VDCF03 - 02GB - DCF80-100 Workshop Manual

A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop
manual 2 Transmission
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 Terminologi och Index

A Foreword 1
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About machine version ...................................................................................... 3
Copyright ........................................................................................................... 3
Reading instructions ................................................................................... 4
Warning information .......................................................................................... 4
Important information ........................................................................................ 4
Read operator’s manual .................................................................................... 4
Read the Maintenance manual ......................................................................... 4
The workshop manual’s contents ...................................................................... 5
Function group structure ................................................................................... 6
References between different information types ............................................... 7
Product alternatives and optional equipment .................................................... 8
Machine card ..................................................................................................... 9
Function descriptions ...................................................................................... 10
About the documentation ......................................................................... 13
The documentation’s parts .............................................................................. 13
Ordering documentation .................................................................................. 13
Feedback .................................................................................................. 14
Form for copying ............................................................................................. 14
Workshop manual DCF 80-100 VDCF03.02GB

2 A Foreword
VDCF03.02GB Workshop manual DCF 80-100

A Foreword – Foreword 3
Foreword
mm mm mm mm mm mm
About the Workshop Manual

General
page
–
Thank you for choosing Kalmar Industries as your machine supplier.

We hope that we'll meet your expectations.
Conditions
page
–
The instructions are based on the use of generally available standard

tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet governing national standards and regulations for lifting devices.
Cargotec will not accept any responsibility in the event of a modifica-
tion 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
page
–
NOTE
The workshop manual should be accessible to service personnel.
About machine version

page
–
The information in this publication corresponds to the machine’s de-

sign and appearance at the time of delivery from Cargotec. Due to cus-
tomisations, there may be variations and/or deviations.
Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in the manual are valid at
the time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Extreme hazard to personal health and risk of proper-

ty damage!
Only use equipment that is approved by Cargotec.
Copyright
page
–
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.

4 A Foreword – Reading instructions
Reading instructions
Warning information
page
–
Warnings provide information about potential dangers that, if the warn-

ings 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 regula-
tion is not followed.
CAUTION
Situation that could lead to product damage if regula-
tion is not followed.
Important information
page
–
Important information is denoted with NOTE and is intended to facili-

tate the work process, handling or to increase understanding of the
information.
NOTE
Important information not related to safety.
Read operator’s manual

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s manual.
000262
Read the operator’s manual
Read the Maintenance manual

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Maintenance manual.
001128
Read the Maintenance manual

A Foreword – Reading instructions 5
The workshop manual’s contents

page
–
The workshop manual contains information for corrective mainte-

nance (replacement of components) and serves to supplement the
maintenance manual. The workshop manual is accompanied by sup-
plier documentation for engine, transmission and drive axle. Wherever
possible, the workshop manual makes refers to the maintenance man-
ual and supplier documentation to avoid double information.
The workshop manual is divided into the following sections.
A Foreword General information about the workshop manual’s purpose, contents and reading in-
structions as well as survey for feedback of views and any inaccuracies.
B Safety Keep in mind for your safety.
C Preventive maintenance Reference to maintenance manual: Preventive maintenance.
0 Complete machine
1 Engine
2 Transmission
3 Power transmission
Technical description, comprehensive function descriptions and a description of the
4 Brakes function of components included in the machine, divided into function groups.
5 Steering The components used for each function are described under each subfunction. Con-
sequently, common components are described in several places, but in general un-
6 Suspension der the first function to use the component.
7 Load handling Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
8 Control system
only has a description what is unique for the new function.
9 Frame, body, cab and
Work instructions for corrective maintenance (replacement of components).
accessories
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
E Schematics Wiring and hydraulic diagrams.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanation of terms and abbreviations that
can appear in the sections, index for headings in the sections.

Function group structure

page
–
The information in the manual is divided in a structure of functions at

different levels, based on the machine’s design and use, called func-
tion groups.
The highest level (called main group) indicates area, such as
group 7 Load handling. The second level (called two-position) indi-
cates function, such as 7.2 Lift/lower. The third and fourth levels are
used to break down functions into smaller parts (components).
The main group and two-position group level structure for the function
groups is used for all Cargotec machines, e.g., 4.3 Power-assisted
brake system. Machine-specific function group adaptations are done
at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc assembly. Function groups (headings) are only included
in the documentation of a machine if the machine has that function or
component. Thus, there may be gaps in function group numbering,
e.g., the three-position heading level 4.8.7 Oil cooler is included for
some machines but not for others.
The function groups are intended to be used as a search term to be
able to find various types of information between different sections and
manuals. The information of a function group is divided into smaller
segments based on type of content, such as description or
replacement.
The Maintenance Manual and Workshop Manual contain different in-
formation. The Maintenance Manual only contains information re-
quired for preventive maintenance and minor troubleshooting. The
Workshop Manual contains more in-depth information and repair
instructions.
References between sections in the same manual are indicated with
section and group number, e.g., "see section 4 Brakes,
group 4.3.9 Wheel brake". References within a section are indicated
with a page number, e.g. "see Sensor fuel level, description page 24".
There are no references between the Maintenance Manual and Work-
shop Manual. If more information on a function group is required,
search under the same function group in the other manual. For more
in-depth information on where different types of information are locat-
ed and what references are made, see References between different
information types page 7.

References between different information types

page
–
The maintenance manual and workshop manual are mainly divided

into function groups, see The workshop manual’s contents page 5.
Certain parts are broken out as separate parts to increase usability,
e.g., "Technical data".
The basic rule of searching for information is to use function groups to
find different types of information regarding the function or component
in question. As a supplement to this, there are references according to
the following.
Function descriptions Hydraulic diagrams

(Technical description) (Section E)
Component descriptions Error codes

(Technical description, normally in Workshop manual) (Section D)
Diagnostics Wiring diagrams

(Group 8.4) (Section E)
• From Function description to Component description, to enable

fast finding of more information about the different components
that create a function.
• From Function description to Hydraulic diagram, to enable fast
finding of the right hydraulic diagram for the function in question.
• From Component description or Function description to Diagnos-
tics, to enable fast finding of the right diagnostic menu that can be
used to check the component (only applies to electrical
components).
• From Diagnostics to Wiring diagrams, to enable fast finding of the
right circuit diagram for further troubleshooting.
• From Diagnostics to Component description or Function descrip-
tion, to enable fast finding of more information about the compo-
nent’s appearance and position when troubleshooting.
• From Error codes to Diagnostics, to enable fast finding of the right
diagnostic menu to troubleshoot component or function in
question.
• From Error codes to Function description or Component descrip-
tion, to enable fast finding of more information about components
or function.

