09
88/19
88/31
Description
Limitation
Action
Connections
and
components
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
SPN/FMI
520280/9
520280
/19
520280
/31
Signal customer
function 4, active
error.
No limitation.
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
CAN/POWER,
menu 3
89/19
89/31
520281/9
520281
/19
520281
/31
Signal customer
function 5, active
error.
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
520282/9
No limitation.
Code
90/19
90/31
Description
Limitation
Action
Connections
and
components
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
SPN/FMI
520282
/19
520282
/31
D:73
Signal customer
function 6, active
error.
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
91/19
91/31
520283/9
520283
/19
520283
/31
Signal customer
function 7, active
error.
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
92/19
520284/9
520284
/19
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
D:74
Code
92/31
Connections
and
components
Diagnostic
menu
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Description
Limitation
Action
Signal customer
function 8, active
error.
No limitation.
SPN/FMI
520284
/31
93/19
93/31
520285/9
520285
/19
520285
/31
Signal customer
function 9, active
error.
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
94/19
94/31
520286/9
520286
/19
520286
/31
Signal customer
function 10, active
error.
No limitation.
No limitation.
No limitation.
VDRT02.02GB
CAN/POWER,
menu 3
Code
95/02
Connections
and
components
Diagnostic
menu
Description
Limitation
Action
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
No limitation or Shut
down while error is
active.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
No limitation or Shut
down while error is
active.
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
SPN/FMI
520287/2
D:75
95/19
95/31
96/02
520287/9
520287
/19
520287
/31
520288
/02
CAN/POWER,
menu 3
96/19
520288
/09
520288
/19
Incorrect accelerator
pedal signal via the
CAN bus.
Incorrect accelerator
pedal signal via the
CAN bus.
No limitation.
No limitation.
CAN/POWER,
menu 3
VDRT02.02GB
D:76
Code
96/31
Connections
and
components
Diagnostic
menu
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Description
Limitation
Action
Signal accelerator
pedal, active error.
No limitation.
SPN/FMI
520288
/31
520289/2
No limitation.
97/09
97/19
97/31
520289/9
520289
/19
520289
/31
No limitation.
No limitation.
No limitation.
CAN/POWER,
menu 3
520290/0
Transmission oil
temperature too high
sump.
Transmission locked
in neutral position
(Shut down).
Check the
transmission oil cooler,
clean if necessary.
Check the thermostat
in the transmission oil
cooler.
98/02
98/16
520290/2
520290
/16
Incorrect signal
from sensor for
transmission oil
temperature sump.
Transmission locked
in neutral position
(Shut down).
No limitation.
VDRT02.02GB
Code
98/31
Description
Limitation
Action
Signal transmission
oil temperature sump,
active error.
No limitation.
SPN/FMI
520290
/31
D:77
Connections
and
components
Diagnostic
menu
520291/0
Transmission oil
temperature too high,
radiator.
Transmission locked
in neutral position
(Shut down).
Check the
transmission oil cooler,
clean if necessary.
Check the thermostat
in the transmission oil
cooler.
99/02
99/16
520291/2
520291
/16
Incorrect signal
from sensor for
transmission oil
temperature radiator.
Transmission locked
in neutral position
(Shut down).
No limitation.
99/31
520291
/31
Signal transmission
oil temperature cooler,
active error.
No limitation.
101/01
520293/1
Risk of slipping
clutches
Check the
transmission oil level
Check the sensor.
101/02
520293/2
Incorrect signal
oil pressure
transmission.
Transmission in locked
neutral position (Shut
down).
101/31
520293
/31
No limitation.
102/00
520294/0
Clutch pressure,
clutch forward, too
high.
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
VDRT02.02GB
D:78
Code
102/02
Description
Limitation
Action
No limitation.
SPN/FMI
520294/2
Connections
and
components
Diagnostic
menu
520294
/16
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
102/31
520294
/31
No limitation.
103/00
520295/0
No limitation.
Clutch pressure,
clutch reverse, too
high.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
103/02
520294/2
No limitation.
103/16
520295
/16
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
103/31
520295
/31
No limitation.
104/00
520296/0
No limitation.
Clutch pressure,
clutch forward high
gear, too high.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
104/02
520296/2
No limitation.
VDRT02.02GB
Code
104/16
Description
Limitation
Action
No limitation.
Check the
transmission oil level
SPN/FMI
520296
/16
D:79
Connections
and
components
Diagnostic
menu
104/31
520296
/31
No limitation.
105/00
520297/0
No limitation.
Clutch pressure,
clutch gear 1, too
high.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
105/02
520297/2
No limitation.
105/16
520297
/16
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
105/31
520297
/31
No limitation.
106/00
520298/0
No limitation.
Clutch pressure,
clutch gear 2, too
high.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
106/02
520298/2
No limitation.
106/16
520298
/16
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
VDRT02.02GB
D:80
Code
106/31
Description
Limitation
Action
No limitation.
SPN/FMI
520298
/31
Connections
and
components
Diagnostic
menu
520299/0
No limitation.
Clutch pressure,
clutch gear 3, too
high.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
107/02
520299/2
No limitation.
107/16
520299
/16
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
107/31
520299
/31
No limitation.
108/00
520300/0
No limitation.
Clutch pressure,
clutch gear 4, too
high.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
108/02
520300/2
No limitation.
108/16
520300
/16
No limitation.
Check the
transmission oil level
Check the sensor.
Check the hydraulics
in the transmission.
108/31
520300
/31
No limitation.
VDRT02.02GB
Code
122/02
122/09
122/19
122/31
123/02
520314/9
520314
/19
520314
/31
520315/2
520315
/31
124/31
520316/2
520316
/31
CAN/POWER,
menu 3
Action
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
No limitation or Shut
down while error is
active.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
No limitation or Shut
down while error is
active.
No limitation or Shut
down while error is
active.
D793/11
B751/2
No limitation.
Incorrect signal
rotation speed drum.
CAN/POWER,
menu 3
D793/12
B751/1
124/02
Diagnostic
menu
Limitation
Connections
and
components
Description
SPN/FMI
520314/0
D:81
No limitation or Shut
down while error is
active.
No limitation.
D793/11
B751/2
D793/12
B751/1
VDRT02.02GB
D:82
Code
125/02
125/31
Description
Limitation
Action
Incorrect signal
rotation speed output
shaft.
No limitation or Shut
down while error is
active.
No limitation.
SPN/FMI
520317/2
520317
/31
Connections
and
components
Diagnostic
menu
D793/45
CAN/POWER,
menu 15
D793/45
CAN/POWER,
menu 15
D793/45
CAN/POWER,
menu 15
D793/45
CAN/POWER,
menu 15
D793/20
CAN/POWER,
menu 15
144/01
144/16
144/18
520336/0
520336/1
520336
/16
520336
/18
Control unit,
transmission (D793),
battery voltage too
high.
Transmission locked
in neutral position
(Shut down).
Control unit,
transmission (D793),
battery voltage too
low.
Transmission locked
in neutral position
(Shut down).
Control unit,
transmission (D793),
battery voltage high.
No limitation.
Control unit,
transmission (D793),
battery voltage low.
No limitation.
If equipment for
assisted start is
connected, disconnect
it.
Check alternator,
battery and cable
harness between
battery and alternator.
Check the voltage
feed.
If equipment for
assisted start is
connected, disconnect
it.
Check the cable
harness to the control
unit.
Check alternator,
battery and cable
harness between
battery and alternator.
145/00
145/01
VDRT02.02GB
520337/0
520337/1
Control unit,
transmission (D793),
ignition voltage too
high.
Transmission locked
in neutral position
(Shut down).
Control unit,
transmission (D793),
ignition voltage too
low.
Transmission locked
in neutral position
(Shut down).
D793/60
If equipment for
assisted start is
connected, disconnect
it.
Check alternator,
battery and cable
harness between
battery and alternator.
D793/20
D793/60
CAN/POWER,
menu 15
Code
145/16
145/18
Description
Limitation
Action
Control unit,
transmission (D793),
ignition voltage high.
No limitation.
Control unit,
transmission (D793),
ignition voltage low.
No limitation.
SPN/FMI
520337
/16
520337
/18
D:83
Connections
and
components
D793/20
D793/60
If equipment for
assisted start is
connected, disconnect
it.
Check the cable
harness to the control
unit.
D793/20
D793/60
Diagnostic
menu
CAN/POWER,
menu 15
CAN/POWER,
menu 15
Check alternator,
battery and cable
harness between
battery and alternator.
154/12
520346
/12
Control unit,
transmission (D793),
memory error.
Transmission locked
in neutral position
(Shut down).
154/31
520346
/31
Control unit,
transmission (D793),
memory error.
Transmission locked
in neutral position
(Shut down).
155/31
520347
/31
Control unit,
transmission (D793),
memory error.
Transmission locked
in neutral position
(Shut down).
156/31
520348
/31
Control unit,
transmission (D793),
memory error.
Transmission locked
in neutral position
(Shut down).
161/31
520353
/31
Incorrect
configuration.
No limitation.
162/31
520354
/31
Incorrect
configuration.
No limitation.
163/31
520355
/31
Incorrect
configuration.
No limitation.
164/31
520356
/31
Incorrect
configuration.
No limitation.
176/31
520368
/31
No limitation.
520371
/31
No limitation.
VDRT02.02GB
D:84
Code
180/31
Connections
and
components
Diagnostic
menu
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
CAN/POWER,
menu 3
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Description
Limitation
Action
No limitation.
SPN/FMI
520372
/31
520373
/31
Output speed
limitation, active error.
No limitation.
182/31
520374
/31
No limitation.
183/31
520375
/31
No limitation.
184/31
520376
/31
No limitation.
185/31
520377
/31
No limitation.
193/09
194/09
VDRT02.02GB
520385/9
520386/9
Control unit,
cab (D790-1),
communication error.
Control unit,
cab (D790-1),
communication error.
No limitation.
No limitation.
CAN/POWER,
menu 3
Code
195/09
197/09
198/09
Description
Limitation
Action
Connections
and
components
Control unit,
cab (D790-1),
communication error.
No limitation.
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
Use diagnostic
menu to check
communication.
D793/22
D7901/K13:1
D7901/K13:1
D793/23
SPN/FMI
520387/9
520389/9
520390/9
D:85
Control unit,
cab (D790-1),
communication error.
Control unit,
cab (D790-1),
communication error.
No limitation.
No limitation.
Diagnostic
menu
CAN/POWER,
menu 3
CAN/POWER,
menu 3
CAN/POWER,
menu 3
240/XX
520432
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
241/XX
520433
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
242/XX
520434
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
243/XX
520435
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
244/XX
520436
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
245/XX
520437
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
246/XX
520438
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
247/XX
520439
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
248/XX
520440
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
VDRT02.02GB
D:86
Code
Description
Limitation
Action
SPN/FMI
Connections
and
components
Diagnostic
menu
249/XX
520441
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
250/XX
520442
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
251/XX
520443
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
253/XX
520444
/XX
Incorrect
configuration.
No limitation.
Reprogram Control
unit, transmission
(D793).
VDRT02.02GB
D:87
Control system
Error codes machine
Table Error codes machine
Code
Connections and
components
Diagnostic menu
Group
Description
Limitation
Action
Communication error
with Control unit,
attachment (D791-1).
Attachment functions
not working.
D791-1
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit,
attachment option
(D791-2).
Levelling, tilt,
overheight extension
not working.
D791-2
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit,
attachment left jack
pair (D791-3).
D791-3
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit,
attachment right jack
pair (D791-4).
D791-4
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit,
frame rear (D797-R).
D797-R
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit,
frame front (D797-F).
D797-F
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication
error with Control
unit, frame option
(D797-O).
D797-O
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit KID
(D795).
Controls in steering
wheel panel and
display not working.
D795
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
Communication error
with Control unit, cab
option (D790-3).
Mini-wheel or joystick
control not working.
D790-3
CAN/POWER,
menu 2
11.6.2
Redundant
CAN bus
11
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
12
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
13
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
VDRT02.02GB
D:88
Code
Connections and
components
Diagnostic menu
Group
Description
Limitation
Action
14
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
15
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
16
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
17
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
18
No limitation.
Varies depending on
machine
configuration.
CAN/POWER,
menu 1
and 21
11.6.2
Redundant
CAN bus
20
Accelerator pedal
(B690) not calibrated.
Poor sensitivity in
accelerator pedal.
Calibrate the
accelerator pedal.
See section 8 Control
system, group
8.5.2.3 Calibrate
DRIVE-TRAIN.
D7901/K6:11
B690
CALIBRATION:
DRIVETRAIN,
menu 1
and 2
1. Engine
21
Communication error
with Control unit,
transmission (D793).
Use diagnostic
menu to check
communication.
D7901/K13:1
D793/M2
CAN/POWER,
menu 3
11.6.3
CAN bus
drive-train
D7901/K13:2
D793/L2
Use diagnostic
menu to check
communication.
Yuchai:
D7901/K13:1,
K13:2
D794/1:34,
1:35
CAN/POWER,
menu 3
11.6.3
CAN bus
drive-train
22
Communication error
with Control unit,
engine (D794).
Cummins:
D7901/K13:1,
K13:2
D794/46,
37
23
Contact Cargotec
support.
D790-1
11.5.3.1
Control
unit, cab
24
D7901/K2:8
58-5/3:2
9.4.3
Cabin fan
VDRT02.02GB
Code
25
26
27
28
29
Description
Limitation
Action
Interference during
software download.
Buffer for error codes
from Control unit,
engine (D794), active
error code when
downloading.
D:89
Connections and
components
Diagnostic menu
Group
D794
ENGINE,
menu 8
11.5.3.10
Engine
control unit
D7901/K1:2,
K1:3,
K1:4
F58-5/1:1,
1:2
CAN/POWER,
menu 6
11.5.1.3
Ignition
voltage
(15)
D7901/K4:5,
K 5:11,
K5:13,
K7:2, K
9:7, K10:3
CAN/POWER,
menu 6
11.5.3.1
Control
unit, cab
D7901/K11:13
K30091/87
CAN/POWER,
menu 5
11.5.1.4
Emergency stop
switch voltage (15E)
D7911/K8:5
S107/7
HYD,
menu 5
4.5
Parking
brake
D793
TRANSM,
menu 13
11.5.3.9
Transmission control unit
D7901/K2:4
M650-2/53
CAB,
menu 3
9.5.7
Wiper
motor rear
D7901/K2:5
H428
LIGHTS,
menu 9
9.6.8
Revolving
beacon
Repeat software
download.
30
31
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the control unit.
32
Incorrect 5 V reference
voltage to analogue
cab controls. Voltage
below 4.9 V or above
5.1 V.
Analogue controls
in cab not working
(mini-wheel/steering
lever and controls for
air conditioning).
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the component.
33
34
35
36
37
38
39
No feedback signal
for emergency stop
switch voltage from
Relay, emergency
stop switch voltage
(K3009-1).
Control breaker
cannot be disengaged.
All hydraulic functions
are blocked.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Interference during
software download.
Buffer for error codes
from Control unit,
transmission (D793),
active error code when
downloading.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D7911/K8:13
S107/1
Repeat software
download.
40
41
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the component.
VDRT02.02GB
D:90
Code
43
44
45
Description
Limitation
Action
Check bulb.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Connections and
components
Diagnostic menu
Group
D7901/K2:6
E404-1L
LIGHTS,
menu 1
9.6.9
Working
light, cab
D7901/K2:7
E404-1R
LIGHTS,
menu 1
9.6.9
Working
light, cab
D7901/K2:1
M650-1/53
CAB,
menu 2
9.5.1
Wiper front
D7901/K2:2
M657-1/2
CLIMATE,
menu 6
9.4.3
Cabin fan
D7901/K2:3
M612/3
CLIMATE,
menu 6
9.4.2
Fresh air
and recirculation
damper
D7901/K4:1
Y673/5
CLIMATE,
menu 7
9.4.5
Water
valve
D7901/K4:2
Y673/6
CLIMATE,
menu 7
9.4.5
Water
valve
D7901/K4:3
Y672/5
CLIMATE,
menu 8
9.4.14 Air
distributor
D7901/K4:4
Y672/6
CLIMATE,
menu 8
9.4.14 Air
distributor
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
47
48
Recirculation damper
for ventilation not
working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
49
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
50
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
51
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
VDRT02.02GB
Code
53
54
55
56
57
60
61
62
Description
Limitation
Action
Windscreen washer
rear and roof not
working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Reduced or no
background lighting
in instruments and
controls.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D:91
Connections and
components
Diagnostic menu
Group
D7901/K5:4
M651-2
CAB,
menu 1
9.5.4
Washer
motor and
reservoir
D7901/K5:5
S109/9
LIGHTS,
menu 7
9.6.7
Flashing
hazard
lights
D7901/K6
:1, K 8:15,
K 9:2, K
10:5, all
inputs of
type A Digital in
LIGHTS,
menu 13
D7901/K7:8
S815/5
7.1.1
Control
lever
D7901/K7:9
S815/7
7.1.1
Control
lever
D7901/K10:7
K383/86
CAB,
menu 8
9.3.3
Heating
coil
D7901/K10:8
K304/86
LIGHTS,
menu 3
9.6.10
Working
lights,
boom
D7901/K10:9
P708,
K358/86
CAN/POWER,
menu 7
9.3.5 Air
suspension
VDRT02.02GB
D:92
Code
63
64
65
66
67
68
69
71
74
Description
Limitation
Action
No ignition voltage to
the machine's Control
units.
Check cabling
between the
control unit and
the component with
diagnostic menu.
No emergency stop
switch voltage to the
machine's Control
units.
No emergency stop
switch voltage to the
machine's Control
units.
No voltage feed
to engine and
transmission.
VDRT02.02GB
Connections and
components
Diagnostic menu
Group
D7901/K10:10
K315-1/86
CAN/POWER,
menu 4
11.5.1.3
Ignition
voltage
(15)
D7901/K10:11
K30091/86
CAN/POWER,
menu 5
11.5.1.4
Emergency stop
switch voltage
D7901/K10:11
K30091/86
CAN/POWER,
menu 5
11.5.1.4
Emergency stop
switch voltage
D7901/K10:13
M651-1
CAB,
menu 1
9.5.4
Washer
motor and
reservoir
D7901/K10:14
M650-3/53
CAB,
menu 4
9.5.6
Wiper
motor roof
D7901/K10:15
M667
D7901/K10:16
K315-2/86
CAN/POWER,
menu 4
11.5.1.3
Ignition
voltage
(15)
D7901/K11:6
E434-1
LIGHTS,
menu 12
9.6.12
Interior
lighting
cab
D7901/K11:11
H850/1,
K3016/86
CAB,
menu 5
9.7.1 Horn
Code
75
Description
Limitation
Action
Check cabling
between the
control unit and
the component with
diagnostic menu.
D:93
Connections and
components
Diagnostic menu
Group
CAN/POWER,
menu 4
11.5.1.3
Ignition
voltage
D797R/K1:37
S246
CLIMATE,
menu 3
9.4.10
Pressure
switch
D7901/K4:7
Y672/9
CLIMATE,
menu 4
9.4.6
Fresh air
and recirculation
damper
D7901/K6:11
R690/2
ENGINE,
menu 1
1 Engine
D7901/K7:3
S815-P1/8
BOOM,
menu 1
7.1.1
Control
lever
D7901/K7:4
S815-P2/4
BOOM,
menu 1
7.1.1
Control
lever
D7901/K7:5
S815P3/11
ATTACH,
menu 1
7.1.1
Control
lever
D7901/K7:6
S815-P4/1
ATTACH,
menu 1
7.1.1
Control
lever
No signal from
Pressure switch,
air conditioning
(S246), despite the
AC compressor being
activated.
81
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
85
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the component.
87
88
89
Incorrect signal
from Control lever
(S815-P1) for
lifting/lowering. Signal
voltage below 0.2 V or
above 4.8 V.
Incorrect signal
from Control lever
(S815-P2) for
extension. Signal
voltage below 0.2 V or
above 4.8 V.
Incorrect signal
from Control lever
(S815-P3) for rotation.
Signal voltage below
0.2 V or above 4.8 V.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the switch.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the switch.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the switch.
90
Incorrect signal
from Control lever
(S815-P4) for tilt.
Signal voltage below
0.2 V or above 4.8 V.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the switch.
VDRT02.02GB
D:94
Code
92
93
Description
Limitation
Action
Incorrect signal
from Steering
lever (R825-1) or
Mini-wheel (R825-1).
Signal voltage below
0.2 V or above 4.8 V.
Joystick control
or mini-wheel not
working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Joystick control
or mini-wheel not
working.
Connections and
components
Diagnostic menu
Group
D7901/K9:8
R825-1/P2
STEERING, menu
1
5.1.2 Miniwheel
D7901/K9:9
R825-2/H2
STEERING, menu
1
5.1.2 Mini
steering
wheel
D7901/K10:4
Y673/9
CLIMATE,
menu 4
9.4.5
Water
valve
D7901/K4:8
B775-1/2
CLIMATE,
menu 1
9.4.17
Sensor
cab temperature
D7901/K4:9
B774/2
CLIMATE,
menu 2
9.4.18
Sensor,
ambient
temperature
D7901/K4:10
B775-2/2
CLIMATE,
menu 2
9.4.16
Sensor,
temperature outlet
fan
D7901/K4:11
B775-3/2
CLIMATE,
menu 2
9.4.12
Sensor
temperature refrigerant
D797F/K2:7
CAN/POWER,
menu 8
11.5.1.2
Redundant
voltage
feed of
Control
units
D797F/K2:8
CAN/POWER,
menu 8
11.5.1.2
Redundant
voltage
feed of
Control
units
5.1.3
Joystick
94
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the motor.
96
97
Incorrect signal
from Sensor, cab
temperature (B775-1).
Sensor indicates
temperature below -43
C or above 105 C.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
98
99
101
Redundant voltage
feed left to Control
unit, frame front
(D797-F) does not
reach destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the control unit.
102
Redundant voltage
feed right to Control
unit, frame front
(D797-F) does not
reach destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the control unit.
VDRT02.02GB
Code
103
104
105
Description
Limitation
Action
Incorrect power
supply to Control unit,
frame front (D797-F).
Voltage below 18 V or
above 32 V.
Incorrect emergency
stop switch voltage
to Control unit, frame
front (D797-F).
Functions normally
supplied emergency
stop switch voltage
have no feed. All
hydraulic functions are
blocked.
Incorrect 5 V reference
voltage to pressure
sensor. Voltage below
4.9 V or above 5.1 V.
Regeneration lift,
weight indicator and
overload system not
working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
106
Check cabling
between the
control unit and
the component with
diagnostic menu.
D:95
Connections and
components
Diagnostic menu
Group
D797F/K2:1,
K2:9,
K2:10
F58-2/1:1,
1:2
CAN/POWER,
menu 8
11.5.1.3
Ignition
voltage
(15)
D797F/K2:11
F58-3/2:1
CAN/POWER,
menu 8
11.5.1.4
Emergency stop
switch voltage
D797F/K1:8
B768R1/1,
B768R2/1,
B768-L1/1,
B768-L2/1
CAN/POWER,
menu 9
8.2.1.7
Sensor,
hydraulic
pressure
lift cylinder
D797F/K1:14
M674/1
HYD,
menu 2
4.8.8
Cooling
fan
D797F/K1:1
E402L/1
LIGHTS,
menu 6
9.6.1
Headlights
D797F/K1:15
E402R/1
LIGHTS,
menu 6
9.6.1
Headlights
D797F/K1:42
E400L/1,
E400R/1
LIGHTS,
menu 6
9.6.1
Headlights
D797F/K1:2
Y6005/1
BOOM,
menu 4
7.2.5
Control
valve lift,
lower and
extension
108
110
111
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the solenoid
valve.
VDRT02.02GB
D:96
Code
112
113
114
115
116
117
118
119
Description
Limitation
Action
Check cabling
between the
control unit and
the component with
diagnostic menu.
Extension in not
working.
VDRT02.02GB
Connections and
components
Diagnostic menu
Group
D797F/K1:3
Y6004/1
BOOM,
menu 5
7.2.5
Control
valve lift,
lower and
extension
D797F/K1:4
Y6006/1
BOOM,
menu 7
7.3.5
Control
valve lift,
lower and
extension
D797F/K1:5
Y6007/1
BOOM,
menu 6
7.3.5
Control
valve lift,
lower and
extension
D797F/K1:30
Y6002/1
BOOM,
menu 2
7.2.7 Valve
block lift
cylinder
D797F/K1:31
Y6001/1
BOOM,
menu 2
7.2.7 Valve
block lift
cylinder
D797F/K1:32
Y6051/1
BOOM,
menu 3
7.2.7 Valve
block lift
cylinder
D797F/K1:33
Y6052/1
BOOM,
menu 3
7.2.7 Valve
block lift
cylinder
D797F/K1:7
Y642/1
HYD,
menu 5
4.5.3
Solenoid
valve
parking
brake
Code
120
121
122
123
124
Description
Limitation
Action
Check bulb.
Direction indicator
right front not working.
Incorrect 24 V
reference voltage
to Break contact
(opening switch)
parking brake (S200),
Break contact
(opening switch)
low brake pressure
(S204), Make-contact
(closing switch)
brake lights (S216)
and Break contact
(opening switch)
declutch (S220-2).
D:97
Connections and
components
Diagnostic menu
Group
D797F/K1:9
H422/1
LIGHTS,
menu 8
9.6.6
Direction
indicators
D797F/K1:10
H423/1
LIGHTS,
menu 8
9.6.6
Direction
indicators
D797F/K1:25
H416-1/1
LIGHTS,
menu 5
9.6.2
Running
lights
D797F/K1:29
H417-1/1
LIGHTS,
menu 5
9.6.2
Running
lights
D797F/K1:39
S200/1,
S204/1,
S216/1,
S220/1
CAN/POWER,
menu 9
4.5.5
Break
contact
(opening
switch)
parking
brake
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
4.3.8
Makecontact
(closing
switch)
brake
lights
4.3.7
Break
contact
(opening
switch)
brake
pressure
133
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D797F/K1:21
B768-L1/3
OP, menu
3 [V]
HYD,
menu 6
[bar]
7.2.9
Sensor,
hydraulic
pressure
lift cylinder
VDRT02.02GB
D:98
Code
134
135
136
137
138
139
140
145
Description
Limitation
Action
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Extension in not
working.
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
VDRT02.02GB
Connections and
components
Diagnostic menu
Group
D797F/K1:22
B768-L2/3
OP, menu
3 [V]
7.2.9
Sensor,
hydraulic
pressure
lift cylinder
D797F/K1:23
B768-R1/3
OP, menu
3 [V]
D797F/K1:24
B768-R2/3
OP, menu
3 [V]
D797F/K1:16
Y6005/2
BOOM,
menu 4
7.2.5
Control
valve lift,
lower and
extension
D797F/K1:17
Y6004/2
BOOM,
menu 5
7.2.5
Control
valve lift,
lower and
extension
D797F/K1:18
Y6006/2
BOOM,
menu 7
7.3.5
Control
valve lift,
lower and
extension
D797F/K1:19
Y6007/2
BOOM,
menu 6
7.3.5
Control
valve lift,
lower and
extension
OP, menu
4
8.2.1.5
Sensor
boom
angle
HYD,
menu 6
[bar]
HYD,
menu 6
[bar]
7.2.9
Sensor,
hydraulic
pressure
lift cylinder
HYD,
menu 6
[bar]
7.2.9
Sensor,
hydraulic
pressure
lift cylinder
Code
146
147
Description
Limitation
Action
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Reduced braking
capacity.
D:99
Connections and
components
Diagnostic menu
Group
OP, menu
4
8.2.1.6
Sensor
boom
length
D797F/K2:13
B762/1
HYD,
menu 2
4.8 Temperature
control,
cleaning
and brake
oil
D797F/K2:13
B762/1
HYD,
menu 2
4.8.10
Sensor
brake oil
temperature
149
Contact Cargotec
support.
150
Defective overload
protection.
Overload system
not working. All lift
functions operate at
reduced speed.
OP, menu
15
8.2.1
Overload
system
Check cabling
between the
control unit and
the component with
diagnostic menu.
D797R/K2:7
CAN/POWER,
menu 10
11.5.1.2
Redundant
voltage
feed of
Control
units
D797R/K2:8
CAN/POWER,
menu 10
11.5.1.2
Redundant
voltage
feed of
Control
units
D797R/K2:1,
K2:9,
K2:10
F58-2/3:1
CAN/POWER,
menu 10
11.5.1.3
Ignition
voltage
(15)
D797R/K2:11
F58-2/3:2
CAN/POWER,
menu 10
11.5.1.4
Emergency stop
switch voltage
Redundant voltage
feed left to Control
unit, frame rear
(D797-R) does not
reach destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Redundant voltage
feed right to Control
unit, frame rear
(D797-R) does not
reach destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the control unit.
153
154
VDRT02.02GB
D:100
Code
155
Description
Limitation
Action
Incorrect 5 V reference
voltage to analogue
sensors. Voltage
below 4.9 V or above
5.1 V.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Connections and
components
Diagnostic menu
Group
D797R/K1:8
B771/1,
B777/1
CAN/POWER,
menu 11
8.2.1.5
Sensor
boom
angle
8.2.1.6
Sensor,
boom
length,
(analogue
sensor)
156
Check cabling
between the
control unit and
the component with
diagnostic menu.
D797R/K1:14
M668/1
HYD,
menu 1
10.6.3
Cooling
fan
D797R/K1:1
E404-3L
LIGHTS,
menu 3
9.6.10
Working
lights,
boom
D797R/K1:15
E404-3R
LIGHTS,
menu 3
9.6.10
Working
lights,
boom
D797R/K1:28
E405L
LIGHTS,
menu 11
9.6.5
Back-up
lights
D797R/K1:42
E405R
LIGHTS,
menu 11
9.6.5
Back-up
lights
D797R/K1:2
B7221L/A,
B7221R/A
OP, menu
1
8.2.1.4
Sensor,
steering
axle load
158
159
160
161
Overload system
indicates overload.
VDRT02.02GB
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
Code
162
163
164
165
166
167
168
169
D:101
Diagnostic menu
Group
8.2.1.6
Sensor,
boom
length
(position
sensor)
Description
Limitation
Action
Connections and
components
Damping in/out/1.5 m
not working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D797R/K1:2
B777/A,
B769-3/A,
B769-4/A
OP, menu
1
Regeneration
extension not working.
D797R/K1:4
Y6046/1
BOOM,
menu 3
7.3.7 Valve
block,
extension
cylinder
D797R/K1:5
Y6050/1
BOOM,
menu 2
7.3.7 Valve
block,
extension
cylinder
D797R/K1:30
H965/1
LIGHTS,
menu 11
9.7.5
Back-up
alarm
Attachment functions
not working.
D797R/K1:31
Y6003/1
HYD,
menu 6
7.4.2 Valve
block,
top lift
hydraulics
D797R/K1:32
H411L/1
LIGHTS,
menu 11
9.6.4
Brake light
D797R/K1:33
H411R/1
LIGHTS,
menu 11
9.6.4
Brake light
D797R/K1:7
H416-2/1
LIGHTS,
menu 5
9.6.2
Running
lights
BOOM,
menu 8
VDRT02.02GB
D:102
Code
170
171
172
173
174
175
178
183
Description
Limitation
Action
Check bulb.
Direction indicator
right rear not working.
Overload system
indicates overload.
Unloading of hydraulic
oil pumps at boom not
working.
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Diagnostic menu
Group
D797R/K1:9
H417-2/1
LIGHTS,
menu 5
9.6.2
Running
lights
D797R/K1:10
H412L/1
LIGHTS,
menu 5
9.6.3 Tail
lights
D797R/K1:25
H412R/1
LIGHTS,
menu 5
9.6.3 Tail
lights
D797R/K1:29
H426/1
LIGHTS,
menu 8
9.6.6
Direction
indicators
D797R/K1:39
H427/1
LIGHTS,
menu 8
9.6.6
Direction
indicators
D797R/K1:11
B7221L/C
OP, menu
1
8.2.1.4
Sensor,
steering
axle load
D797R/K1:40
Y6062/1
BOOM,
menu 2
7.3.8 Valve
block
pump
unloading
D797R/K1:21
B771/3
OP, menu
4
8.2.1.5
Sensor
boom
angle
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check sensor
adjustment.
Check the sensor.
D797R/K1:12
B7221R/C
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the solenoid
valve.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the sensor.
VDRT02.02GB
Connections and
components
Code
184
Description
Limitation
Action
Overload system
not working. All
lift functions run at
reduced speed. Error
code 150 activated.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D:103
Connections and
components
Diagnostic menu
Group
D797R/K1:22
B777/3
OP, menu
4
8.2.1.6
Sensor
boom
length
D797R/K1:11
M645/1
CLIMATE,
menu 6
9.4.8 Compressor
D797R/K1:36
K360/86
ENGINE,
menu 5
1 Engine
D797R/K2:13
B776/1
HYD,
menu 1
10.6 Temperature
control,
cleaning
and hydraulic oil
D797R/K2:13
B776/1
HYD,
menu 1
10.6.4
Sensor hydraulic oil
temperature
D797R/K2:15
B757
CAB,
menu 7
1.2.2
Sensor
fuel level
192
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the component.