Product alternatives and optional equipment

page
–
The information in the manual is divided into modules. If a product al-

ternative or optional equipment is installed, handling may differ from
that indicated in the modules depending on what is being described.
See below.
Special equipment is not described in the manual. If uncertain as to
what equipment is installed on the machine, use the machine card to
determine which information is relevant. See Machine card page 9.
Product alternative
Product alternative describes options that are fitted instead of a spe-
cific piece of standard equipment (e.g. engine alternative).
Equivalent information for different product alternatives is described in
separate paragraphs after each other under 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 alterna-
tive, e.g. "(Product alternative Climate control system ECC)". In addi-
tion, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
000264
Optional equipment refers to options that can be added to standard

equipment for more or improved functions.
Symbol for optional equipment
Information on optional equipment is described in separate segments
together with the standard equipment. The optional equipment de-
scription covers how the equipment affects standard function and what
components are added.

Machine card
page
–
NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
IMPORTANT
Changes made on the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
The machine card indicates of which drawings the machine consists.

In many cases these can be associated to options and product alter-
natives. For more information about handling of product alternatives
and optional equipment, see Product alternatives and optional equip-
ment page 8. The machine card is delivered with the parts catalogue.
The machine card is divided into the same function groups as the
spare parts catalogue, maintenance manual and workshop manual.
For practical reasons, the machine card only uses the first and second
level of the function group register. The function groups are written in
groups of four characters, e.g., group 0107 refers 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.

Function descriptions
page
–
The function descriptions are schematic overviews that describe how

a function works as well as which components and signals work
together.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions 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.
40 7 Lasthantering 7.5 Spridning
7.5 Spridning
Spridning, funktionsbeskrivning
F ruts ttning B rv rde H nvisning

Man verbrytare Inte aktiverad Flik 11 Gemensam el, grupp 11.5.1.4 Man verbrytarsp nning
Twistlocks/L sklaffar Ol sta eller f rbi- Twistlocks, beskrivning sida 65 eller Lyftkrok, beskrivning sida 77
koppling aktiverad Flik 8 Styr- och vervakningssystem, grupp 8.2.2 F rbikoppling
1
D1
1b
1a
2
D790-1
10 D797-1 D791-1 8,9,17,18

3
D8 D9
D3 10,19 11,20
C
P1 12
4
T1 15
D15
A B A B 21
D16
2
9 5 15 16
C
6 13,22 14,22
7
8
3
009345
Pos F rklaring Signalbeskrivning H nvisning

1a Str mst lare spridning 20 40
- U = 24 V Str mst llare spridning 20 -40 , beskrivning
(S1012) s nder sp nningsignal till sida 7
Reglerenhet hytt (D790-1). D1: Diagnosmeny, se flik 8 Styr- och vervak-
ningssystem, grupp 8.4.9.3 ATTACH, meny 3
1b Man verspak (S815-T1.1 och Spridning: US815-T4 = 24 V Man verspak, beskrivning sida 6
S815-T1.2) s nder sp nningssignal D1: Diagnosmeny, se flik 8 Styr- och vervak-
Ut: US815-T1.2 = 24 V
till Reglerenhet hytt (D790-1). ningssystem, grupp 8.4.9.2 ATTACH, meny 3
In: US815-T1.1 = 24V
2 Reglerenhet hytt (D790-1) s nder Kontrolleras av styr- och Flik 11 Gemensam el, grupp 11.5.3.1 Regle-
7 spridning in eller ut p CAN-bussen. vervakningssystemet, fel renhet hytt (D790-1) 4
visas med felkod.
6
010058
VDCF03.01SE Verkstadsmanual DCF 90-100

5
Example of function description

1. Flag diagnostics, indicates that the signal can be checked with a

diagnostic test; see group 8.4 Diagnostics
2. Hydraulic force (solid double line)
3. Illustration of function, (lifting/lowering)
4. Reference to description of component
5. Signal description, reference value for signal out from component
6. Description of the component’s function
7. Position number, reference to position in illustration
8. Position number in illustration, reference to row in table
9. Flag pressure check connection (Check point), indicates that
there is pressure check connection for checking the pressure
signal
10. Electric power (solid single line)

Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols
1 2 are based on standard symbols for wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7 8 M 7. Hydraulic oil pump with fixed displacement
8. Electric motor
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12
12. Radiator
D790-1 13. Bulb
13 14 14. Control system, two control units with CAN bus

D797-F 15. Restriction
16. Adjustable restriction
15 16
17. Inductive position sensor
17 18 18. Electrically controlled servo valve
19. Thermal bypass valve
19 ˚C 20 ˚C
20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 22
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
26 27
28. Shuttle valve
29. Non-return valve
28 29
000523

A Foreword – About the documentation 13
About the documentation

The documentation’s parts
page
–
The documentation for the machine consists of the following parts:
Operator’s manual
The operator’s manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
There is supplementary documentation that can be ordered for the
machine.
• Workshop manual.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
page
–
Documentation is ordered from the dealer.

Always indicate publication number when ordering.

14 A Foreword – Feedback
Feedback
Form for copying
page
–
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. Thank you
for your cooperation!
To: Cargotec Sweden AB

Product Support
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: .........................................................................................................................................
Phone: ............................................................................................................................................................
E-mail: ............................................................................................................................................................
Date: .................................... - .................. - ..................
Manual
information Name / Publication number: ............................................................................................................................
Section / page number: ...................................................................................................................................
Suggestions,
views, ........................................................................................................................................................................
remarks, etc.
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................

B Safety 1
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurising ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 8
Working under the machine .............................................................................. 9
Lifting heavy components ................................................................................. 9
Vibration .......................................................................................................... 10
Noise ............................................................................................................... 10
Dissolvent ........................................................................................................ 11
Fire and explosion risk .................................................................................... 12
Fluid or gas under pressure ............................................................................ 14
Coolant ............................................................................................................ 15
Refrigerant ...................................................................................................... 15
Air pollution ..................................................................................................... 16
Tensioned springs ........................................................................................... 18
Electric motors ................................................................................................. 18
Rotating components and tools ....................................................................... 18
Tyres and rims ................................................................................................. 19
Lifting equipment ............................................................................................. 20
Spare parts ........................................................................................................... 21
Non-ionised radiation ........................................................................................... 22
Environment ............................................................................................. 23
General ........................................................................................................... 23

2 B Safety

B Safety – Safety 3
Safety
mm mm mm mm mm mm
General safety information

Safety concerns everyone!
page
–
The safety information applies to all who work with the machine! Per-
sons 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:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools intended for the work in
question
• wear the correct clothing
• use common sense and work carefully. Do not take any risks!
Kalmar Industries has in this publication documented and warned for
situations and risks that may occur in connection with using as well as
service/repairs of the machine during normal circumstances.
That’s why it’s important that all who work with the machine or repair/
service the machine read and follow the information in the mainte-
nance manual and operator’s manual.
A near accident is a warning!

page
–
An incident (near-accident) is an unexpected event where neither per-

sons, machine or property are injured or damaged. However, an inci-
dent indicates that there is an injury risk and actions must be taken to
avoid the risk of injuries.