D797R/K1:26
M645/1
197
High temperature
hydraulic oil.
No limitation.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the component.
Check that cooling fan
is working.
Check that the radiator
is not clogged.
Check the sensor.
198
Incorrect temperature
display.
Incorrect display of
fuel volume (empty or
full).
251
Redundant voltage
feed left to frame
control unit (D791-1)
does not reach
destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D7911/K2:7
CAN/POWER,
menu 16
11.5.1.2
Redundant
voltage
feed of
Control
units
252
Redundant voltage
feed left to frame
control unit (D791-1)
does not reach
destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
D7911/K2:8
CAN/POWER,
menu 16
11.5.1.2
Redundant
voltage
feed of
Control
units
199
Check cabling
between the
control unit and
the component with
diagnostic menu.
VDRT02.02GB
D:104
Code
253
254
257
258
259
260
261
Description
Limitation
Action
Incorrect power
supply to Control unit,
attachment (D791-1).
Voltage below 18 V or
above 32 V.
Functions normally
supplied emergency
stop switch voltage
have no feed. No
attachment functions
working.
Incorrect emergency
stop switch voltage
to Control unit,
attachment (D791-1).
Functions normally
supplied emergency
stop switch voltage
have no feed. No
attachment functions
working.
Automatic spreading
20"-40" not working.
Rotation of attachment
not working.
VDRT02.02GB
Connections and
components
Diagnostic menu
Group
D791-1/K2:1/9/10
F52-1
F58-3/1:1
CAN/POWER,
menu 16
11.5.1.4
Emergency stop
switch voltage
D7911/K2:11
F58-3/1
CAN/POWER,
menu 16
11.5.1.4
Emergency stop
switch voltage
D7911/K1:1
E406R
LIGHTS,
menu 2
9.6.11
Working
lights attachment
D7911/K1:15
E406L
LIGHTS,
menu 2
9.6.11
Working
lights attachment
D7911/K1:28
H9003/1
ATTACH,
menu 15
7.5
Spreading
(positioning)
D7911/K1:42
E404-4L,
E404-4R
LIGHTS,
menu 2
9.6.11
Working
lights attachment
D7911/K1:2
Y6008/1
ATTACH,
menu 11
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check fuse F58-3/1,
replace if necessary.
Check fuse F52-1,
replace if necessary.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the component.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the solenoid
valve.
Code
262
263
264
265
266
267
268
269
Description
Limitation
Action
Rotation of attachment
not working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Spreading not
working.
Spreading not
working.
Side shift of
attachment not
working.
Side shift of
attachment not
working.
D:105
Connections and
components
Diagnostic menu
Group
D7911/K1:3
Y6009/1
ATTACH,
menu 12
D7911/K1:4
Y6018/1
ATTACH,
menu 13
D7911/K1:5
Y6019/1
ATTACH,
menu 14
D7911/K1:30
Y6021/1
ATTACH,
menu 8
D7911/K1:31
Y6020/1
ATTACH,
menu 8
D7911/K1:32
Y6040/1
ATTACH,
menu 9
7.9.1.3
Control
valve, attachment
D7911/K1:33
Y6039/1
ATTACH,
menu 9
7.9.1.3
Control
valve, attachment
D7911/K1:7
Y6012-1/1
ATTACH,
menu 15
7.7.4 Lock
valve, tilt
VDRT02.02GB
D:106
Code
270
271
Description
Limitation
Action
Check cabling
between the
control unit and
the component with
diagnostic menu.
Twistlocks, rotation
stop, and spreading
not working.
Connections and
components
Diagnostic menu
Group
D7911/K1:9
Y6012-2/1
ATTACH,
menu 15
7.7.4 Lock
valve, tilt
D7911/K1:10
B769/A,
B777-2/A,
B7225/A,
B7202R/A,
B7204R/A,
B7205R/A,
B7203R/A,
B7202L/A,
B7204L/A,
B7205L/A,
B7203L/A,
B7224/A
ATTACH,
menu 5, 6,
7, 21
7.5.10
Position
sensor,
spreading
7.6.10
Sensor,
rotation
stop
7.9.1.8
Sensor,
alignment
7.9.1.9
Sensor,
twistlocks
8.2.1.6
Sensor,
boom
length
(position
sensor)
272
273
274
287
Indicator light,
alignment twistlock,
not working.
Rotation of attachment
not working.
VDRT02.02GB
Check bulb.
Check the bulb holder.
D7911/K1:25
H562/1
ATTACH,
menu 10
7.9.1
Twistlocks
D7911/K1:29
H564/1
ATTACH,
menu 10
7.9.1
Twistlocks
D7911/K1:39
H563/1
ATTACH,
menu 10
7.9.1
Twistlocks
D7911/K1:16
Y6008/2
ATTACH,
menu 11
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check bulb.
Check the bulb holder.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Check the solenoid
valve.
Code
288
289
290
298
299
300
Description
Limitation
Action
Incorrect signal
from Solenoid valve,
rotation anticlockwise
(Y6009). Return
current does not
correspond with
control current.
Rotation of attachment
not working.
Check cabling
between the
control unit and
the component with
diagnostic menu.
Incorrect signal
from Solenoid
valve, spreading out
(Y6018). Return
current does not
correspond with
control current.
Spreading not
working.
Incorrect signal
from Solenoid valve,
spreading in (Y6019).
Return current does
not correspond with
control current.
Spreading not
working.
Sensor, twistlock
indicates that left
twistlock is between
open and locked
position.
Sensor, twistlock
indicates that right
twistlock is between
open and locked
position.
Sensor, alignment,
indicates
unreasonable
distance.
D:107
Connections and
components
Diagnostic menu
Group
D7911/K1:17
Y6009/2
ATTACH,
menu 12
D7911/K1:18
Y6018/2
ATTACH,
menu 13
D7911/K1:19
Y6019/2
ATTACH,
menu 14
ATTACH,
menu 7
7.9.1.9
Sensor
twistlock
ATTACH,
menu 7
7.9.1.9
Sensor
twistlock
ATTACH,
menu 6
7.9.1.8
Sensor,
alignment
795/K1:7
CAN/POWER,
menu 14
11.5.1.2
Redundant
voltage
feed of
Control
units
451
Redundant voltage
feed left to Control unit
KID (D795) does not
reach destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
VDRT02.02GB
D:108
Code
Connections and
components
Diagnostic menu
Group
Description
Limitation
Action
452
Redundant voltage
feed right to Control
unit KID (D795) does
not reach destination.
Check cabling
between the
control unit and
the component with
diagnostic menu.
795/K1:8
CAN/POWER,
menu 14
11.5.1.2
Redundant
voltage
feed of
Control
units
460
No messages
received on CAN
buffer 1.
Incorrect values in
operating menus.
D795/K1:
10, K1:11,
K1:12,
K1:13
CAN/POWER,
menu 1, 2,
21
11.6.2
Redundant
CAN bus
461
No messages
received on CAN
buffer 2.
D795/K1:5
, K1:6
CAN/POWER,
menu 1, 2,
21
11.6.2
Redundant
CAN bus
500
8.2.6
Service
indicator
VDRT02.02GB
E:1
E Schematics
Contents E Schematics
Schematics......................................................................................................... E:3
Common hydraulics ........................................................................................ E:3
Hydraulic diagrams, compilation ................................................................ E:3
Hydraulic diagram basic machine .............................................................. E:4
Hydraulic diagram top lift............................................................................ E:6
Common electrics ........................................................................................... E:8
Circuit diagram, description ....................................................................... E:8
Component designations ......................................................................... E:10
Circuit diagrams, compilation ................................................................... E:10
VDRT02.02GB
E:2
VDRT02.02GB
E Schematics Schematics
E:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation
Drawing number
A40740.0800
A40853.0100
VDRT02.02GB
VDRT02.02GB
43
41
42
44
0 1 3 8 4 3 [A 4 0 4 7 0 .0 8 0 0 v e r 0 1 ]
45
39
40
38
40
40
46
36
37
35
40
34
40
33
32 31
29
30
27
28
26
25
24
17
22
23
16
20
21
18
13
15 14
10
19
11
11
12
9 10
E:4
E Schematics Common hydraulics
1.
Lift cylinder
2.
3.
Extension cylinder
4.
5.
Lift cylinder
6.
7.
8.
Brake valve
9.
E:5
VDRT02.02GB
VDRT02.02GB
C 1-
P P
C 2+ C 1+
0 1 3 8 8 8 (A 4 0 8 5 3 .0 1 0 0 v e r. 4 )
C 2-
10
11
T1
P 1
LS P B
P S
T3B
T2B
P 2B
TP B
E:6
E Schematics Common hydraulics
1.
Tilt cylinder
2.
Damping block
3.
4.
5.
6.
7.
8.
Twistlock cylinders
9.
E:7
VDRT02.02GB
E:8
Common electrics
Circuit diagram, description
A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
-X M 6 7 4 m
Connectors
-X M 6 7 4 f
013017
X37-: All grounding points start with X37, e.g. X37-201, which is
a grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in
electronic box, cab.
Zero references are in the control units.
Components
Components
+ C H A S S IS
-S 2 2 0 -2
P
1
2
D E C L U C H IN G
3 ,0 M P a
VDRT02.02GB
1
013018
Cable marking
E:9
A 01012
0525
W 212D
Cable marking
A 01011
0524
W 212C
All cables are either white (ground signal) or grey (other wiring) and
labelled with numbers.
Cable numbering is interpreted as follows:
0523
W 212B
A 01016
0527
W 212E
013019
A 01010
W 212A
References
013020
/9 .1 0 _ 1 .A 2
00816
A01012: cables that start with A are in the electronic box in the
cab.
W212D: cables that end with a capital letter are jointed in the
wiring from a main cable with the same number. Each joint will
have its own letter.
References
/4 .0 _ 1 .B 1
00816
A n a lo g In 0 -5 V
/0 .0 _ 4 .D 5
+BO O M
-D 7 9 1 -1
M E A S U R E P O IN T S C A L E
013021
-X 4 1 1
21
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box
3 with 8 fuses.
For most fuse boxes there is also a table and an explanation of the
circuits that the various fuses protect.
VDRT02.02GB
E:10
Component designations
The components in circuit diagrams have a prefix and number, the
prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is
provided as an appendix after the circuit diagrams.
Prefix
Description
Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
Sheet
Designation
0.0_1
0.0_2
0.0_4
0.0_5
1.0_2
1.0_3
1.1_1
Circuit drive-train
2.1_1
Circuit drive-train
4.0_1
4.0_2
7.1_1
Circuit Joystick
7.2_1
7.3_1
7.5_1
7.5_3
7.6_1
Circuit Rotation
7.9_1
Circuit Twistlock
7.9_2
Circuit Twistlock
8.2_1
Circuit OP + Scale
8.2_2
Circuit OP + Scale
VDRT02.02GB
Sheet
Designation
8.2_3
Circuit Bypass
9.1_1
9.1_2
9.1_3
9.1_4
9.1_5
9.1_6
9.1_7
9.3_1
9.3_2
9.4_1
9.4_2
9.4_3
9.5_1
Circuit Wipers
9.6_1
9.6_2
9.6_3
9.6_5
Circuit Lighting
9.6_6
Circuit Lighting
9.6_7
Circuit Lighting
9.6_8
Circuit Lighting
9.6_9
9.6_10
9.7_1
9.7_2
9.7_3
9.7_4
9.8_1
Circuit Radio
10.0_1
Circuit Hydraulics
11.5_1
Circuit Current
11.5_2
Circuit Current
11.5_3
Circuit Current
11.5_4
Circuit Current
11.5_5
11.5_7
Circuit 24 V
11.5_8
11.5_9
11.5_10
11.6_3
11.6_4
1.0_1A1
Circuit Yuchai
1.0_1A2
Circuit Yuchai
E:11
VDRT02.02GB
E:12
Sheet
Designation
1.0_1B1
2.0_1A1
2.0_1A1
2.0_1A2
VDRT02.02GB
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32
A 685
A 779
A 782
A 783
A 784
A 785
A 786
A 799
A 806
A 810
A 827
A 900
A 905
A 907
A 908
A 909
A 911
A 912
A 940
A 950
A 955
A 960
SVENSKA
Kretskort elcentral
Reglerenhet termostat AC
Reglersystem terladdning (EC)
Logik interface 2 drivmotorer
Logik interface gaspdrag
Logik interface bromsregl
Logik interface styrsystem
Servofrstrkare styrsystem
Logik allm (option)
Aggregat klimatanlggning
Kondensor AC, flkt
Vxellda
Radio/bandspelare
Kommunikationsradio
Monitor
Kamera
Skrivare
Dataterminal
Alkols
Logik batterivakt
Logik transistortndning
Logik vervarvningsskydd (LPG)
Logik rev-sprr/aut-vxl
A
B
B
B
B
B
B
B
B
B
B
B
B
B
961
649
690
697
751
752
753
754
755
756
757
758
759
760
Motor/kupevrmare
Termostat klimatannlggning
Fartreglage (EC)
Elbroms
Givare varvtal turbin
Givare varvtal inre vxellda
Varvtalsgivare motor
Givare lufttryck
Givare hydraulfilter indikering
Temperatur kylvtska motor
Brnslenivgivare
Varvtalsgivare v-lda
Nivindikator kylvtska
Givare rev-sprr/aut-vxl trans
B
B
B
B
B
B
B
B
B
B
B
762
763
764
765
766
767
768
769
770
771
772
ENGLISH
Printed circuit board, Junction box
Control unit, termostat AC
Control system, recharging (EC)
Logic (interface) two main motors (EC)
Logic (interface) throttle
Logic (interface) brake control
Logic (interface) control system
Servo amplifier steering system
Logic, general (option)
Aggregate, air conditioner
Condensor AC, fan
Gearbox
Radio/tape recorder
Communication radio
Monitor
Camera
Printer
Dataterminal
Interlock device
Logic switch , battery watch
Logic transistor ignition
Logic overspeed protection (LPG)
Logic unit, reversing interlock/automatic
gear changing
Engine- and cab heater
Thermostat, air condition
Speed control (EC)
Electric brake
Transmitter, speed turbin
Transmitter, speed internal gear chain
Transmitter, engine revolution
Transmitter, air pressure
Transmitter, hydraulics filter indication
Transmitter, engine coolant temperature
Transmitter, fuel level
Transmitter, gear box revolution
Transmitter, coolant level
Transmitter, reversing interlock / automatic
gear change system (on gearbox output
shaft)
Transmitter, reversing interlock / automatic
gear changing system (engine speed)
Transmitter, brake flushing circuit
Transmitter, hydraulic fluid level
Transmitter, gear box servo pressure
Transmitter, oil pressure gear box
Transmitter, oil temperature gear box
Transmitter, oil pressure engine
Transmitter, hydraulic pressure
Transmitter, end position
Transmitter, steering wheel angle
Transmitter, angle
Transmitter, temperature brake fluid
VDRT02.02SE/GB
NUMBER
B 773
B 774
B 775
B 776
B 777
B 778
B 789
B 902
B 7224
B 7225
B 7226
B 7227
B 7228
B 7229
B 7230
B 7231
B 7232
B 7233
B 7234
B 7235
B 7236
C 821
D 740
D 742
D 743
D 744
D 780
D 781
D 790
D 791
D 792
D 793
D 794
D 796
D 797
D 798
D 2000
SVENSKA
Givare nrvaro
Givare utomhustemp
Givare temp klimatanlggning
Givare temp hydraulolja
Givare lge
Givare drivbrytning
Givare allmn
Hgtalare
Givare, mtlge vg
Givare, rotationsstopp
Givare, tryck lyftcylinder
Givare, tryck klmma
Givare lyfthjd analog
Givare tiltvinkel analog
Givare ultraljud last position
Givare, Over Height, Ben uppe
Givare,IR Last position
Givare lambda sond
Givare vatten i brnsle
Givare temp avgaser
Givare tryck avgaser
KONDENSATOR
FleetManager kontrollenhet
FleetManager kortlsare
FleetManager accelerations givare
Galvaniskt isolerad CAN brygga
Reglersystem drivmotor
Reglersystem pumpmotor
Elektronisk kontrollenhet ECU, hytt
Elektronisk kontrollenhet aggregat
Elektronisk kontrollenhet styrning
Elektronisk kontrollenhet vxellda
Elektronisk kontrollenhet motor
Elektronisk kontrollenhet, lasthantering
Elektronisk kontrollenhet, ram
Elektronisk kontrollenhet, stolvndning
Elektronisk kontrollenhet, proportionalventil
ENGLISH
Transmitter, presence
Transmitter, ambient temperature
Transmitter, temperature air condition
Transmitter, hydraulic temperature
Transmitter, position
Transmitter, drive break
Transmitter, common
Loud speaker
Sensor, measurepoint scale
Sensor, rotation stop
Sensor, pressure lift cylinder
Sensor, pressure clamp
Sensor lift height analogue
Sensor tilt angle analogue
Sensor, ultrasonic load position
Sensor, Over Height, Leg upper position
Givare,IR Load position
Sensor lambda sond
Transmitter water in fuel
Sensor exhaust temperature
Sensor exhaust pressure
CAPACITOR
FleetManager control unit
FleetManager card device
FleetManager acceleration sensor
Galvanic insulated CAN bridge
Control system traction motor
Control system pump motor
Electronic Control Unit ECU, cab
Electronic Control Unit, attachment
Electronic Control Unit, steering system
Electronic Control Unit, gearbox
Electronic Control Unit, engine
Electronic Control Unit, Loadhandling
Electronic Control Unit, frame
Electronic Control Unit, seat rotation
Electronic control unit, propotional valve
D
E
E
E
E
E
E
E
E
E
E
E
E
9001
400
400
401
401
402
403
404
405
406
406
408
408
kerstrms fjrrkontroll
G-lampa v fram
G-lampa h fram
G-lampa v bak
G-lampa h bak
G-lampa fjrrljus
G-lampa lastljus
G-lampa arbetsljus
G-lampa backljus
G-lampa cont belysning vnster
G-lampa cont belysning hger
G-lampa park ljus v fram
G-lampa park ljus h fram
E
E
VDRT02.02SE/GB
NUMBER
E 432
E 433
E 434
E 435
E 436
E 437
E 438
E 439
E 440
E 456
E 456
E 458
E 458
SVENSKA
G-lampa handsfack belysning
G-lampa instegs belysning
G-lampa innerbelysning
G-lampa lsbelysning
G-lampa identifikationsljus
G-lampa identifikationsljus/takskylt
G-lampa motorrumsbelysning
Nummerskyltsbelysning
G-lampa vrmereglage belysning
G-lampa backljus blackout IR vnster
G-lampa backljus blackout IR hger
G-lampa fram blackout vnster
G-lampa fram blackout hger
E
E
E
E
E
E
E
E
E
E
E
464
464
669
802
803
804
805
808
835
888
962
E
E
F
F
F
F
F
F
F
G
G
G
4370
8092
51
52
56
58
59
62
64
30
658
659
Skljus
Eluppvrmd ruta
Skringshllare 1-polig
Skringshllare 2-polig
Skringshllare 6-polig
Skringshllare 8-polig
Skringshllare 12-polig
Batterihandske 2-polig
Batterihandske 4-polig
Batteri
Generator (extra)
Generator utan laddregulator
ENGLISH
Light bulb, glove pocket light
Light bulb, step-in lighting
Light bulb, interior lighting
Light bulb, reading lighting
Light bulb, identification light
Light bulb, identification light/roof sign
Light bulb, engine compartment light
Light license plate
Light bulb, heating control light
Light bulb, rear light blackout IR left-hand
Light bulb, rear light blackout IR right-hand
Light bulb, roading light blackout left-hand
Light bulb, roading light blackout right-hand
Light bulb, roading light blackout IR lefthand
Light bulb, roading light blackout IR righthand
Light bulb, working light cab blackout IR left
Light bulb, working light cab blackout IR
right
Light bulb, working light boom20' b.out IR
left
Light bulb, working light boom20' b.out IR
right
Light bulb, working light boom40' b.out IR
left
Light bulb, working light boom40' b.out IR
right
Light bulb,Container light IR left-hand
Light bulb,Container light IR right-hand
Heater compartment/engine diesel
Electrical heated observation mirror
Electrical heated seat
Cigarett lighter
Electrical heating cab
Electrical heater air dryer
Ignition plug
Air Dryer, Compressor
Logic indication of wear, brush electrical
motor
Search light
Electrical heated window
Fuse holder, 1-pole
Fuse holder, 2-pole
Fuse holder, 6-pole
Fuse holder, 8-pole
Fuse holder, 12-pole
Battery connector, 2-pole
Battery connector, 4-pole
Battery
Alternator extra
Alternator without loading regulator
VDRT02.02SE/GB
NUMBER
G 660
G 662
H 410
H 410
H 411
H 411
H 412
H 412
H 413
SVENSKA
Generator med laddregulator
Laddregulator
G-lampa broms ljus v fram
G-lampa broms ljus h fram
G-lampa broms ljus v bak
G-lampa broms ljus h bak
G-lampa bak ljus v bak
G-lampa bak ljus h bak
G-lampa bak ljus v fram (VBFS)
ENGLISH
Alternator with loading regulator
Loading regulator
Light bulb, brake light, left-hand forward
Light bulb, brake light, right-hand forward
Light bulb, brake light, left-hand rear
Light bulb, brake light, right-hand rear
Light bulb, rear light, left-hand rear
Light bulb, rear light right-hand rear
Light bulb, rear light, left-hand forward
(VBFS)
Light bulb, rear light,right-hand forward
(VBFS)
Light bulb, side position light, left-hand
forward
Light bulb, side position light, left-hand rear
H
H
H
H
H
H
H
H
H
428
445
446
451
452
453
H
H
H
H
454
454
457
457
H
H
H
H
H
H
465
466
467
468
500
501
VDRT02.02SE/GB
NUMBER
H 503
H 504
H 505
H 506
H 507
H 508
H 509
H 510
H 512
H 514
H 519
H 524
H 525
H 528
H 530
H 531
H 532
H 533
H 547
H 549
H 550
H 551
H 552
H 554
SVENSKA
Varn lampa oljetryck motor
Kont lampa helljus
Varn lampa laddning
Varn lampa laddning (extra)
Varn lampa frdbroms
Varn lampa parkerings broms
Varn lampa niv kylvatten
Kont lampa diff sprr
Varn lampa temp momentfrst
Kont lampa vervxel
Kont lampa halvljus
Kont lampa luftfilter
Kont lampa UNIKAT
Kont lampa frvrmning
Kont lampa framhjuls styrning
Kont lampa 4-hjuls styrning
Kont lampa crab styrning
Kont lampa hyd.pump
Varn lampa centralvarning
Varn lampa oljetryck v-lda
Varn lampa hyttlsning
Varn lampa temp v-lda
Varn lampa bromstryck
Varn lampa temp spolkrets bromsar
ENGLISH
Warning lamp, oil pressure engine
Indicating lamp, main beam
Warning lamp, loading
Warning lamp, loading extra
Warning lamp, brake
Warning lamp, parking brake
Warning lamp, coolant level
Indicating lamp, diff. interlock
Warning lamp, temperature converter
Indicating lamp, overdrive clutch
Indicating lamp, dipped lights
Indicating lamp, air filter
Indicating lamp, UNIKAT
Indicating lamp, preheating
Indicating lamp, forward wheel steering
Indicating lamp, 4-wheel steering
Indicating lamp, crab steering
Indicating lamp, emergency hyd. pump
Warning lamp, central warning
Warning lamp, oil pressure gear box
Warning lamp, cab lock
Warning lamp, temperature gear box
Warning lamp, brake pressure
Warning lamp, temp. cooling system
brakes
Warning lamp, temperature coolant engine
H
H
H
H
H
H
H
H
H
H
556
560
561
562
563
564
565
569
569
570
H
H
H
H
H
571
572
573
574
575
H
H
H
H
H
H
H
H
H
H
576
577
578
579
580
581
582
583
584
599
VDRT02.02SE/GB
NUMBER
H 850
H 853
H 965
H 5000
H 5001
H 9003
K 300
K 301
K 302
K 303
K 304
K 305
K 306
K 307
K 308
K 309
K 310
K 311
K 312
K 313
K 314
K 315
K 316
K 317
K 318
K 319
K 320
K 321
K 322
K 323
K 324
K 325
K 326
K 327
K 328
K 329
K 330
K 331
K 332
K 333
K 334
K 335
SVENSKA
Signalhorn
Summer
Backvarnare
Kont lampa tryck lyfttng
Varn lampa, Over Height ben uppe
Varningssignal aut. rrelse
Rel hel/halvljus
Rel dimljus
Rel fjrrljus
Rel lastljus
Rel arbetsljus
Rel backljus
Rel helljus
Rel halvljus
Rel bromsljus
Rel parkeringsbroms
Rel krvisare v
Rel krvisare h
Rel startelement
Rel vndbar frarstol
Rel parkeringsbroms
Rel tndningsls
Rel torkare
Rel strlkastartorkare
Rel AT-regulator
Rel varningsblinkers
Rel elektrisk stopp
Rel intervalltorkare
Rel kylvtskeniv
Rel blinkers
Rel rangesprr
Rel blinkande bromsljus (back)
Rel blinkande bromsljus (runt)
Rel vxel neutral
Rel vxelskifte
Rel vxel hg/lg
Rel startsprr
Rel drivning fram
Rel drivning bak
Tidrel frvrmning
Rel frikoppling/drivbrytning
Rel vxelventil 1:a (diesel, gas)
K
K
K
K
K
K
K
K
K
337
338
339
340
341
342
343
344
345
ENGLISH
Horn
Buzzer
Reversing alarm
Indicating lamp, pressure lift tong
Warn. Lamp, Over Height leg upper pos
Warning alarm aut. movement
Relay, main/dipped beam
Relay, fog light
Relay, distance light
Relay, mast light
Relay, working light
Relay, reversing light
Relay, main beam
Relay, dipped beam
Relay, brake light
Relay, parking light
Relay, direction indicator left
Relay, direction indicator right
Relay,element preheater
Relay, rotating drivers seat (VBFS)
Relay, parking brake
Relay, ignition key
Relay, wiper
Relay, roading lights wiper
Relay, AT-regulator
Relay, hazard blinkers
Relay, electical stop
Relay, intermittent wiper
Relay, coolant level
Relay, blinkers
Relay, range interlock
Relay, flashing brake lights (reversing)
Relay, flashing hazard brake lights
Relay, gear neutral
Relay, gear shift
Relay, high/low gear
Relay, start interlock
Relay, forward driving
Relay, reversing driving
Time relay, automatically preheating
Relay, free wheel/drive disconnection
Relay, gear change valve 1-gear
(diesel,LPG)
Relay, gear change valve 2-gear
(diesel,LPG)
Relay, motor drive direction
Relay, cooling fan drive motor
Relay, cooling fan electrical box
Time relay, start delay
Time relay, stop delay
Relay, switching 2/4 WD
Relay, fog light rear
Relay, torque amplifier
Relay, interlocking of turntable
VDRT02.02SE/GB
NUMBER SVENSKA
K 346 Rel frikoppling stollsning
K 347 Rel stolvndning/ljussignal
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
ENGLISH
Relay, releasing of seat interlocking
Relay, multifunction, seat rotation/light
signal
Relay, fan heating
Relay, speed control
Relay, pump contactor/pump control
Relay, cab hoist up
Relay, cab hoist down
Relay, safety loop
Relay, signal control system
Relay, sensor control
Shift relay, length/sideways driving
Relay, hazard beacon
Relay, compressor air
Relay hydraulic oil cooler
Relay, starting solenoid
Relay, compressor air conditione
Relay, water valve air conditioner
Relay, condenser air conditione
Relay seat switch
Relay, electrical screen elevator up
Relay, electrical screen elevator down
Relay, steerin
Relay, low brake pressure
Relay, central lubrication
Relay, central lubrication, attatchment
Relay, liftheight
Relay, flashing beacon, lifting height limiter
K
K
K
K
K
373
375
376
377
378
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
379
380
381
382
383
384
385
386
387
388
389
399
3001
3002
3003
3004
3005
3006
3007
Rel bakljus
Huvudkontaktor reglersystem
Kontaktor fram reglersystem
Kontaktor bak reglersystem
Kontaktor by-pass
reglersystem/Fltfrsvagning
Kontaktor pumpmotor
Kontaktor
Kontaktor terladdning
Rel, frbikoppling skerhetssystem
Rel, Stolsvrme
Rel vattenseparator
Rel brnslepump insprutning
Rel, hg motortemperatur.
Rel alternativ gaspedal
Rel, Extra frdriktningsvljare
Rel, Pausvrme
Rel option
Rel rotation
Rel tilt
Rel sidofring
Rel lngdinstllning
Rel twist lock
Rel spridning
Rel lyft/snk
Relay light
Main contactor, operating control
Contactor, forward operating control
Contactor, reversing operating control
Contactor, by-pass operating control/
Field weakening
Contactor, pump motor
Contactor
Contactor, recharging
Relay, by-pass safety system
Relay, heated seat
Relay, waterseparator
Relay, fuel injection pump
Relay, high motor temperature
Relay alternative throttle pedal
Relay, Extra direction selector
Relay, Paus heat
Relay, option
Relay, rotation
Relay, tilt
Relay, side shifting
Relay, length adjustment
Relay, twist lock
Relay, spreading
Relay, lifting/lowering
VDRT02.02SE/GB
NUMBER
K 3008
K 3009
K 3010
K 3011
K 3012
K 3013
K 3014
K 3015
SVENSKA
Rel hydraulfunktion extra
Rel manverbrytare hydr
Rel bromsljus vxl std/blackout
Rel backljus vxl std/blackout
Rel arb.bel hytt vxl std/blackout
Rel arb.bel. bom 20' vxl std/blackout
Rel arb.bel. bom 40' vxl std/blackout
Rel vxl bromsljus/blinkers v
K
K
K
K
3016
3017
3018
3305
Rel signalhorn
Rel containerbelysning
Rel containerbelysning IR
Rel VBFS, backljus
K
K
K
K
3306
3307
3308
3310
K
K
K
K
K
K
K
K
K
K
K
K
K
K
L
M
M
M
M
M
M
M
M
M
M
M
3404
3405
3412
3768
3769
3770
3771
3772
3773
3774
3776
93774
830
608
609
612
650
650
650
650
651
652
653
654
ENGLISH
Relay, extra hydraulic function
Relay, operating switch
Relay, brake light shift std/blackout
Relay, reversing light shift std/blackout
Relay, working light cab, shift std/blackout
Relay,working light boom20' shift std/b.out
Relay,working light boom40' shift std/b.out
Relay, shift brake light/direction indicator
left
Relay, shift brake light/direction indicator
right
relay, horn
Relay, Container light
Relay, Container light IR
Relay, rotating drivers seat, reversing light
Relay, rotating drivers seat, main beam
Relay, rotating drivers seat, dipped beam
Relay, rotating drivers seat, brake light
Relay, rotating drivers seat, direction
indicator left
Relay, rotating drivers seat, direction
indicator right
Relay, seat belt
Relay, rotating drivers seat, forward driving
Relay, rotating drivers seat, reversing
driving
Relay, rotating drivers seat, speed control
Relay, rotating drivers seat, mast light
Relay,reversealarm
Relay, rotating drivers seat, rear light
Relay, hydraulic pressure
Relay, blocking of cab tilt
Relay, alignment
Relay, Hook
Relay, charge signal (D+)
Relay 12V for radio memory
Relay, cooling fan oil
Relay heated window
Relay, Holdcircuit
Ignition coil
Pump unit, cab hoist
Regulating motor, throttle
Regulating motor, re-circulation
Washer motor
Light motor
Light washer motor
Starter motor
VDRT02.02SE/GB
NUMBER
M 655
M 656
M 657
M 661
M 663
M 664
M 666
M 667
M 668
M 670
M 671
M 672
M 674
M 675
M 677
M 693
M 694
M 695
M 696
M 698
M 9000
P 700
P 701
P 702
P 703
P 704
P 705
P 706
P 707
P 708
P 709
P 710
P 711
P 712
P 714
P 715
P 795
Q 144
R 807
R 820
R 825
R 828
R 8071
R 8072
R 8073
R 8074
R 8075
R 8076
R 8077
R 8078
R 8079
R 8080
R 8081
R 8082
SVENSKA
Kylflkt drivmotor (EC)
Kylflkt elskp (EC)
Flktmotor vrme
Fnsterhissmotor
Doseringspump klimatanlggning
Cirk pump klimatanlggning
Flktmotor cirkulation
Cirkulationspump vrmesystem
Kylflkt hydraulolja
Kompressor
Doseringspump diesel
Spjll motor, ECC
Kylflkt bromsolja
Motor, Stolsvndning
Motor Lsning stolsvridning
Pump centralsmrjning
Styrmotor
Drivmotor (EC)
Pumpaggregate ndstyrning
Pumpmotor (EC)
Motor hj/snkbar stolspelare
Hastighetsmtare
Mtare oljetemp v-lda
Klocka
Varvtalsmtare
Tryckluftsmtare
Mtare oljetryck v-lda
Termometer temp kylvtska motor
Brnslemtare
Timrknare
Kapacitetsmtare batteri
Tidur motor/kupevrmare
Rknare, impuls
Mtare oljetryck motor
Mtare, temp. Hydraulolja
Extra instrument allm
Display
Batterifrnskiljare
Potentiometer
Motstnd
Reglage spakstyrning
Shuntmotstnd
Potentiometer lyft/snk
Potentiometer tilt
Potentiometer sidofring
Potentiometer spridning
Potentiometer extra
Potentiometer mast in/ut
Potentiometer hger framhjul
Potentiometer vnster framhjul
Potentiometer hger bakhjul
Potentiometer vnster bakhjul
Potentiometer tiltvinkel
Potentiometer flkthastighet, ECC
ENGLISH
Cooling fan, main motor (EC)
Cooling fan, electrical box (EC)
Heating fan
Screenelevator motor
Dosage pump, air condition
Circulating pump, air condition
Circulation fan
Circulation pump heating system
Cooling fan, hydraulic oil
Compressor
Dosage pump diesel
Draught valve motor, ECC
Cooling fan, brake fluid
Motor, Seat rotation
Motor Locking revolving seat
Pump, central lubrication
Steering motor
Drive motor (EC)
Pump, emergency steering
Pump motor (EC)
Motor rise/lower seat column
Speedometer
Gear box oil temperature gauge
Clock
Engine rev meter
Air pressure gauge
Gear box oil pressure gauge
Temperature gauge, engine coolant
Fuel gauge
Hour meter
Capacity gauge, battery
Timer, engine- and cab heater
Counter, impulse
Motor oil pressure gauge
Hydraulic fluidtemperature, guage
Extra instrument, general
Display
Battery disconnecting switch
Potentiometer
Resistor
Controls, (steering with control levers).