4 B Safety – Safety instructions
Safety instructions
General
page
–
Read and observe the following safety instructions below before start-
ing to work with the machine:
• Service position page 5
• Hydraulic and brake systems, depressurising page 5
• Oils page 7
• Fuel system page 8
• Clothing, etc. page 9
• Several mechanics on the same machine page 9
• Working under the machine page 10
• Lifting heavy components page 10
• Vibration page 11
• Noise page 11
• Dissolvent page 12
• Fire and explosion risk page 13
• Fluid or gas under pressure page 15
• Coolant page 16
• Refrigerant page 16
• Air pollution page 17
• Tensioned springs page 18
• Electric motors page 18
• Rotating components and tools page 19
• Tyres and rims page 19
• Lifting equipment page 20

B Safety – Safety instructions 5
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position entails:
• The machine is parked, i.e. parking brake applied.
• Trolley and attachment in totally lowered position
• Engine off.
• Main electric power voltage turned off (with the battery
disconnector).
009797
Machine with trolley and attachment in totally lowered

position
Hydraulic and brake systems, depressurising

page
–
1 Machine in service position, see Service position page 5.

2 Depressurise the hydraulic system by draining servo pressure
from the accumulator.
Turn the main current on, turn the starter key to position I and ac-
tivate the load handling functions several times.
3 Turn the start key to position 0 and switch off the main power.
009798

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

accumulator charging valve.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
005648
5 Depressurise the attachment.

Open relief valve top lift.
CAUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.

009961
Check that the relief valve for the attachment is

closed before starting the engine.
The figure above shows open valve

Oils
page
–
The following safety instructions must be followed for work when han-
dling oils.
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems

completely before starting to work in the systems. Hy-
draulic and brake systems are pressurised and the oil
may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.

Hot oil may cause burns, rashes and irritation! The oil
can also be corrosive to the eyes and skin, as well as
mucous membranes in the throat.
IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Always take action to avoid spills. In places where

drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs are sealed tightly before re-

ceptacles are moved.
Handle all oil as environmentally hazardous waste.

Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall al-
ways be handled by an authorised company.

Fuel system
page
–
The following safety instructions must be followed for work when han-
dling 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/glow-

ing 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 pres-
sure. The pressure is so high that the jet can injure
the skin, which may result in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,

avoid skin contact with fuel. If a component is to be
disconnected, hold a rag over the coupling as protec-
tion and collect the fuel. Fuel can be corrosive to the
eyes and skin, as well as mucous membranes in the
throat.
CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine failure in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.

IMPORTANT
Always take action to avoid spills. In places where
drain 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 released causes damage to the environ-
ment and may also cause fires. Fuel shall always be
handled by an authorised company.
Clothing, etc.
page
–
Clothes should be in good condition. Remove loose hanging clothing

(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in mov-
ing parts.
Long hair must be tied up securely, otherwise it may easily get caught
in moving parts. Be careful when performing welding work or work re-
quiring open flames since hair catches fire easily.
Several mechanics on the same machine

page
–
WARNING
Be extra careful if several mechanics work on the
same vehicle, so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are 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
• Make sure that the machine’s lifting equipment is completely low-
ered or secured in some other way.
• Move the battery disconnector to position zero and remove
the key.
• Be aware of the risks when several persons are working around
the vehicle.
• Make your co-workers aware of what you are working with.
• Do not work with the drive wheels on the both sides of the ma-
chine at the same time.
Working under the machine

page
–
Working under cab

On machines with a tilting cab, the cab must be in the fully tilted down
position.
Working under the frame

A raised vehicle may not, for any reason, be supported or raised in
parts that belong to the wheel suspension or steering. Always support
under the frame or wheel axle.
Risks
Mechanical or hydraulic tools and lifting devices may fall over or acci-
dentally lower due to malfunctions or incorrect use.
Safety precautions
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.
Lifting heavy components

page
–
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type-approved lifting tools or other devices to

move heavy components. Make sure that the device is
stable 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, especially
when there are is such equipment adapted for certain work. See work-
shop manual for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• 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 or help in advance.
• Use gloves. They’re often good protection to reduce crushing and
cutting injuries to fingers.
• Always use protective shoes.
Vibration
page
–
Use of vibrating tools, e.g. impact nut runner or grinder, for an extend-
ed period of time may cause injuries as vibration is transmitted from
the tool to hands - especially when fingers get cold.
Safety precautions
Use heavy gloves that protect against the cold and somewhat against
vibrations.
Switch between work duties to give the body time to rest.
Vary your work position and grip so that your body is not affected in
only one position by the vibration.
Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High pitches (high frequencies) are more damaging than
low pitches at the same sound level. Impact noise can also be hazard-
ous, e.g., hammer blows.
Risks
At noise levels higher than the limits hearing damage can 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.
Limit noise with noise-absorbing screens, for example, noise-absorb-
ing materials in roof and on walls.

Dissolvent
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi-
ness, headaches and nausea. They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent comes into direct contact with the skin, this may cause
drying and cracking. Risk of skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absorbed
by the blood.
If the body is continuously exposed to solvents, the nervous system
may be affected. Symptoms include sleep disorders, depression,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety precautions
Avoid inhaling dissolvent fumes by providing good ventilation, or wear-
ing a fresh-air mask or respiratory device with a suitable filter for the
toxic gases.
Never leave a dissolvent container without tight-sealing lid.
Use solvents with low content of aromatic substances. This reduces
the risk of injuries.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are dissolvent-resistant.

Fire and explosion risk

page
–
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 from fires makes you sleepy, suffocate, and

can kill! Smoke from fires can injure lungs and respi-
ratory organs even in small amounts.
Avoid inhaling smoke from fires, do not stand in the

smoke. Use breathing protection when putting out
fires and working with burnt materials.
DANGER
Tyres are flammable and can cause fire with explosive
development.
Extreme danger!
Always seek safety if tyres catch fire.

Examples of fire and explosion prone substances are oils, petrol, die-
sel fuel oil, organic solvents (paint, plastics, detergents), rust preven-
tive agents, welding gas, gas for heating (acetylene), high
concentrations of dust particles consisting of combustible materials.
Rubber tires are flammable and cause explosive fires.
Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing the oil in the engine, hydraulic system and transmis-
sion, keep in mind that the oil may be hot and cause burn injuries.
Welding on or near 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 charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Today’s machines contain a lot of electronic equipment. When weld-
ing, the control units must be disconnected and the electric power
must be turned off with the battery disconnector. Powerful welding cur-
rents 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 protec-
tion and protective goggles. In addition, welding work may not be done
near plastic or rubber materials without first protecting them from the
heat. Paints, plastics, and rubber develop a number of substances that
may be hazardous to health when heated. Be careful 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 any flammable materials in the engine com-

partment as soon as they are discovered, be extra
thorough on hot surfaces such as exhaust systems,
manifolds, or turbo. If these is a leak of oil, fuel, or
coolant, determine the cause and take appropriate ac-
tion before starting the engine.
• Make a habit of visually checking the engine and engine compart-

ment before starting the engine and after operating, when the en-
gine has been turned off. This makes it easier to quickly notice if
anything abnormal has happened or is about to happen. Pay spe-
cial attention to oil, fuel, or coolant leaks, loose bolts, worn or
poorly tightened drive belts, loose connections, damaged hoses,
and electric cables. The check only takes a few minutes and can
prevent serious failures and expensive repairs.
• Store a hazardous substance in an approved and sealed
container.
• Make sure that there is no ignition source near flammable or ex-
plosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.
Fluid or gas under pressure

page
–
Lines with high pressure may be damaged during work and fluid or gas
may jet out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid may leak out when the connection for the hose
is loosened.
A gas cylinder subjected to careless handling may explode, for exam-
ple, if it falls onto a hard surface. Gas can jet out from damaged valves.
Risks
Risk of damage/injury in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changing.
• Air conditioning.

Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer’s recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows that it is
about to rupture. Change as soon as possible! Check connections
thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulators must first be punctured before
they are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurising.
• Never use your hands to detect a leak. A fine high-pressure jet
from a hydraulic hose can easily penetrate a hand and causes
very severe injuries.
• First open the cooling system’s cap for the filling point, to release
the high pressure. Hot steam and coolant may otherwise
spray out.
Coolant
page
–
The coolant in the machine’s cooling system consists of water, anti-

corrosion compound, and possibly anti-freeze fluid, for example, eth-
ylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.
Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and protective safety glasses if there is a
risk of splashing or spraying.
• First open the filler cap to release the high pressure. Be careful.
Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
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 legisla-
tion 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 sys-
tem), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according
to the manual when working on the air conditioning system. Spe-
cial certification and authorisation is often required of the person
who may do the work. (Note national legislation and local regula-
tions!)
• Use protective gloves and protective safety glasses if there is a
risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
page
–
Air pollution is the impurities in the air around us which are considered
as hazardous to health. Certain pollution is more prominent in certain
environments.
The following health-hazardous air pollution is particularly prominent
in workshops:
• Carbon monoxide (fumes) is present in exhausts. Odourless
and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke is particularly hazardous to health when welding
on oily surfaces, galvanised or lacquered materials.
• Oil mist for example, is formed when applying anti-corrosion
agent.
• Grinding dust and gases are generated when grinding and heat-
ing plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.

Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
formed.
• Use suitable protective gloves and breathing protection when
there is a risk of oil mist. Make sure that the protection is oil-proof.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that exhausts are
removed from the workshop.
Tensioned springs
page
–
Examples of tensioned springs:

1. Torque springs in, e.g. pedals
2. Thrust spring (cup springs) in parking brake cylinder
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries amongst other things.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled 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
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.
Electric motors
page
–
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 start-
ing any work on the machine.

Rotating components and tools

page
–
Examples of rotating components and tools:

• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinders
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
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
Tyres and rims

page
–
DANGER
Tyres should be regarded as pressurised containers.
They constitute fatal danger if handled incorrectly.
Parts could be thrown out with explosive force and

cause severe injuries.
Never repair damaged tyres, rims or lock rings. Tyre

changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims or lock rings may be ejected.
Inflating wheels: Tyres, rims or lock rings may be ejected.

Safety precautions
• Deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and protective safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the machine’s lift-
ing equipment in particular, the greatest caution must be exercised
with respect to securing the mast, carriage and attachment.
Always make a habit of lowering the carriage to its lowest position be-
fore 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 5.
Safety precautions
• Do not start work until the carriage is completely lowered. If by na-
ture the work requires a raised carriage, this must be secured.

Spare parts
page
–
WARNING
For safety reasons, the following spare parts may
only be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Lift cylinder
• Valve block lift
• Tilt cylinder
• Twistlocks, lifting hook
• Control breaker (for hydraulic function)
• Emergency stop
• Hydraulic cylinders, cab tilt
• Accumulator
• Tilt valve
• Main valve load handling
• Accumulator charging valve
• All control units
page
–

Non-ionised radiation
WARNING
Optional equipment such as two-way radio, RMI, tele-
phone, etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical

products.
Use two-way radio, RMI, phone, etc., when no persons

with active or non-active medical products are
nearby.
NOTE
When persons with active or non-active 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 ap-
proved by Cargotec.

B Safety – Environment 23
Environment
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

pact on our global environment. Nature, animals and man are subject-
ed daily to risks in connection with various forms of chemical handling.
There are still no 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 environmen-
tally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to reuse materials in new products. Ac-
cording to calculations by Kalmar Industries, the machine can be recy-
cled to more than 90% by weight.
Environmentally hazardous waste

Components such as batteries, plastics, and various chemicals and
other items that may constitute environmentally hazardous waste
must be handled and taken care of in an environmentally safe and
sound manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged causes environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Repair the leak
immediately.
Air conditioning
The refrigerant in the air conditioning unit for the cab contributes to the
greenhouse effect and may not be intentionally released into the open
air. Special training is required for all service work on the air condition-
ing unit. Many countries demand certification by a governing authority
for such work.
Working in a contaminated area

The machine shall be equipped for work within a contaminated area
(environmental contamination, polluted, or health-hazardous area) be-
fore work is started. Also, special local regulations apply to such han-
dling and to service work on such a machine.

24 B Safety – Environment
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and in electric cabling. Some
models have counterweights of cast lead.
If the machine is equipped with air conditioning, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.

C Preventive maintenance 1
mm mm mm mm mm mm
Preventive maintenance
page
–
See Maintenance manual DCF 90-100, section C Preventive

maintenance.
Maintenance manual DCF 90-100 VDCF03.02GB

2 C Preventive maintenance – C Preventive maintenance
VDCF03.02GB Maintenance manual DCF 90-100

1
0 Complete machine
Table of Contents 0 Complete machine

mm mm mm mm mm mm
Complete machine ......................................................................................... 3

Complete machine, description ............................................................................. 3
Troubleshooting, general work instructions ............................................................ 5
Troubleshooting without an error code, example ................................................... 6
Troubleshooting with an error code, example ........................................................ 7
Troubleshooting cable harnesses .......................................................................... 9
Troubleshooting hydraulic hoses .......................................................................... 10

2

Complete machine 3
Complete machine
mm mm mm mm mm mm
Complete machine, description

page
–
Kalmar DCF80-100 is a forklift truck for handling empty containers.