Shunt-resitor
Potentiometer lift/lower
Potentiometer tilt
Potentiometer side shifting
Potentiometer spreading
Potentiometer extra
Potentiometer reach in/out
Potentiometer right front wheel
Potentiometer left front wheel
Potentiometer right rear wheel
Potentiometer left rear wheel
Potentiometer tilt angle
Potentiometer fan speed, ECC
VDRT02.02SE/GB
NUMBER
R 8083
R 8084
R 8085
R 8086
R 8087
R 8088
R 8089
S 100
S 101
S 102
S 103
S 104
S 105
S 106
S 107
S 108
S 109
S 110
S 111
S 112
S 113
S 114
S 115
S 116
S 117
S 118
S 119
S 120
S 121
S 122
S 123
S 124
S 125
S 126
S 127
S 128
S 129
S 130
S 131
S 132
S 135
S 136
S 137
S 138
S 139
S 141
S 142
S 143
S 145
S 147
S 149
S 150
S 152
S 156
SVENSKA
Potentiometer temperatur, ECC
Potentiometer spjll, ECC
Potentiometer rotation
Potentiometer sax
Potentiometer klmma
Potentiometer skevning
Potentiometer kroklsning
Strmstllare ljus
Strmstllare omk hel/halvljus
Strmstllare dimljus
Strmstllare fjrrljus
Strmstllare lastljus
Strmstllare arbetsljus
Strmstllare containerljus
Strmstllare park broms
Strmstllare centr smrjning
Strmstllare varningsljus
Strmstllare rot varningsljus
Strmstllare fnsterhiss
Strmstllare kylanlggning (AC)
Strmstllare styrning alt
Strmstllare lsbelysning
Strmstllare instr belysning
Strmstllare innerbelysning
Strmstllare vrme
Strmstllare flktm vrme
Strmstllare vindrutetorkare
Strmstllare spolare
Strmstllare blackout
Strmstllare nd hydraulpump
Strmstllare backspegel
Strmstllare kallstart
Strmstllare avgasbroms
Strmstllare diff sprr/broms
Strmstllare vrmesystem diesel
Strmstllare kraftuttag sida
Strmstllare kraftuttag bak
Strmstllare hg/lgvxel
Strmstllare frdvljare fram
Strmstllare frdvljare bak
Strmstllare vxelvljare
Strmstllare framhjuls styrning
Strmstllare 4-hjuls styrning
Strmstllare crab styrning
Strmstllare defroster
Strmstllare Stegbelysning
Strmstllare fot
Strmstllare sitsvrme
Strmstllare AT-regulator
Strmstllare krvisare
Strmstllare signalhorn
Strmstllare startls/ellas
Strmstllare intervalltorkare
Strmstllare kupevrmare
10
ENGLISH
Potentiometer temperature, ECC
Potentiometer draught valve, ECC
Potentiometer rotation
Potentiometer extender
Potentiometer clamp
Potentiometer levelling
Potentiometer flaps
Switch, light
Switch, main/dipped beam
Switch, fog light
Switch, distance light
Switch, mast lights
Switch, working lights
Switch, container light
Switch, parking brake
Switch, central lubricator
Switch, hazard lights
Switch, rotating hazard beacon
Switch, window regulator
Switch, air conditioner (AC)
Switch, alternative steering
Switch, reading light
Switch, instrument illumination
Switch, interior lighting
Switch, heating
Switch, heater fan
Switch, wiper
Switch, washer
Switch, blackout
Switch, emergency hydraulic pump
Switch, observation mirror
Switch, cold start
Switch, exhaust brake
Switch, diff. Block
Switch, heating system diesel
Switch, power take off side
Switch, power take off rear
Switch, high/low gear
Switch, gear selector forward
Switch, gear selector rear
Switch, gear shift
Switch, forward wheel steering
Switch, 4-wheel steering
Switch, crab steering
Switch, defroster
Switch, Steplight
Switch, foot
Switch, seat heater
Switch, AT-regulator
Switch, direction indicators
Switch, horn
Switch, main key switch
Switch, intermittent wiper
Switch, cab heating
VDRT02.02SE/GB
NUMBER
S 157
S 158
S 159
S 160
S 161
SVENSKA
Strmstllare stoltilt
Strmstllare dimbakljus
Strmstllare extra fram/back vljare
Strmstllare komb fram/back
Strmstllare komb signal, ljus hel/halv
spol,torkare m intervall krvisare
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
163
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
190
191
192
195
196
197
198
199
200
S
S
S
S
S
S
205
206
207
208
S
S
S
S
S
S
S
214
215
216
217
218
219
220
Brytkontakt innerbelysning
Brytkontakt handskfack belysning
Slutkontakt diff sprr
Slutkontakt lampa temperatur spolkrets
bromsar
Slutkontakt vervxel
Slutkontakt temp motor
Slutkontakt bromsljus
Slutkontakt backljus
Slutkontakt AT-regulator
Slutkontakt lampa luftfilter
Brytkontakt drivning
11
ENGLISH
Switch, seat tilt
Switch, rear fog light
Switch, extra direction selector
Switch, combi-forward/reverse
Switch, combi-horn, light main/dipped
beam, washer, wiper (intermittent), direction
indicator
Switch, combi horn, light main/dipped
beam, washer, wiper w 2int., forward/revers
Switch, start 2nd gear
Switch, seat heater
Switch, interlocking of turntable
Switch, pneumatic springing
Switch, interlocking of seat
Switch, reversible seat
Switch, evaporator (LPG)
Switch, fifth wheel up/down
Switch, fifth wheel forward/reverse
Switch, fifth wheel, levelling
Switch, projecting
Switch, cab hoist up
Switch, cab hoist down
Switch, cab movement
Switch, reset
Switch Aut/man gearshifting
Switch, 4-WD
Switch, air conditioner
Switch, re-circulation
Switch, joy-stick X
Switch, joy-stick X+Y
Switch, length/sideways driwing
Switch, equalizing fifth wheel
Switch, option
Contact, breaking,warning lamp,parking
brake
Contact, breaking, warning lamp, brake
Contact, breaking, warning lamp, oil
pressure engine
Contact, breaking, pressure
accumulatortank
Contact, breaking, interior lighting
Contact, breaking, glove
Contact, making, diff. interlock
Contact, making, warning lamp temperature
brake
Contact, making, over drive
Contact, making, temperature engine
Contact, making, brake lights
Contact, making, reversing light
Contact, making, AT-control
Contact, making, indicating light air filter
Contact, breaking, drive cut off
VDRT02.02SE/GB
NUMBER SVENSKA
S 221 Slutkontakt temp vxellda
S 222 Slutkontakt lampa temp moment frstrkare
S 223 Slpkontakt signal
S 224 Slutkontakt insprutningspump
S 225 Brytkontakt skerhetsblte
S 228 Slutkontakt hyttlsning
S 229 Slutkontakt stolslsning
S 230 Brytkontakt stol
S 231 Slutkontakt fotkontroll stolvndning
S 232 Brytkontakt lampa luftanslutning slp
12
S
S
S
S
S
S
233
235
236
239
240
241
S
S
ENGLISH
Contact, making, temperature gear box
Contact, making, warning lamp temperature
torque amplifier.
Contact, brush, horn
Contact, making, injection pump
Contact, breaking, seat belt
Contact, making, cab locking
Contact, making, seat locking
Contact, breaking, seat
Contact, making, seat rotation, foot switch
Contact, breaking, warning lamp air
connection
Contact, warning, interlocking of turntable
Contact, making, side shifting of seat
Contact, water level
Contact, breaking, thermic
Contact, making, thermic
Contact, breaking, warning lamp air supply
to trailer
Contact, making, warning lamp, oil
pressure gear box
Contact, breaking, coolant pressure (air
condition)
Contact, making, hydraulics
Contact, making, hydraulic pressure control
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
246
250
251
260
261
262
263
264
265
266
267
268
269
270
271
299
720
S
S
S
S
S
S
S
S
800
815
840
1001
1002
1003
1004
1005
Startelement
Manverspak
Strmfrdelare
Strmstllare, TW
Strmstllare, lossa TW
Strmstllare, lsa TW
Strmstllare, stopp vid 30'-35'
Strmstllare, frbikoppling av
skerhetssystem
1006 Strmstllare, fllning frmre ben
Start element
Control lever
Distributor
Switch, TW
Switch, unlocking of TW
Switch, locking of TW
Switch, stop at 30 -35
Switch, overriding of the safety system
Switch, front legs down
VDRT02.02SE/GB
NUMBER
S 1007
S 1008
S 1009
S 1010
S 1011
S 1012
S 1013
S 1014
S 1015
S 1017
S 1018
S 1019
S 1020
S
S
S
S
S
S
1021
1022
1023
1024
1025
1026
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1440
7200
7201
7202
7202
7203
7203
7204
7204
7205
SVENSKA
Strmstllare, fllning bakre ben
Strmstllare, klmma/lossa ben
Strmstllare, Motor information
Srmstllare, tilt av hytt
Strmstllare IR ljus
Strmstllare utskjut 20-40
Strmstllare stdben
Strmstllare frbikoppling rotationstopp
Strmstllare frbikoppling hjdbeg/tp-beg
Strmstllare diagnostik ka/minska
Strmstllare diagnostik on/off
Strmstllare rastvrme
Strmstllare automatisk slpp/klm
funktion
Strmstllare sax
Strmstllare vertikalhllning
Strmstllare lsning vre arm
Strmstllare Korta Armen av/p
Strmstllare pappersfunktioner av/p
Strmstllare omkoppling
pappers/klmmagregat
Strmstllare lyfthjdsfrval
Strmstllare lyfthjdsfrval ka
Strmstllare lyfthjdsfrval minska
Strmstllare lraringng givare ultraljud
Strmstllare, Over Height Upp/Ned
Brytare backljus
Flytta korta armen
Strmstllare frbikoppling startsprr
Strmstllare Val av klmtryck
Strmstllare Korta Armen av/p
Strmstllare lsning skevning
Strmstllare vre armpar/Sidofring
Strmstllare Inching
Switch stopp motor
Strmstllare motorrumsbelysning
Strmstllare hjdjustering stol
Strmstllare lngdjustering stol
Strmstllare Tankvljare
Strmstllare Avstngning backalarm
Strmstllare eluppvrmd ruta
Henrik testar en brytare!
Strmstllare fjrrstyrning
Strmstllare styrning spegel
Huvudstrmbrytare
Givare, axeltryck hger
Givare, axeltryck vnster
Givare, anliggning vnster fram
Givare, anliggning hger fram
Givare, anliggning vnster bak
Givare, anliggning hger bak
Givare, ppen vnster twistlock
Givare, ppen hger twistlock
Givare, lst vnster twistlock
13
ENGLISH
Switch, rear legs down
Switch, clamping/-releasing legs
Switch, Engine information
Switch, tilt of cab
Switch IR light
Switch, Extension 20-40
Switch, Support jacks
Switch, over ride rotation stop
Switch, over ride height limit/tp-limit
Switch, diagnostics increase/decrease
Switch, diagnostics on/off
Switch, paus heat
Switch automatic release/clamp funktion
Switch extender
Switch, vertical position
Switch, lock upper arm
Switch, Short Arm on/off
Switch, paper funktions on/off
Switch, switch papper/bale clamp
Switch, lift height selection
Switch, lift height selection increase
Switch, lift height selection decrease
Switch, teaching ultrasonic sensor
Switch, Over Height Up/Down
Switch reverse light.