The machine has a lift capacity of up to 8 – 10 metric tons depending
on version.
The engine is a straight six-cylinder, four-stroke, turbocharged low-
emission diesel engine with unit injectors and air to air intercooling and
electronically controlled fuel injection.
The transmission is hydromechanical with gear wheels in constant
mesh. It has up to three gears in each direction, depending on the ver-
sion. The power of the engine is transmitted via a torque converter.
1 2 3 4 9 The power transmission consists of a propeller shaft and a rigid drive

5 6 7 8
axle with hub reduction. The machine has front-wheel drive.
The service brake is of wet disc type, built together with drive wheel
hubs. The parking brake is of dry disc type and acts on the drive axle’s
input shaft.
Steering takes place with the rear wheels and a double-acting hydrau-
lic cylinder. The steering axle is oscillation-mounted in the frame.
The wheels are mounted on the hubs with nuts and clamps. Twin
wheels are mounted on the drive axle, while the steering axle has sin-
gle wheels.
Load handling is components and functions for handling loads. The
load is lifted with a side lifting attachment fastened to a lifting carriage
009775
that sits on a mast. Load handling is divided into the functions lifting/
lowering, tilt, side shift, spreading, levelling and load securing. Lifting/
1. Counterweight
lowering is a function for raising and lowering the lifting carriage. Side
2. Steering axle
shift is moving the side lifting attachment laterally along the lifting car-
3. Cab
riage. Spreading is adjusting the width between Twistlock or lifting
4. Tank
hooks of the side lifting attachment. Tilt is angling the load in the lon-
5. Drive axle
gitudinal direction of the truck with the help of the mast. Levelling is an-
6. Tilt cylinder
gling the side lifting attachment in the lateral direction of the truck.
7. Fork carriage
Load securing is locking the load onto the side lifting attachment.
8. Mast
9. Side lifting attachment The control system has functions for warning the operator of danger-
ous situations and malfunctions on the machine. The control system
has diagnostics that simplify troubleshooting.
The frame bears the machine. The frame houses the engine, trans-
mission, drive axle and steering axle. The sides of the frame house the
fuel and hydraulic oil tanks. The cab can be tilted as an option.
The hydraulic system is fed by four hydraulic oil pumps, which are
mounted together to form two pump banks, which in turn are mounted
on the gearbox’ power-take off. Three variable pumps feed load han-
dling, steering and other hydraulic functions. A fixed pump feeds the
brake system’s the brake and cooling circuits across an accumulator
charging valve. The hydraulic oil tank sits on the right side of the ma-
chine. The hydraulic oil filter is a return filter housed inside the hydrau-
lic oil tank.

4 Complete machine
The machine’s electrical system is based on control units at strategic

locations on the machine. The control units receive signals from sen-
sors and contacts and control components close to the respective con-
trol unit. The control units have redundant voltage feed and
communicate via redundant CAN bus. Engine and transmission have
their own control units from the respective supplier. These control
units communicate via CAN bus with a control unit in the cab.

Complete machine 5
Troubleshooting, general work

page
–
instructions
When troubleshooting, it is important that the work is structured and
logical. The point of the troubleshooting described in the maintenance
manual is to exclude components as error source so that the real error
source can be pin-pointed. A suggested structured work method is de-
scribed below.
When troubleshooting, it is important to understand how the machine
functions. Certain malfunctions can be pin-pointed directly using func-
tion descriptions. Sections 0–12 contain descriptions of the various
machine functions.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnector, must be in position 1.
• Battery voltage, should be 22–30 V.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• Engine oil
• Transmission oil
• Hydraulic oil
• Coolant
• Washer fluid
3 Check if there are error codes.
4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with an error code, example page 7.
In the error code lists there are recommended actions for every
error code. Error code lists are found in section D Error codes.
5 If there is no error code or the problem persists, use the function
description for the function affected in section 0–12.
The function description contains information on which compo-
nents are involved in the function and how these components
work together. In some cases, there is information on what con-
ditions are required in order for it to be possible to activate the
function. Measurement points are marked with flags (C as in
checkpoint for measuring outlet, D for diagnostic menu).

6 Complete machine
Troubleshooting without an error

page
–
code, example
1 Choose suitable section 0–12 to locate the function and subfunc-
tion that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the func-
tion affected in order to locate where in the function chain that the
signal or reaction is incorrect.
4 The malfunction is probably between the two units where the sig-
nal is incorrect. Start by checking the component that should
send the signal.
5 If the component that is to send the signal seems to be intact,
check the transmission of the signal (electric cables or hydraulic
hoses).
For electric cables, see Troubleshooting cable harnesses
page 9.
For hydraulic hoses, see Troubleshooting hydraulic hoses
page 10.
6 If the cables or hoses between the components seem to be intact,
then check the component that receives the signal.

Complete machine 7
Troubleshooting with an error code,

page
–
example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It is impor-
tant to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g. error code 34.
2 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.
3 Follow the instructions in the field "Action".
4 Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control sys-
tem, group 8.4 Diagnostics as well as section E Schematics.
5 Use the function group to find more information if needed.
In section 0–12 there is a function description, the function’s in-
cluded components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.
6 If possible, eliminate component faults by testing the component
individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are often checked by measuring pressure
(then described in the function group and indicated in the section
C Preventive maintenance). Sometimes valves can be activated
mechanically to determine if the malfunction is electric or
hydraulic.
7 If the component’s measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses
page 9.
For hydraulic hoses, see Troubleshooting hydraulic hoses
page 10.
8 If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The main electric power must be turned off with the battery
disconnector!
9 Disconnect the cable harness from the component in question.
10 Turn on the main electric power with the battery disconnector.

8 Complete machine
11 Turn the ignition key to operating position.

12 Check that voltage reaches the component.
Table 1. Example of error code information in error code list
Connections
Diagnostic Function
Code Description Limitation Action and
menu group
components
34 Signal error from Parking brake Check cabling be- D790-1/K8:5 HYD, menu 5 4.1.2 Parking
parking brake cannot be tween the control - S107, K8:13 brake control
switch, indi- released. unit and the compo- - S107
cates released nent with diagnos-
and applied at tic menu.
same time or Check component.
nothing at all.

Complete machine 9
Troubleshooting cable harnesses

page
–
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
1 Study the circuit diagram in question, check where the suspected

cable is connected and if, and if so where, it is spliced.
2 Turn off the main electric power with the battery disconnector.
3 Unplug the connector at the control unit or component in
question.
CAUTION
Wipe and re-grease the connectors.
Risk of corrosion on contact surfaces.
Clean all connectors loosened during troubleshoot-

ing using electronic cleaner 923836.0826 and re-
grease them with connector grease 923836.0552
4 Check if there is an open circuit.
NOTE
Some components cannot be checked without power supply
to the component. In such cases, proceed to step 5.
a. Measure resistance between connections to the component
in the connector at the control unit or component.
b. The resistance must correspond with the component. Other-
wise there may be an open circuit or short-circuiting in cable
harness and/or component.
5 Check if there is a short circuit to the frame:
a. Unplug the connector at both the control unit and the compo-
nent in question.
b. Measure the resistance of one lead at a time. Measure be-
tween the lead and a frame-connected part of the machine.
c. The multimeter should show infinite resistance.

10 Complete machine
Troubleshooting hydraulic hoses

page
–
WARNING
Hot and pressurised oil!
Always depressurise hydraulic and brake systems

completely before starting to work in the systems. Hy-
draulic and brake systems are pressurised and the oil
may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.

Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat.
1 Depressurise the hydraulic and brake systems, see

section B Safety.
2 Study the hydraulic diagram in question, check between which
components the suspect hose is connected and if, and if so
where, it is spliced.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next
component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Change damaged hoses. When removing a hydraulic hose,
O-ring replacement is always recommended on the hoses where
they are installed (ORFS).

1 Engine 1
1 Engine
Table of Contents 1 Engine

mm mm mm mm mm mm
1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 23
1.1.1 Ignition ................................................................................................. 23
1.1.2 Accelerator ........................................................................................... 24
1.2 Fuel system .............................................................................................. 25
1.2.1 Fuel tank .............................................................................................. 25
1.2.2 Sensor fuel level .................................................................................. 26
1.6 Air intake and exhaust outlet .................................................................... 27
1.6.1 Air cleaning system .............................................................................. 27
1.6.3 Exhaust system ................................................................................... 27
1.6.4 Intercooler ............................................................................................ 28
1.7 Cooling system ......................................................................................... 29
1.7.4 Radiator and expansion tank ............................................................... 30
1.7.5 Cooling fan ........................................................................................... 31
1.7.7 Coolant ................................................................................................ 33
1.7.8 NO (normally open) switch, coolant level ............................................ 38
1.7.10 Engine heater ...................................................................................... 38
1.9 Control system, engine ............................................................................. 39
1.9.1 Engine control unit ............................................................................... 39
1.11 Start/stop .................................................................................................. 40
1.11.1 Starter motor ........................................................................................ 40
1.11.2 Stopping device ................................................................................... 40

2 1 Engine

1 Engine 3
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The machine is equipped with the following engine alternative:
• Volvo TAD760VE (step III as per directive 97/68/EU)
• Cummins QSB6.7 (step III as per directive 97/68/EU)
If there are differences between different engine alternatives, this is
written in brackets after headings or under figures in order to clarify
what is being shown.
Component supplier documentation

The Workshop manual only describes components and work descrip-
tions that concern the installation in the machine. For descriptions and
instructions of the engine’s components and systems, refer to supplier
documentation.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.

4 1 Engine
Engine, function description

page
–
(Volvo TAD760VE engine)

Volvo TAD760VE is a straight 6-cylinder, 4-stroke turbocharged low-
emission diesel engine with unit injectors, common rail technology and
air-to-air intercooler.
Condition Reference value Reference

Disconnected (when cable is in start lock-out is activated). Engine heater, description page 38
Engine heater
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
7 009685
8 M
The illustration depicts the function description for Volvo TAD760VE.
Pos Explanation Signal description Reference

1 The ignition switch (S150) sends a U = 24 V Ignition key lock, description page 23
voltage signal to cab control unit D1: Diagnostic menu, see section 8 Control sys-
KCU (D790-1) when the start key is tem, group 8.4.1.5 CAN/POWER, menu 5 and
turned to position 1 or the preheating 8.4.6.4 ENGINE, menu 4
position.
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics,
ignition on via the CAN bus. If the tem, error shown with er- group 11.5.3.11 Control unit KIT (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.

1 Engine 5

3 If preheating has been activated with U = 24 V Se Control unit, engine, general page 39
the start key or automatically, then
the engine control unit (D794) feeds
voltage to the preheating relay and
through this also the preheating coils
(E800-1).
4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control sys-
each cylinder with a glow plug. tem, group 8.4.6.5 ENGINE, menu 5
voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is tem, group 8.4.6.4 ENGINE menu 4
turned to start position.
6 Control unit KIT (D790-2) sends a - See section 11 Common electrics,

start signal on the CAN bus. group 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is control- U = 24 V Starter motor, description (engine alternative
led by the engine control unit (D794) Volvo) page 40
through starter relays and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
(D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (engine alternative
engine. Volvo) page 40
D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensor sends signals - Se Control unit, engine, general page 39
to Control unit, engine (D794) that
controls the injectors so the engine
starts.
10 The accelerator pedal (B690) sends U = 0.5–4.5 V Accelerator page 24

the cab control unit (D790-1) a volt- Lower voltage than 0.5 V D10: Diagnostic menu, see section 8 Control
age signal proportional to the down- and higher voltage than system, group 8.4.6.1 ENGINE, menu 1
ward press of the pedal. 4.5 V is used to detect
faults in cable harnesses
and controls.
11 Control unit, cab (D790-1) sends a Checked by control sys- See section 11 Common electrics,
message with the rpm request on tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
the CAN bus. ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
12 Control unit, engine (D794) increas- - Se Control unit, engine, general page 39
es the engine speed. D12: Diagnostic menu, see section 8 Control

6 1 Engine

13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level
(B759) sends a voltage signal to the page 38
engine control unit (D794) if the cool-
ant level in the expansion tank is
low.
14 Control unit, engine (D794) sends Checked by control sys- Se Control unit, engine, general page 39
engine data and warning messages tem, error shown with er- D14: Diagnostic menu, see section 8 Control
on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6,
8.4.6.7 ENGINE, menu 7 and 8.4.6.8 ENGINE,
menu 8
15 Control unit KID (D795) shows en- - See section 11 Common electrics,
gine data via display figures. group 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 26
the frame control unit (D797-1) a D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel system, group 8.4.3.7 CAB, menu 7
level in the tank.
17 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics,
transmits fuel level on the CAN bus. tem, error shown with er- group 11.5.3.2 Frame control unit (D797-1)
ror code.
18 The KID control unit (D795) shows - See section 11 Common electrics,
fuel level in the operating menu for group 11.5.3.12 KID control unit (D795)
engine and transmission.
19 Speed limitation - See Supplier documentation, transmission

The output shaft speed sensor D19: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- system, group 8.4.7.6 TRANSM, menu 2
trol unit (D793) pulses with frequen-
cy proportional to output shaft rpm.
20 Control unit, transmission (D793) Checked by control sys- See section 11 Common electrics,
transmits the speed on the CAN bus. tem, error shown with er- group 11.5.3.9 KIT control unit (D793)
ror code.
the machine’s speed. group 11.5.3.12 KID control unit (D795)
22 If the rotation speed of the output Checked by control sys- See section 11 Common electrics,
shaft is so high that it corresponds tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
with the limit for the machine’s speed ror code.
limitation then Control unit, cab
(D790-1) sends reduce engine
speed on the CAN bus.
23 Control unit, engine (D794) limits the - Se Control unit, engine, general page 39
engine speed.