Move short arm
Switch Override Start interlock
Switch, Clamp pressure selection
Switch , Short Arm on/off
Switch, lock levelling
Switch Upper arms/Sideshift
Switch, Inching
Switch, Stop engine
Switch, light engine compartment
Switch, Seat height level
Switch, Seat for/aft adjustment
Switch, Tankselector
Switch, Rev. Alarm on/off
Switch electrical heated shield
Switch remote control
Switch mirror control
Sensor, axle pressure right
Sensor, axle pressure left
Sensor, alignment left front
Sensor, alignment right front
Sensor, alignment left rear
Sensor, alignment right rear
Sensor, unlocked twistlock left
Sensor, unlocked twistlock right
Sensor, locked twistlock left
VDRT02.02SE/GB
NUMBER
S 7205
S 7206
S 7207
S 7208
S 7209
S 7210
S 7211
S 7212
S 7213
S 7214
S 7215
S 7216
S 7217
S 7218
S 7219
S 7220
S 7221
S 7222
S 7223
U 741
U 823
U 824
U 901
U 910
U 941
V 665
V 8090
W 903
W 906
W 8093
X
37
X
39
X
72
X
77
X
78
Y 600
Y 601
Y 602
Y 603
Y 604
Y 605
Y 606
Y 607
Y 610
Y 611
Y 613
Y 614
Y 615
Y 616
Y 617
Y 618
Y 620
Y 621
Y 622
SVENSKA
Givare, lst hger twistlock
Givare, gaffel aggregat
Givare, 2WD/4WD
Givare, hytt i krlge
Givare, oljefilter indikering
Givare, hytt i transportlge
Givare, lyfthjd
Givare, krlge
Givare, Anliggning frmre ben
Givare, Anliggning bakre ben
Givare, klm frmre ben
Givare, klm bakre ben
Givare, frmnre kn
Givare, bakre kn
Givare, frmre ben
Givare, bakre ben
Givare, styraxel
Givare, stdben uppe
Givare, stdben nere
FleetManager batterifilter
Signalomvandlare hger
Signalomvandlare vnster
Spnningsomvandlare
Spnningsomvandlare 80V/24V
Laddningsutjmnare
Diod
Laser, pappersaggretgat
Antenn radio
Antenn kommunikationsradio
Genomfring, kablage
Terminal stomanslutning
Terminal minusanslutning
Stickuttag 2-polig
Stickuttag 7-polig
Stickuttag extra 7-polig
M-ventil avgasbroms
M-ventil diff sprr
M-ventil broms
M-ventil vrme
M-ventil kraftuttag sida
M-ventil kraftuttag bak
M-ventil 2/4 hjulsdrift
M-ventil hg/lg vxel
M-ventil hydraulsystem allm
M-ventil fldesbegrnsning
M-ventil momentfrstrkare
M-ventil rangesprr
M-ventil hjulvridning
M-ventil kallstart
M-ventil AT-regulator by-pass
M-ventil vatten klimatanlggning
M-ventil vndskiva upp
M-ventil vndskiva ner
M-ventil vndskiva fram
14
ENGLISH
Sensor, locked twistlock right
Sensor, fork attachment
Sensor, 2WD/4WD
Sensor, Cab in drive position
Sensor, Oil filter indication
Sensor, Cab in transportation position
Sensor, lifting height
Sensor, driving position
Sensor, Alignment front legs
Sensor, Alignment rear legs
Sensor, Clamp front legs
Sensor, Clamp rear legs
Sensor, front knee
Sensor, rear knee
Sensor, front legs
Sensor, rear legs
Sensor, steering axle
Sensor, brace up
Sensor, brace down
FleetManager battery filter
Signal amplifier, right
Signal amplifier, left
Voltage converter
Voltage converter 80 V / 24 V
Even charger
Diode
Lase, Pulp an Paper
Aerial, radio
Aerial, communication radio
Lead-through, harness
Earthing terminal on chassis
Terminal, negative terminal
Outlet, 2-pole
Outlet, 7-pole
Outlet, extra, 7-pole
Solenoid valve, exhaust brake
Solenoid valve, diff. interlock
Solenoid valve, brake
Solenoid valve, heater
Solenoid valve, power take off, side
Solenoid valve, power take off, rear
Solenoid valve, 2/4WD
Solenoid valve, high/low gear
Solenoid valve, hydraulics, general
Solenoid valve, flow restriction
Solenoid valve, torque amplifier
Solenoid valve, ranging interlock
Solenoid valve, wheel turning
Solenoid valve, cold start aid
Solenoid valve, AT-regulator by-pass
Solenoid valve, water air conditioner
Solenoid valve, fifth wheel up
Solenoid valve, fifth wheel down
Solenoid valve, fifth wheel forward
VDRT02.02SE/GB
NUMBER
Y 623
Y 624
Y 625
Y 626
Y 627
Y 628
Y 630
Y 631
Y 632
Y 633
Y 634
Y 635
Y 636
Y 637
Y 638
Y 639
Y 640
Y 641
Y 642
Y 643
Y 644
Y 645
Y 646
Y 647
Y 648
Y 673
Y 676
Y 699
Y 826
Y 6001
Y 6002
Y 6003
SVENSKA
M-ventil vndskiva bak
M-ventil skevning h
M-ventil skevning v
M-ventil AT-regulator
M-ventil vakuum
M-ventil brnsleblandning
M-ventil v-lda fram
M-ventil v-lda back
M-ventil v-lda spole 1
M-ventil v-lda spole 2
M-ventil v-lda spole 3
M-ventil klmtryck
M-ventil styrning
M-ventil flytlge skevning
M-ventil stopp insprut pump
M-ventil lsning orbitrol ls
M-ventil gasol
M-ventil frngare (LPG)
M-ventil park broms
M-ventil lsning stol (VBFS)
M-ventil lsning vndskiva
Magnetkoppling komp AC
M-ventil stolsvndning
M-ventil stolstilt
M-ventil luftfjdring
Vatten ventil motor, ECC
M-ventil Broms stolsvndning
M-ventil option
Ventil spakstyrning
M-ventil blockering hger
M-ventil blockering vnster
M-ventil inkoppling av hydraulik till topplyft
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
6004
6005
6006
6007
6008
6009
6010
6011
6012
6013
6014
6015
6016
6017
6018
6019
6020
6021
6022
M-ventil snk
M-ventil lyft
M-ventil bom ut
M-ventil bom in
M-ventil vridning medsols
M-ventil vridning motsols
M-ventil tilt ut
M-ventil tilt in
M-ventil tilt
M-ventil fllning frmre ben
M-ventil fllning bakre ben
M-ventil klmma/lossa ben
M-ventil Hyttskjutning fram
M-ventil Hyttskjutning bak
M-ventil spridning ut
M-ventil spridning in
M-ventil sidofring vnster
M-ventil sidofring hger
M-ventil extra hydraulfunktion ut
15
ENGLISH
Solenoid valve, fifth wheel rear
Solenoid valve, levelling right hand
Solenoid valve, levelling left hand
Solenoid valve, AT-regulator
Solenoid valve vacuum
Solenoid valve fuelmixture
Solenoid valve, gear box, forward gear
Solenoid valve, gear box, rear gear
Solenoid valve, gear box, 1 gear
Solenoid valve, gear box, 2 gear
Solenoid valve, gear box, 3 gear
Solenoid valve, clamping pressure
Solenoid valve, steering
Solenoid valve, equalizing fifth wheel
Solenoid valve, stop injection pump
Solenoid valve, locking LS orbitrol
Solenoid valve, LPG
Solenoid valve, evaporator (LPG)
Solenoid valve, parking brake
Solenoid valve, seat locking (VBFS)
Solenoid valve, fifth wheel locking
Magnetic clutch, compressor AC
Solenoid valve, seat rotation
Solenoid valve, seat tilt
Solenoid valve, pneumatic springing
Water valve motor, ECC
Solenoid valve Brake seat turning
Solenoid valve, option
Valve, (steering with control levers).
Solenoid valve, blocking right
Solenoid valve, blocking left
Solenoid valve, activation of toplift
hydraulics
Solenoid valve, lower
Solenoid valve, lift
Solenoid valve, boom out
Solenoid valve, boom in
Solenoid valve, rotation clockwise
Solenoid valve, rotation counter-clockwise
Solenoid valve, tilt out
Solenoid valve, tilt in
Solenoid valve, tilt
Solenoid valve, lowering front legs
Solenoid valve, lowering rear legs
Solenoid valve, clamping/releasing legs
Solenoid valve, cab movement forward
Solenoid valve, cab movement reverse
Solenoid valve, spreading out
Solenoid valve, spreading in
Solenoid valve, side shift left
Solenoid valve, side shift right
Solenoid valve, extra hydraulic function out
Solenoid valve, extra hydraulic function in
VDRT02.02SE/GB
NUMBER
Y 6024
Y 6025
Y 6026
SVENSKA
M-ventil stativ ut
M-ventil stativ in
M-ventil hger framhjul styrning vnster
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
6034
6035
6036
6037
6038
6039
6040
6041
6042
6043
6044
6045
6046
6047
6048
6049
6050
6051
6052
6053
6054
6055
6056
6057
6058
6059
6060
6061
6062
6063
6064
6065
6066
6067
M-ventil skevning
M-ventil skevning hger
M-ventil skevning vnster
M-ventil kylflkt
M-ventil frikoppling koppling
M-ventil ppna twistlock
M-ventil lsa twistlock
M-ventil nd, twistlock
M-ventil mellan bom
Magnetventil, fllning torn (RTCH)
M-ventil blockering twistlock
M-ventil blockering lyft
M-ventil utskjut
M-ventil, hyttilt upp
M-ventil, hyttilt ner
M-ventil, kylkrets broms
M-ventil blockering utskjut
M-ventil, regenerering hger
M-ventil, regenerering vnster
M-ventil, krlge
M-ventil, klmma ihop
M-ventil, klmma isr
M-ventil, frmre kn ut
M-ventil, frmre kn in
M-ventil, bakre kn ut
M-ventil, bakre kn in
M-ventil, frmre ben upp
M-ventil, bakre ben upp
M-ventil, urkoppling hydraulpump
M-ventil, stdben upp
M-ventil, stdben ner
M-ventil, frikoppling vridbroms
M-ventil, v-lda, drivning
M-ventil, v-lda, oljetryck till 1:a/3:e vxeln
16
ENGLISH
Solenoid valve, mast out
Solenoid valve, mast in
Solenoid valve, right front wheel, steering
left
Solenoid valve, right front wheel, steering
right
Solenoid valve, left front wheel, steering left
Solenoid valve, left front wheel, steering
right
Solenoid valve, right rear wheel, steering
left
Solenoid valve, right rear wheel, steering
right
Solenoid valve, left rear wheel, steering left
Solenoid valve, left rear wheel, steering
right
Solenoid valve, levelling
Solenoid valve, levelling right
Solenoid valve, levelling left
Solenoid valve, Cooling fan
Solenoid valve, lockup clutch
Solenoid valve, unlocked twist lock
Solenoid valve, locked twist lock
Solenoid valve, emergency, twistlock
Solenoid valve, middle boom
Solenoid valve, boom lowering (RTCH)
Solenoid valve, blocking twistlock
Solenoid valve, blocking lift
Solenoid valve, projecting
Solenoid valve, cab tilt up
Solenoid valve, cab tilt down
Solenoid valve, cooling cicuit brake
Solenoid valve, blocking projecting
Solenoid valve, regeneration right
Solenoid valve, regeneration left
Solenoid valve, driving position
Solenoid valve, clambing in
Solenoid valve, clambing out
Solenoid valve, front knee out
Solenoid valve, front knee in
Solenoid valve, rear knee out
Solenoid valve, rear knee in
Solenoid valve, front legs up
Solenoid valve, rear legs up
Solenoid valve interruption hydraulic pump
Solenoid valve, brace up
Solenoid valve, brace down
Solenoid valve, lockup rotation brake
Solenoid valve, gearbox, drive
Solenoid valve, gearbox,oilpressure to
1st/3rd gear
Solenoid valve externder/rotation
VDRT02.02SE/GB
NUMBER SVENSKA
Y 6069 M-ventil, v-lda, oljetryck till 2:a/4:e vxeln
Y
Y
Y
Y
Y
6070
6071
6072
6073
6074
6075
Y
Y
Y
Y
Y
Y
Y
Z
6076
6077
6078
6079
6080
6081
6082
822
17
ENGLISH
Solenoid valve, gearbox,oilpressure to
2nd/4th gear
Solenoid valve, Over Height up
Solenoid valve, Over Height down
Solenoid valve clamp pressure
Proportional valve, Opti speed
Solenoid valve, gearbox, gearswitch for
2nd/4th gear
Solenoid valve, gearbox, gearswitch for
1st/3rd gear
Solenoid valve, blocking lower
Solenoid valve, Inching
Solenoid valve, upper arm off
Solenoid valve, Sideshift/Upper arms
Solenoid valve, activate sliding cab
Solenoid valve, accumulator charge
Solenoid valve, pressure restriction
Signal filter
VDRT02.02SE/GB
F:1
F Technical data
VDRT02.02GB
F:2
VDRT02.02GB
F:3
F Technical data
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.
1 Engine
Yuchai YC6M360-30
2000 rpm
2000 rpm
Number of cylinders
6 cylinders
6 cylinders
1960 W (28 V / 70 A)
24 V (2 x 12 V / 135 Ah)
Alternator
System voltage
2 Transmission
Dana HR36000
4 4
Cummins QSM11
Merritor PRC7534
Wet Disc Brakes - Drive wheel
Spring brake - Drive wheel
Hydraulic servo
5 Steering
6 Suspension
18.00x25, PR40 E4
Dimensions front-rear
1.0 MPa
9 Cab
Equivalent sound pressure level in cab
according to EN12053 with measurement
uncertainty R=2.5 dB. Measurement value
with standard engine.
LpAZ 73 dB(A)
0,5 m/s2
VDRT02.02GB
F:4
Output (W)
Socket
Check lamps
1.2
W2x4.6d
Interior lighting
10
S8.5
Tail lights
BA15s
Brake light
21
BA15s
Direction indicators
21
BA15s
Position lamps
W2.1x9.5d
75/70
P43t-38 (H4)
Back-up lights
70
PK22s (H3)
Work lights
70
PK22s (H3)
35
70
PK22s (H3)
Volumes
Any deviation from this table must be approved in writing by Cargotec.
Yuchai YC6M360-30
Cummins QSM11
Fuel tank
550 l
Fuel quality
Cummins QSM11
35 l
40 l
ES Compleat, Premix
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling system
if different types of coolant are mixed.
When changing and topping up coolant, the same type of
coolant must be used as was used before.
Yuchai YC6M360-30
28 l
Dana HR36000
50 l
VDRT02.02GB
34 l
Cummins QSM11
Merritor PRC7534
50 l
Differential
Hub reduction
Oil type, quality
F:5
2x10 l
See Oils and lubricants, recommendation, page F:7.
4 Brakes
Brake system
Oil type, quality
7 Load handling
Planetary gear hydraulic motor
Brake hydraulic motor
Oil type, quality
140 l
See Oils and lubricants, recommendation, page F:7.
Spreading (positioning) motor
Rotation motor
2.3 l
2.45 l
0.6 l
Cummins QSM11
Refrigerant, volume
2000 g
R134a
Washer fluid
10 Common hydraulics
Hydraulic oil tank, volume
600 l
VDRT02.02GB
F:6
H 8=2575
L3=6250
L 3= 11450
42
(4 3 )
(3 1 )
45
(4 5 )
31
(3 1 )
(1 5 )
45
(4 5 )
31
(3 1 )
15
(1 5 )
45
(4 5 )
31
(3 1 )
15
(1 5 )
45
(4 5 )
31
(3 1 )
15
(1 5 )
L4=1965
L5=3815
L6=6315
A 1
A 2
6250
B =4150
1600
R4
100
VDRT02.02GB
0
=4
50
100
014133
9400
R 3=
R 2=1
200
R 1=830
0
V M IN -M A X = 6 0 5 5 -1 2 1 8 5
H
H
H
H
5=18100
4=15100
3=4600
2=3925
9 '6 "
(8 '6 " )
F:7
-20
-10
+10
+20
+30
+40
-4
+14
+32
+50
+68
+86
+104
Cummins QSM11
API CH-4 or ACEA E5
SAE 50
SAE 40
Caterpillar TO-4
SAE 30
MIL-PRF-2104G
NOTE
Engine oil or GL-5 oil must not be used.
SAE 20
SAE 10W
SAE 0W-20
API GL-5
SAE 75W-90
SAE 80W-140
SAE 75W-90
10 Common hydraulics
ISO VG 68
ISO VG 46 HV
ISO VG 32
VDRT02.02GB
F:8
NOTE
Oil filters shall always be changed in connection with oil change.
Change interval for engine oil requires that the sulphur content in
the fuel does not exceed 0.5%.
*) The oil in the brake system must meet one of the quality requirements
as well as be a UTTO oil (Universal Tractor Transmission Oil).
ACEA = Association des Constructeurs Europenne d'Automobiles
API = American Petroleum Institute
Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for
all lubrication points except hoisting equipment and slide plates.
For hoisting equipment use a universal grease type EP according to
NLGI Grade 2 (EP2) with 3-5% molybdenum sulphide content.
For slide plates use a lubricant approved by Cargotec. Order from
Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun,
part no. 923110.0360 and 5 kg can part no. 923595.0003.
NOTE
Select lubrication class according to the prevailing climate.
Contact grease
Contact grease 923836.0552.
Sealant silicone
Sealant silicone 923107.0308.
Silicone adhesive
Silicone adhesive 923854.0100.
Coolant
Use ready-mixed recommended coolant. Choose the mixture of
coolant that is adapted for the right temperature.
NOTE
It is important that the coolant is mixed correctly all year round to
ensure adequate corrosion protection. The corrosion-protective
properties decline with time which is why the coolant has to be
changed in accordance with specified intervals.
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.