1 Engine 7
Component locations (Volvo engine)

page
–
4
3 8
2
1 9
10
11
12
13
14
15
16
17
18
010197
19
Volvo TAD760VE, left side (in machine’s direction of travel)
1. Sensor coolant temperature 11. Water pump

2. Solenoid valve EGR 12. Sensor oil pressure
3. Crankcase ventilation 13. Oil filter
4. Injector and preheating (6 pcs.) 14. Sensor fuel pressure
5. Turbo 15. Fuel filter
6. Filling point engine oil 16 Solenoid valve proportional valve high-pressure pump fuel
(MPROP)
7. Connection cab heating 17. Electrical connection, Control unit, engine (D794)
8. Alternator 18. Sensor camshaft rpm
9. Fuel pump 19. Oil plug
10. Sensor fuel pressure (distribution pipe)

8 1 Engine
3
2
010198
1
Volvo TAD760VE, right side (in machine’s direction of travel)
1. Oil plug 4. Sensor crankshaft rpm

2. Starter motor (M654) 5. Thermostat housing
3. Drain point coolant

1 Engine 9
Engine, separation
page
–
DANGER
The engine is very heavy.
Risk of crushing!
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Remove the radiator.
5 Use a jack to secure the transmission.

10 1 Engine
6 Remove the screws holding the cover plate to the flywheel.
7 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
9 Remove the bolts between engine and transmission.

10 Remove the screws in the engine brackets.
11 Withdraw the engine rearwards to separate it from the
transmission.
NOTE
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
12 Lift the engine away.

1 Engine 11
Assembly
13 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
008301
14 Insert two studs into the flywheel housing as a guide when the en-
gine is installed.
15 Transfer the engine brackets to the new engine; tighten to
169 Nm (oiled screw).
007775
16 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772

12 1 Engine
17 Lift the engine into place. Make sure that the studs on the fly-
wheel come into correct alignment and do not damage the flex
plate.
18 Install the bolts that affix the transmission and engine, but do not
tighten the bolts fully. Leave about a millimetre between the en-
gine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.
007776 19 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 40 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
20 Tighten the screws that attach the transmission and engine.

Tighten the transmission to the transmission mountings. Refit the
cover plate and propeller shaft.

1 Engine 13
21 Measure and check that the engine is centred in the frame.

22 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
23 Fit the cover washer under the flywheel.
24 Remove the hoisting equipment from the engine.
25 Remove the jack from underneath the transmission.
26 Connect the required hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.
27 Bleed air from the engine’s fuel system before starting.
007973

14 1 Engine
Engine, function description

page
–
(Cummins QSB6.7 engine)

Disconnected (when cable is in start lock-out is activated). Engine heater, description page 38
Engine heater
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
009622
8 M 7
The illustration depicts the function description for Cummins QSB6.7

voltage signal to cab control unit D1: Diagnostic menu, see section 8 Control sys-
KCU (D790-1) when the start key is tem, group 8.4.1.5 CAN/POWER, menu 5 and
turned to position 1 or the preheating 8.4.6.4 ENGINE, menu 4
position.
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics,
ignition on via the CAN bus. If the tem, error shown with er- group 11.5.3.11 Control unit KIT (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.

1 Engine 15

3 If preheating has been activated with U = 24 V Se Control unit, engine, general page 39
the ignition key or automatically,
then the Control unit engine (D794)
feeds voltage to the preheating relay
and through this also the preheating
element (E800).
4 The preheating coil (E800) heats the - D4: Diagnostic menu, see section 8 Control sys-
primary air to the engine. tem, group 8.4.6.5 ENGINE, menu 5
voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is tem, group 8.4.6.4 ENGINE menu 4
turned to start position.
6 Control unit KIT (D790-2) sends a - See section 11 Common electrics,

start signal on the CAN bus. group 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is control- U = 24 V Starter motor, description (engine alternative
led by the engine control unit (D794) Cummins) page 40
through starter relays and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
KCU (D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (engine alternative
engine. Cummins) page 40
D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensor sends signals - Se Control unit, engine, general page 39
to Control unit, engine (D794) that
controls the injectors so the engine
starts.
10 The accelerator pedal (B690) sends U = 0.2–4.8 V Accelerator page 24

the cab control unit (D790-1) a volt- Lower voltage than 0.2 V D10: Diagnostic menu, see section 8 Control
age signal proportional to the down- and higher voltage than system, group 8.4.6.1 ENGINE, menu 1
ward press of the pedal. 4.8 V is used to detect
malfunction in cable har-
nesses and controls.
11 The cab control unit (D790-1) sends Checked by control sys- See section 11 Common electrics,
the engine control unit (D794) an tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
rpm request via the CAN bus. ror code. D11: Diagnostic menu, see section 8 Control
12 Control unit, engine (D794) increas- - Se Control unit, engine, general page 39
es the engine speed. D12: Diagnostic menu, see section 8 Control

16 1 Engine

13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level
(B759) sends a voltage signal to the page 38
engine control unit (D794) if the cool-
ant level in the expansion tank is
low.
14 Control unit, engine (D794) sends Checked by control sys- Se Control unit, engine, general page 39
engine data and warning messages tem, error shown with er- D14: Diagnostic menu, see section 8 Control
on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6,
8.4.6.7 ENGINE, menu 7 and 8.4.6.8 ENGINE,
menu 8
15 Control unit KID (D795) shows en- - See section 11 Common electrics,
gine data via display figures. group 11.5.3.11 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 26
the frame control unit (D797-1) a A warning message ap- D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel pears on the display if the system, group 8.4.3.7 CAB, menu 7
level in the tank. amount of fuel in the tank
is less than 15% for more
than 40 seconds.
transmits fuel level on the CAN bus. tem, error shown with er- group 11.5.3.2 Frame control unit (D797-1)
ror code.
fuel level in the operating menu for group 11.5.3.12 KID control unit (D795)
engine and transmission.
19 Speed limitation - See Supplier documentation, transmission

The output shaft speed sensor D19: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- system, group 8.4.7.6 TRANSM, menu 2
trol unit (D793) pulses with frequen-
cy proportional to output shaft rpm.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics,
transmits speed on the CAN bus. tem, error shown with er- group 11.5.3.9 KIT control unit (D793)
ror code.
the machine’s speed. group 11.5.3.12 KID control unit (D795)
22 If the rotation speed of the output Checked by control sys- See section 11 Common electrics,
shaft is so high that it corresponds tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
with the limit for the machine’s speed ror code.
limitation then Control unit, cab
(D790-1) sends reduce engine
23 Control unit, engine (D794) limits the - Se Control unit, engine, general page 39
engine speed.