VDRT02.02GB
F:9
Condition
Bolt
Nut
Lubrication
untreated
untreated
oil
bright galvanised
dry or oil
hot-galvanised
untreated
dry or oil
8.8
Quality
10.9
12.9
M81
27 Nm
24 Nm
30 Nm
39 Nm
46 Nm
M101,25
54 Nm
48 Nm
61 Nm
78 Nm
91 Nm
M121,25
96 Nm
85 Nm
108 Nm
135 Nm
162 Nm
M161,5
230 Nm
205 Nm
260 Nm
323 Nm
388 Nm
M181,5
330 Nm
294 Nm
373 Nm
466 Nm
559 Nm
M4
3,2 Nm
2,9 Nm
3,6 Nm
4,6 Nm
5,5 Nm
M5
6,4 Nm
5,7 Nm
7,2 Nm
9,1 Nm
11 Nm
M6
11 Nm
9,8 Nm
12,5 Nm
16 Nm
19 Nm
M8
26 Nm
24 Nm
30 Nm
38 Nm
45 Nm
M10
52 Nm
47 Nm
59 Nm
74 Nm
89 Nm
M12
91 Nm
81 Nm
103 Nm
128 Nm
154 Nm
M16
220 Nm
198 Nm
250 Nm
313 Nm
375 Nm
M20
430 Nm
386 Nm
490 Nm
620 Nm
732 Nm
M24
750 Nm
668 Nm
848 Nm
1050 Nm
1270 Nm
M30
1480 Nm
1317 Nm
1672 Nm
2080 Nm
2500 Nm
1/4
12,5 Nm
11,1 Nm
14,1 Nm
17,6 Nm
20 Nm
5/16
25 Nm
22,3 Nm
28,3 Nm
35 Nm
42 Nm
3/8
44 Nm
39 Nm
50 Nm
62 Nm
73 Nm
7/16
70 Nm
62 Nm
79 Nm
100 Nm
118 Nm
1/2
107 Nm
95 Nm
121 Nm
151 Nm
178 Nm
9/16
153 Nm
136 Nm
173 Nm
216 Nm
255 Nm
5/8
210 Nm
187 Nm
237 Nm
298 Nm
353 Nm
Condition
Fine M-thread
M-thread
UNC-thread
VDRT02.02GB
F:10
8.8
Quality
10.9
12.9
3/4
370 Nm
390 Nm
418 Nm
524 Nm
619 Nm
7/8
594 Nm
528 Nm
671 Nm
839 Nm
990 Nm
889 Nm
791 Nm
1005 Nm
1260 Nm
1480 Nm
1 1/8
1260 Nm
1120 Nm
1424 Nm
1780 Nm
2100 Nm
1 1/4
1760 Nm
1565 Nm
1990 Nm
2490 Nm
2940 Nm
1 3/8
2320 Nm
2065 Nm
2620 Nm
3280 Nm
3870 Nm
1 1/2
3060 Nm
2720 Nm
3455 Nm
4320 Nm
5100 Nm
VDRT02.02GB
Pipe diameter
Tightening torque
mm
Nm
inch
6
1/4
5/16
10
3/8
12
1/2
14
15
16
5/8
18
3/4
20
22
7/8
25
1"
28
30
32
1"1/4
35
38
1"1/2
23-25
33-38
51-57
80-90
120-130
150-170
180-200
200-240
Wrench size
Tightening torque
mm
Nm
inch
17
11/16
23-25
22
13/16
33-38
24
15/16
51-57
36
1 3/8
120-130
41
1 5/8
150-170
F:11
Material fitting
UNF-UN
Metric-ISO
BSSP
Thread (inch)
Tightening torque
(Nm)
Thread
(mm)
Tightening torque
(Nm)
Thread (inch)
7/16-20
21
10x1
20
1/8-28
20
1/2-20
27
12x1,5
35
1/4-19
35
9/16-18
40
14x1,5
45
3/8-19
70
3/4-16
78
16x1.5
55
1/2-14
100
7/8-14
110
18x1.5
68
3/4-14
190
1"1/16-12
180
20x1.5
80
1"-11
300
1"3/16-12
230
22x1.5
98
1"1/4-11
330
1"5/16-12
285
26x1.5
170
1"1/2-11
400
1"5/8-12
320
27x2
180
1"7/8-12
400
33x2
310
42x2
330
48x2
400
Thread
Tightening torque
mm
inch
inch
Nm
1/4"
7/16"
7-13 Nm
10
3/8"
5/8"
14-20 Nm
10
3/8"
11/16"
14-20 Nm
12
1/2"
3/4"
14-26 Nm
16
5/8"
7/8"
27-41 Nm
19
3/4"
1 1/16"
34-46 Nm
3/8"
7-13 Nm
Pressure switch
7/16"
The above values should be considered guidelines and may vary
depending on installation.
VDRT02.02GB
F:12
Unit explanations
Unit
VDRT02.02GB
Abbreviation
Newton metre
Nm
Kgf/m
kpm
Kilo pascal
kPa
Mega pascal
MPa
Kilowatt
kW
Kilojoule
kJ
Btu
Calorie
ca
Inch
in
Feet
ft
Yard
yd
Mile
mile
Centimetre
cm
Metre
Kilometre
km
F:13
Conversion SI-units
Recalculation
factor
Non-SI
Recalculation
factor
SI
Nm
x 10.2
= kgcm
x 0.8664
= lbin
Nm
x 0.74
= lbfft
x 1.36
= Nm
Nm
x 0.102
= kgm
x 7.22
= lbft
kPa
x 4.0
= in.H2O
x 0.249
= kPa
kPa
x 0.30
= in.Hg
x 3.38
= kPa
kPa
x 0.145
= psi
x 6.89
= kPa
SI-unit
Torque
bar
x 14.5
= psi
x 0.069
= bar
kp/cm
x 14.22
= psi
x 0.070
= kp/cm2
N/mm
x 145.04
= psi
x 0.069
= bar
x 145
= psi
x 0.00689
= MPa
kW
x 1.36
= hp (cv)
x 0.736
= kW
kW
x 1.34
= bhp
x 0.746
= kW
kW
x 0.948
= Btu/s
x 1.055
= kW
x 0.74
= ftlb/s
x 1.36
= W
kJ
x 0.948
= Btu
x 1.055
= kJ
x 0.239
= calorie
x 4.19
= J
m/s2
x 3.28
= ft/s2
x 0.305
= m/s2
m/s
x 3.28
= ft/s
x 0.305
= m/s
km/h
x 0.62
= mph
x 1.61
= km/h
MPa
Power (W = J/s)
Energy (J = Nm)
Horsepower/torque
Bhp x 5252 rpm= TQ (lbft)
Temperature
C = (F 32)/1.8
F = (C x 1.8) + 32
Flow factor
l/min (dm3 /min)
x 0.264
= US gal/min x 3,785
= litre/min
VDRT02.02GB
F:14
cm
km
in
ft
yd
mile
cm
0.01
0.00001
0.3937
0.03281
0.01094
0.000006
100
0.001
39.37
3.2808
1.0936
0.00062
km
100000
1000
39370.7
3280.8
1093.6
0.62137
in
2.54
0.0254
0.000025
0.08333
0.02777
0.000015
ft
30.48
0.3048
0.000304
12
0.3333
0.000189
yd
91.44
0.9144
0.000914
36
0.000568
mile
160930
1609.3
1.6093
63360
5280
1760
1 mm = 0.1 cm 1 mm = 0.001 m
cm2
m2
km2
ft2
yd2
in2
cm2
0.0001
0.000001
0.001076
0.000012
0.155000
m2
10000
0.000001
0.01
10.764
1.1958
1550.000
km2
1000000
10000
1076400
1195800
0.01
100
0.0001
1076.4
119.58
ft2
0.092903
0.000929
0.1111
144.000
yd2
0.83613
0.008361
1296.00
in2
6.4516
0.000645
0.006943
0.000771
cm3 = cc
m3
in3
ft3
yd3
cm3 = ml
0.000001
0.001
0.061024
0.000035
0.000001
m3
1000000
1000
61024
35.315
1.30796
dm3 (l)
1000
0.001
61.024
0.035315
0.001308
in3
16.387
0.000016
0.01638
0.000578
0.000021
ft3
28316.8
0.028317
28.317
1728
0.03704
yd3
764529.8
0.76453
764.53
46656
27
kg
oz
lb
0.001
0.000001
0.03527
0.0022
kg
1000
0.001
35.273
2.20459
1000000
1000
35273
2204.59
oz
28.3495
0.02835
0.000028
0.0625
lb
453.592
0.45359
0.000454
16
VDRT02.02GB
F:15
kp/cm2
bar
Pa = N/m2
kPa
lbf/in2
lbf/ft2
kp/cm2
0.98067
98066.5
98.0665
14.2233
2048.16
bar
1.01972
100000
100
14.5037
2088.6
Pa = N/m2
0.00001
0.001
0.001
0.00015
0.02086
kPa
0.01020
0.01
1000
0.14504
20.886
lbf/in2
0.07032
0.0689
6894.76
6.89476
144
lbf/ft2
0.00047
0.00047
47.88028
0.04788
0.00694
VDRT02.02GB
F:16
VDRT02.02GB
G:1
VDRT02.02GB
G:2
VDRT02.02GB
G:3
Description
Accumulator
Attachment
Anti-corrosion agent
Working hydraulics
All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension)
and levelling.
Wheelbase
Bar
Battery disconnector
Boom
Daily inspection
Decitonne
Display
"Window" showing digital information, i.e. on steering wheel panel in the cab.
Operating time
Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle
Drive-train
ECC
EHC
Electrolyte level
Expansion tank
Fixed displacement
Hanging load
Lifted load.
FMI
Main fuse
Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil
Hydraulic system
Indicator
Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
Refrigerant
Low-emission engine
LC
Load centre.
Lift capacity
Lifting point
Solenoid valve
Control valve
Valves that can be used to control something, for example, to release pressure and thus
lower a boom or a fork.
VDRT02.02GB
G:4
Term
Description
Machine model
Machine type. Specified, for example: DRT 450. See also Type designation.
Environmental waste
Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter
Hub reduction
Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drive-train.
OP
Overload Protection. Overload system to warn in the event that the machine is
overloaded.
Planetary gear
Product alternative
Proportional valve
Reachstacker
Machine with special lift boom and top lift attachment for containers.
Serial number
Service position
Servo
A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure
Side shift
Levelling
Spirit Delta
SPN
Spreading (positioning)
Widening of attachment.
Dust reservoir
The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle
Buzzer
Option
Tilting
Transmission oil
Oil for transmission and torque converter. See specifications in operator's manual.
Twistlocks
Four locking pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation
Maintenance
Periodic maintenance actions so that machine functions safely and for a long service life.
UTTO oil
Variable pump
Variable displacement
Wet brakes
Valve slide
Rotation bar
Overload system
A warning system, LLMC (Longitudinal Load Moment Control). The system is used for
stationary load handling, to not jeopardise the machine's forward stability. LLMC is not
designed to control lateral stability or stability when operating.
VDRT02.02GB
Index
A
About the documentation . . . . . . . . .
About the Workshop Manual . . . . . . . .
Accelerator . . . . . . . . . . . . . . .
Accumulator . . . . . . . . . . . . . . .
Accumulator charging valve . . . . . . . .
Accumulator drain valve . . . . . . . . . .
Accumulator servo circuit . . . . . . . . .
Air cleaning system . . . . . . . . . . . .
Air distributor . . . . . . . . . . . . . . .
Air intake and exhaust outlet . . . . . . . .
Air suspension . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . .
Arm rest . . . . . . . . . . . . . . . . .
ATTACH . . . . . . . . . . . . . . . . .
ATTACH, menu 1 . . . . . . . . . . . . .
ATTACH, menu 10 . . . . . . . . . . . .
ATTACH, menu 11 . . . . . . . . . . . .
ATTACH, menu 12 . . . . . . . . . . . .
ATTACH, menu 13 . . . . . . . . . . . .
ATTACH, menu 14 . . . . . . . . . . . .
ATTACH, menu 15 . . . . . . . . . . . .
ATTACH, menu 16 . . . . . . . . . . . .
ATTACH, menu 17 . . . . . . . . . . . .
ATTACH, menu 18 . . . . . . . . . . . .
ATTACH, menu 19 . . . . . . . . . . . .
ATTACH, menu 2 . . . . . . . . . . . . .
ATTACH, menu 20 . . . . . . . . . . . .
ATTACH, menu 21 . . . . . . . . . . . .
ATTACH, menu 22 . . . . . . . . . . . .
ATTACH, menu 3 . . . . . . . . . . . . .
ATTACH, menu 4 . . . . . . . . . . . . .
ATTACH, menu 5 . . . . . . . . . . . . .
ATTACH, menu 6 . . . . . . . . . . . . .
ATTACH, menu 7 . . . . . . . . . . . . .
ATTACH, menu 8 . . . . . . . . . . . . .
ATTACH, menu 9 . . . . . . . . . . . . .
ATTACHMENT . . . . . . . . . . . . . .
Axial piston pump with variable displacement .
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A:12
. . A:3
. . 1:19
. . 4:14
4:11, 4:38
. . . 10:3
7:10, 7:29
. . . 1:21
. . . 9:48
. . . 1:21
. . . 9:16
. . . 11:6
. . . 9:17
. . . 8:79
. . . 8:79
. . . 8:85
. . . 8:86
. . . 8:87
. . . 8:88
. . . 8:89
. . . 8:89
. . . 8:90
. . . 8:90
. . . 8:90
. . . 8:90
. . . 8:80
. . . 8:90
. . . 8:91
. . . 8:91
. . . 8:81
. . . 8:81
. . . 8:82
. . . 8:82
. . . 8:83
. . . 8:83
. . . 8:84
. . 8:102
. . 10:10
B
Back rest cushion . . . . . . . . . . . . . . . . . . 9:15
Back-up alarm . . . . . . . . . . . . . . . . . . . 9:69
Back-up lights . . . . . . . . . . . . . . . . . . . 9:62
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:4
Battery disconnector . . . . . . . . . . . . . . . . 11:3
Body structure . . . . . . . . . . . . . . . . . . . 9:84
BOOM . . . . . . . . . . . . . . . . . . . 8:72, 8:99
BOOM, menu 1. . . . . . . . . . . . . . . . . . . 8:72
BOOM, menu 2. . . . . . . . . . . . . . . . . . . 8:72
BOOM, menu 3. . . . . . . . . . . . . . . . . . . 8:74
BOOM, menu 4. . . . . . . . . . . . . . . . . . . 8:75
BOOM, menu 5. . . . . . . . . . . . . . . . . . . 8:76
BOOM, menu 6. . . . . . . . . . . . . . . . . . . 8:77
BOOM, menu 7. . . . . . . . . . . . . . . . . . . 8:78
BOOM, menu 8. . . . . . . . . . . . . . . . . . . 8:79
Brake cylinder . . . . . . . . . . . . . . . . . . . 4:29
Brake lights . . . . . . . . . . . . . . . . . . . . 9:62
Brake oil filter . . . . . . . . . . . . . . 4:10, 4:31, 4:43
Brake oil pump . . . . . . . . . . . . . . 4:6, 4:31, 4:38
Brake oil tank . . . . . . . . . . . . . . . . . . . 4:38
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:3
Brake valve . . . . . . . . . . . . . . . . . . . . 4:18
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3
Break contact (opening switch) brake oil pressure . . . . 4:23
Break contact (opening switch) declutch . . . . . . . . 2:19
G:5
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. 4:36
. 4:42
10:30
. 9:16
. 9:10
. 8:10
10:29
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. . 8:40
. . 9:80
. . 9:79
. . 9:81
. . 9:79
. . 9:80
. . 9:80
. . 8:40
. . 8:48
. . 8:41
. . 8:42
. . 8:43
. . 8:44
. . 8:45
. . 8:46
. . 8:47
. . 8:47
. . 9:30
. 11:25
. 8:115
. 8:113
. 8:110
. 11:32
. 11:36
. . 8:13
. . 8:13
. . 8:22
. . 8:23
. . 8:23
. . 8:23
. . 8:24
. . 8:24
. . 8:25
. . 8:25
. . 8:25
. . 8:26
. . 8:14
. . 8:26
. . 8:27
. . 8:15
. . 8:16
. . 8:17
. . 8:18
. . 8:19
. . 8:20
. . 8:21
. . 9:83
. . 8:48
. . 8:48
. . 8:49
. . 8:50
. . 8:50
. . 8:51
. . 8:51
. . 8:53
. . 8:54
11:3, E:8
10:3, E:3
. 11:32
. 11:37
. . 0:3
. . 9:37
C
CAB . . . . . . . . . . . . . . . .
Cab cradle . . . . . . . . . . . . . .
Cab frame . . . . . . . . . . . . . .
Cab interior . . . . . . . . . . . . .
Cab structure and suspension . . . . .
Cab substructure . . . . . . . . . . .
Cab substructure, sliding cab . . . . . .
CAB, menu 1. . . . . . . . . . . . .
CAB, menu 10 . . . . . . . . . . . .
CAB, menu 2. . . . . . . . . . . . .
CAB, menu 3. . . . . . . . . . . . .
CAB, menu 4. . . . . . . . . . . . .
CAB, menu 5. . . . . . . . . . . . .
CAB, menu 6. . . . . . . . . . . . .
CAB, menu 7. . . . . . . . . . . . .
CAB, menu 8. . . . . . . . . . . . .
CAB, menu 9. . . . . . . . . . . . .
Cabin fan . . . . . . . . . . . . . .
Cable harness . . . . . . . . . . . .
Calibrate DRIVE-TRAIN . . . . . . . .
Calibrate SCALE . . . . . . . . . . .
Calibration . . . . . . . . . . . . . .
CAN bus . . . . . . . . . . . . . .
CAN bus drive-train . . . . . . . . . .
CAN/POWER . . . . . . . . . . . .
CAN/POWER, menu 1 . . . . . . . .
CAN/POWER, menu 10 . . . . . . . .
CAN/POWER, menu 11 . . . . . . . .
CAN/POWER, menu 12 . . . . . . . .
CAN/POWER, menu 13 . . . . . . . .
CAN/POWER, menu 14 . . . . . . . .
CAN/POWER, menu 15 . . . . . . . .
CAN/POWER, menu 16 . . . . . . . .
CAN/POWER, menu 17 . . . . . . . .
CAN/POWER, menu 18 . . . . . . . .
CAN/POWER, menu 19 . . . . . . . .
CAN/POWER, menu 2 . . . . . . . .
CAN/POWER, menu 20 . . . . . . . .
CAN/POWER, menu 21 . . . . . . . .
CAN/POWER, menu 3 . . . . . . . .
CAN/POWER, menu 4 . . . . . . . .
CAN/POWER, menu 5 . . . . . . . .
CAN/POWER, menu 6 . . . . . . . .
CAN/POWER, menu 7 . . . . . . . .
CAN/POWER, menu 8 . . . . . . . .
CAN/POWER, menu 9 . . . . . . . .
Chassis . . . . . . . . . . . . . . .
CLIMATE . . . . . . . . . . . . . .
CLIMATE, menu 1 . . . . . . . . . .
CLIMATE, menu 2 . . . . . . . . . .
CLIMATE, menu 3 . . . . . . . . . .
CLIMATE, menu 4 . . . . . . . . . .
CLIMATE, menu 5 . . . . . . . . . .
CLIMATE, menu 6 . . . . . . . . . .
CLIMATE, menu 7 . . . . . . . . . .
CLIMATE, menu 8 . . . . . . . . . .
Common electrics . . . . . . . . . .
Common hydraulics . . . . . . . . . .
Communication. . . . . . . . . . . .
Communication between PC and machine
Complete machine . . . . . . . . . .
Compressor . . . . . . . . . . . . .
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VDRT02.02GB
G:6
D
Defroster nozzles . . .
Diagnostics . . . . .
Direction indicators . .
Disc pack . . . . . .
Distribution of electricity
Doors . . . . . . . .
Drive axle . . . . . .
Drive axle block . . .
DRIVE-TRAIN . . . .
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. . 9:49
. . 8:11
. . 9:63
. . 4:29
. . 11:7
. . 9:79
. . 3:4
4:22, 4:38
. . 8:107
Electric protection. . . . . . . .
Electronic box . . . . . . . . .
Electronic box frame . . . . . .
Electronic box, cab . . . . . . .
Emergency stop switch voltage . .
Engine . . . . . . . . . . . .
ENGINE . . . . . . . . . . . .
Engine control unit . . . . . . .
ENGINE, menu 1 . . . . . . . .
ENGINE, menu 10 . . . . . . .
ENGINE, menu 2 . . . . . . . .
ENGINE, menu 3 . . . . . . . .
ENGINE, menu 4 . . . . . . . .
ENGINE, menu 5 . . . . . . . .
ENGINE, menu 6 . . . . . . . .
ENGINE, menu 7 . . . . . . . .
ENGINE, menu 8 . . . . . . . .
ENGINE, menu 9 . . . . . . . .
Entertainment and communication
Environment . . . . . . . . . .
Error code menu . . . . . . . .
Error codes . . . . . . . . . .
Exhaust system . . . . . . . .
Expansion valve . . . . . . . .
Extension . . . . . . . . . . .
Extension cylinder . . . . . . .
EXTRA . . . . . . . . . . . .
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. . .
A:13
. . . 10:33
. . . . 9:10
. 9:63, 9:68
E
. . . 11:3
. . 11:14
. . 11:15
. . 11:14
. . 11:11
1:3, D:8, D:8
. . . . 8:59
. 1:30, 11:22
. . . . 8:59
. . . . 8:64
. . . . 8:59
. . . . 8:60
. . . . 8:60
. . . . 8:61
. . . . 8:62
. . . . 8:62
. . . . 8:63
. . . . 8:64
. . . . 9:70
. . .
B:19
. . . . 8:4
. . D:3, D:3
. . . . 1:21
. . . . 9:44
. . . . 7:26
. . . . 7:30
. . . . 8:95
F
Feedback . . . . . .
Fine filter hydraulic oil .
Fire extinguisher . . .
Flashing hazard lights .
VDRT02.02GB
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Flex plates . . . . . . . . . . .
Floor covering . . . . . . . . .
Footsteps and hand rail . . . . .
Foreword . . . . . . . . . . .
Frame, body, cab and accessories
Fresh air and recirculation damper
Fresh air filter . . . . . . . . .
Fuel system . . . . . . . . . .
Fuel tank . . . . . . . . . . .
Fuses . . . . . . . . . . . . .
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2:10
9:82
9:84
A:3
9:3
9:27
9:26
1:20
1:20
11:3
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. . . 10:6
. 2:9, 9:8
. . . B:3
. . . 9:71
G
Gear pump with fixed displacement .
Gear selector and multi-function lever
General safety information . . . . .
Glass/windows/mirrors . . . . . .
H
Headlights . . . . . . . . . . . . . . . . . . . . . 9:61
Heat exchanger heat . . . . . . . . . . . . . . . . 9:33
Heat exchanger, cooling . . . . . . . . . . . . . . . 9:47
Heating coil . . . . . . . . . . . . . . . . . . . . 9:15
Heating, ventilation and air conditioning . . . . . . . . 9:19
Hood engine compartment . . . . . . . . . . . . . . 9:84
Horn . . . . . . . . . . . . . . . . . . . . . . . 9:68
Hoses, pipes and valves . . . . . . . . . . . . . . 10:21
HYD . . . . . . . . . . . . . . . . . . . . . . . 8:54
HYD, menu 1 . . . . . . . . . . . . . . . . . . . 8:55
HYD, menu 2 . . . . . . . . . . . . . . . . . . . 8:55
HYD, menu 3 . . . . . . . . . . . . . . . . . . . 8:56
HYD, menu 4 . . . . . . . . . . . . . . . . . . . 8:57
HYD, menu 5 . . . . . . . . . . . . . . . . . . . 8:57
HYD, menu 6 . . . . . . . . . . . . . . . . . . . 8:58
Hydraulic cylinders . . . . . . . . . . . . . . . . 10:35
Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:33
Hydraulic oil cooler . . . . . . . . . . . . . . . . 10:26
Hydraulic oil filter . . . . . . . . . . . . . . . . . 10:31
Hydraulic oil pump . . . 5:4, 7:9, 7:29, 7:39, 7:52, 7:68, 7:81
I
Ignition . . . . . . . . . .
Ignition voltage (15) . . . . .
Initiation . . . . . . . . . .
Instrument and control panels
Insulation . . . . . . . . .
Intercooler . . . . . . . . .
Interior fittings, plastic . . . .
Interior fittings, textile . . . .
Interior lighting . . . . . . .
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1:19
11:9
8:96
9:81
9:82
1:22
9:82
9:82
9:65
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. . . 7:6
7:24, 7:35
. . . 7:17
. . . 9:57
. . . 8:27
. . . 8:27
. . . 8:36
. . . 8:37
. . . 8:38
. . . 8:39
. . . 8:28
. . . 8:29
. . . 8:31
. . . 8:31
. . . 8:33
L
Lift and lower. . .
Lift boom . . . .
Lift cylinder . . .
Lighting system. .
LIGHTS . . . . .
LIGHTS, menu 1 .
LIGHTS, menu 10
LIGHTS, menu 11.
LIGHTS, menu 12
LIGHTS, menu 13
LIGHTS, menu 2 .
LIGHTS, menu 3 .
LIGHTS, menu 4 .
LIGHTS, menu 5 .
LIGHTS, menu 6 .
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LIGHTS, menu 7 .
LIGHTS, menu 8 .
LIGHTS, menu 9 .
Link arm . . . . .
Load carrier . . .
Load handling . .
Lock cylinder . . .
Lock mechanism .
Lubrication system
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8:34
8:35
8:36
5:14
7:79
7:3
7:82
7:82
2:13
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Safety . . . . . . . . . . . . . . .
Safety and emergency equipment. . .
Safety instructions . . . . . . . . .
Safety valves. . . . . . . . . . . .
Schematics . . . . . . . . . . . .
Seat . . . . . . . . . . . . . . .
Seat belt. . . . . . . . . . . . . .
Seat cushion . . . . . . . . . . . .
Sensor boom angle . . . . . . . . .
Sensor boom length. . . . . . . . .
Sensor cab temperature . . . . . . .
Sensor fuel level . . . . . . . . . .
Sensor hydraulic oil temperature . . .
Sensor twistlocks . . . . . . . . . .
Sensor, alignment . . . . . . . . .
Sensor, ambient temperature . . . . .
Sensor, engine temperature . . . . .
Sensor, hydraulic pressure lift cylinder .
Sensor, oil temperature brake system .
Sensor, operator-in-seat . . . . . . .
Sensor, temperature outlet fan . . . .
Sensor, temperature refrigerant . . . .
Servo filter . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . .
Side shift . . . . . . . . . . . . .
Side shift cylinder . . . . . . . . . .
Side shift frame. . . . . . . . . . .
Side window . . . . . . . . . . . .
Signalling system . . . . . . . . . .
Sliding cab . . . . . . . . . . . . .
SLIDING-CAB . . . . . . . . . . .
Solenoid valve parking brake . . . . .
Speed limitation . . . . . . . . . .
Spreader beam . . . . . . . . . . .
Spreader chains . . . . . . . . . .
Spreading (positioning) . . . . . . .
Spreading (positioning) motor . . . .
Start battery . . . . . . . . . . . .
Start/stop . . . . . . . . . . . . .
Starter motor . . . . . . . . . . . .
Steering . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . .
Steering axle cradle . . . . . . . . .
Steering cylinder . . . . . . . . . .
Steering valve . . . . . . . . . . .
Stopping device . . . . . . . . . .
Suspension . . . . . . . . . . . .
Switch, direction indicators . . . . . .
Switch, lock twistlocks . . . . . . . .
Synchronised lift . . . . . . . . . .
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9:63, 9:68
. . 6:19
. . 7:76
. . 8:95
. . 9:77
. . 7:67
. . 7:74
. . 7:71
. . 9:61
M
Main beam, attachment . . . . . . . . .
Make-contact (closing switch) brake lights .
Make-contact (closing switch) water in fuel .
Mechanical seat adjustment . . . . . . .
Monitoring . . . . . . . . . . . . . . .
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7:48, 7:66
. . 4:25
. . 1:20
. . 9:17
. . 8:7
N
Nut, washer and clamp . . . . . . . . . . . . . . . 6:20
O
Oil cooler . . . .
Oil, brake system .
OP . . . . . . .
OP, menu 1 . . .
OP, menu 2 . . .
OP, menu 3 . . .
OP, menu 4 . . .
OP, menu 5 . . .
OP, menu 6 . . .
Other . . . . . .
Other functions . .
Overload system .
Revolving beacon.
Rim . . . . . . .
Ring gear . . . .
RMI . . . . . . .
Roof window . . .
Rotation . . . . .
Rotation bar . . .
Rotation motor unit
Running lights . .
G:7
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P
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:86
Parking brake caliper . . . . . . . . . . . . . . . . 4:34
Parking brake disc . . . . . . . . . . . . . . . . . 4:35
Parking brake pads . . . . . . . . . . . . . . . . . 4:34
Parking brake system . . . . . . . . . . . . . . . . 4:30
Parking brake unit . . . . . . . . . . . . . . . . . 4:32
Pipes and hoses . . 4:29, 4:36, 4:44, 5:14, 7:24, 7:37,
7:49, 7:66, 7:78, 7:85, 10:410:5, 10:2010:21, 10:34
Position sensor, spreading . . . . . . . . . . . . . . 7:66
Power assisted system . . . . . . . . . . . . . . . 5:3
Power transmission . . . . . . . . . . . . . . . . . 3:3
Power-assisted brake system . . . . . . . . . . . . 4:5
Pressure limiting valve . . . . . . . . . . . . . . . 10:4
Pressure switch . . . . . . . . . . . . . . . . . . 9:42
Preventive maintenance . . . . . . . . . . . . . . . C:1
Priority valve . . . . . . . . . . . . . . . . . 5:4, 10:21
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:3
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6
R
Radiator and expansion tank . . . . . . . . . . . . . 1:24
Reading instructions . . . . . . . . . . . . . . . . A:4
Rear view mirror . . . . . . . . . . . . . . . . . . 9:78
Rear window . . . . . . . . . . . . . . . . . . . . 9:78
Receiver drier . . . . . . . . . . . . . . . . . . . 9:42
Redundant CAN bus . . . . . . . . . . . . . . . 11:34
Redundant voltage feed of control units . . . . . . . . 11:7
Relief valve, attachment . . . . . 7:49, 7:66, 7:77, 7:85, 10:3
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. . . . B:3
. . . . 9:10
. . . . B:4
. . . . 10:3
. . . . E:3
. . . . 9:11
. . . . 9:10
. . . . 9:14
7:24, 7:88, 8:8
7:37, 7:88, 8:9
. . . . 9:51
. . . . 1:20
. . . 10:27
. . . . 7:85
. . . . 7:84
. . . . 9:52
. . . . 9:36
7:21, 7:88, 8:9
. . . . 4:41
. . . . 9:17
. . . . 9:50
. . . . 9:45
. . 7:9, 7:29
. . . . 8:96
. . . . 7:38
. . . . 7:44
. 7:45, 7:77
. . . . 9:75
. . . . 9:66
. . . . 9:80
. . . 8:107
. . . . 4:31
. . . . 8:10
. . . . 7:64
. . . . 7:57
. . . . 7:50
. . . . 7:53
. . . . 11:4
. . . . 1:31
. . . . 1:31
. . . . 5:3
. . . 8:107
. . 5:13, 6:5
. . . . 5:11
. . . . 5:8
. . . . 1:31
. . . . 6:3
. . . . 9:9
. . . . 7:5
. . . . 7:91
T
Tail lights . . . . . . . . . . . . . . . . . .
Tank . . . . . . . . . . . . . . . . . . . .
Tanks and accumulators . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . .
Temperature control, cleaning and hydraulic oil . .
Temperature control, cleaning and oil brake system
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. 9:62
. 10:5
. 10:5
. F:3
10:25
. 4:37
VDRT02.02GB
G:8
Terminology . . . . . . . . .
Terminology and index . . . .
Thermal bypass valve . . . . .
Torque converter/Clutch system
TRANSM . . . . . . . . . .
TRANSM, menu 1 . . . . . .
TRANSM, menu 10 . . . . . .
TRANSM, menu 11 . . . . . .
TRANSM, menu 12 . . . . . .
TRANSM, menu 13 . . . . . .
TRANSM, menu 14 . . . . . .
TRANSM, menu 2 . . . . . .
TRANSM, menu 3 . . . . . .
TRANSM, menu 4 . . . . . .
TRANSM, menu 5 . . . . . .
TRANSM, menu 6 . . . . . .
TRANSM, menu 7 . . . . . .
TRANSM, menu 8 . . . . . .
TRANSM, menu 9 . . . . . .
Transmission. . . . . . . . .
Transmission cable harness . .
Transmission control unit . . .
Twistlocks . . . . . . . . . .
Tyres . . . . . . . . . . . .
Tyres and rims . . . . . . . .
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. . . . . G:3
. . . . . G:3
. . . . . 4:40
. . . . . 2:10
. . . . . 8:65
. . . . . 8:65
. . . . . 8:70
. . . . . 8:70
. . . . . 8:70
. . . . . 8:70
. . . . . 8:71
. . . . . 8:66
. . . . . 8:66
. . . . . 8:67
. . . . . 8:68
. . . . . 8:69
. . . . . 8:69
. . . . . 8:69
. . . . . 8:69
2:3, D:52, D:52
. . . . . 2:19
. . 2:19, 11:21
. . 7:79, 7:83
. . . . . 6:18
. . . . . 6:16
V
Valve block lift cylinder . . . . . . . . . . . . . . . 7:13
VDRT02.02GB
. . . . . . . . . 7:70
. . . 5:14, 7:25,
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. . 7:53
. . 7:30
. 11:13
. . 11:7
W
Warning parking brake . .
Washer motor and reservoir
Water valve . . . . . . .
Weight indicator . . . . .
Wheel brakes . . . . . .
Wheel hub . . . . . . . .
Wheel spindle . . . . . .
Windscreen . . . . . . .
Wings . . . . . . . . . .
Wiper front . . . . . . . .
Wiper motor front . . . . .
Wiper motor rear . . . . .
Wiper motor roof . . . . .
Wiper rear . . . . . . . .
Wiper roof . . . . . . . .
Wiper/washer system . . .
Work light boom . . . . .
Working lights, attachment .
Working lights, cab . . . .
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. . 9:69
. . 9:53
. . 9:36
. . 7:87
4:26, 4:38
5:14, 6:11
. 5:14, 6:7
. . . 9:72
. . . 9:84
. . . 9:53
. . . 9:54
. . . 9:56
. . . 9:55
. . . 9:53
. . . 9:53
. . . 9:53
. . . 9:64
. . . 9:65
. . . 9:64
G:9
VDRT02.02GB
last page
Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 00
fax +46 372 263 90
www.cargotec.com