1 Engine 17
Component locations
page
–
(Cummins engine)
6 7
8
9
10
11
3 12
13
14
2
15
009440
1 16
Cummins QSB 6.7, left side (in machine’s direction of travel)
1 Hole for flex plate 9 Coolant inlet

2 Flywheel 10 Oil cooler
3 Crankcase ventilation 11 Oil filter
4 Injector drainage 12 Turbo inlet
5 Lifting eye 13 Turbo wastegate
6 Oil filling 14 Exhaust manifold
7 Coolant outlet 15 Starter motor
8 Alternator 16 Flywheel housing

18 1 Engine
7
6
8
10
5
11
4
12
13
14
15
007396
16
Cummins QSB 6.7, right side (in machine’s direction of travel)
1 Drive belt tensioner 9 Sensor fuel pressure in distribution pipe

2 Water pump 10 Fuel rail
3 Fan drive 11 Pressure reducing valve in rail
4 Air inlet 12 Fuel filter
5 Sensor coolant temperature 13 Dipstick
6 Turbo air inlet 14 Electronic control unit (D794)
7 Turbo air outlet 15 Crankshaft speed sensor
8 High-pressure fuel lines 16 Vibration damper (rubber)

1 Engine 19
Engine, replacement
page
–
(Cummins engine)
DANGER
The engine is very heavy.
Risk of crushing!
NOTE
Read the safety instructions for oil before working, see section B
Safety.
2 Attach hoisting equipment to the engine.
NOTE
009088
4 Remove the radiator.
5 Use a jack to secure the transmission.
6 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314

20 1 Engine
7 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be
removed.
8 Take up the slack in the hoisting equipment.
NOTE
008315
Do not lift the engine.
9 Remove the bolts between engine and transmission.

10 Remove the screws in the engine brackets.
11 Carefully detach the transmission from the engine.
12 Withdraw the engine rearwards to separate it from the
transmission.
NOTE
008275
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
13 Lift the engine away.
Assembly
14 Transfer the engine brackets to the new engine; tighten to
008301

1 Engine 21
16 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
007769
Transmission guide stud

17 Lift the engine into place. Guide the stud through the flywheel and
out through the hole in the flywheel housing.
18 Install the screws which fix the transmission and engine, but do
not tighten the screws fully. Leave about a millimetre between the
engine and transmission to facilitate installation of the screws for
the flex plate/flywheel.
19 Remove the stud through the hole in the flywheel housing.
008319
20 Fit the screws that fix the flex plates at the flywheel in two steps.
First fit the screws without tightening. Then rotate the flywheel
one more revolution and tighten the screws to 35 Nm (oiled
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
008315
The engine must be loosened from the engine mounts and sep-
arated from the transmission in order to remove a dropped bolt.
Secure the bolt in the socket when installing.
21 Fit the bolts that fasten the transmission and engine and tighten
them to 52 Nm (oiled bolt).
008275

22 1 Engine
22 Measure and check that the engine is centred in the frame.

23 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
24 Fit the cover plug in front of the flywheel.
25 Remove the hoisting equipment from the engine.
26 Remove the jack from underneath the transmission.
27 Connect the required hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.
007796

1 Engine – 1.1 Controls and instruments 23
1.1 Controls and instruments

1.1.1 Ignition
Ignition key lock, description
page
–
P No function.
0 Stop position. Everything turned off, the key can be removed.
I Operating position.
Voltage to all electrical functions. Engine and transmission con-
trol units are now active.
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.6.4 CAN/POWER, menu 4.
II Preheating position (function applies to Volvo engines only).
When the switch is in the preheating position, the engine’s intake
air is manually heated to a suitable temperature with glow plugs
in each cylinder on Volvo engines (Cummins engines are heated
automatically with a heating coil). The preheating lamp is on dur-
ing the preheating process.
0
The signal can be checked via the diagnostic menu. See
P I section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
III Start position.
Engagement of starter motor for engine start.
II
NOTE
The machine is equipped with an electric restart interlock,
000317
III
which prevents engagement of the starter motor when the
engine is rotating.
Condition for starter motor to engage is that the transmis-
sion is in neutral position and that the engine isn’t already
running.
section 8 Control system, group 8.4.6.4 ENGINE, menu 4.

24 1 Engine – 1.1.2 Accelerator
1.1.2 Accelerator
Accelerator pedal, replacement
page
–

2 Pull one edge of the cover away to facilitate access to the accel-
erator pedal.
3 Disconnect the cable harness from the connector.
4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
6 Fit in the reverse order.
7 Calibrate the accelerator pedal. See section 8 Control system,
group 8.5.2.3 Calibrate DRIVE-TRAIN.
1. Accelerator pedal
2. Brake pedal
Accelerator pedal, calibration

page
–
See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.

1 Engine – 1.2 Fuel system 25
1.2 Fuel system

Fuel system, description
page
–
The fuel tank is located on the machine’s left side and has a sensor for
fuel level. The fuel volume in the tank is shown in an operating menu
on the display in the cab. The fuel pre-filter with water trap and fuel fil-
ter is located on the engine. The water trap is equipped with electric
indication, an event menu is shown in the display when the water trap
has to be drained of water.
For component locations, see the section 1 Engine.
WARNING
The engine’s fuel system operates at very high pres-
sure. The pressure is so high that the jet can injure
the skin, which may result in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,

avoid skin contact with fuel. If a component is to be
disconnected, hold a rag over the coupling as protec-
tion and collect the fuel. Fuel can be corrosive to the
eyes and skin, as well as mucous membranes in the
throat.
1.2.1 Fuel tank

Fuel tank, description
page
–
The fuel tank is located on the left side of the machine behind the oil
tank brake system.

26 1 Engine – 1.2.2 Sensor fuel level
1.2.2 Sensor fuel level

Sensor, fuel level, description
page
–

section 8 Control system, group 8.4.3.7 CAB, menu 7.
3
2
1
009863
1. Filling point fuel

2. Fuel tank
3. Sensor fuel level (behind air filter)

1 Engine – 1.6 Air intake and exhaust outlet 27
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air cleaning system, description
page
–
The air cleaning system consists of an air cleaner with filter, filter indi-
cator, pipes and hoses. There are two filter in the air cleaner that clean
the air and a dust reservoir that collects larger particles. The dust res-
2 ervoir can be emptied without opening the air cleaner.
3
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhausts is essential for effective engine operation.
When the air filter cleans the air for engine, particles collect in the filter
material. With time, so many particles collect that the filter does not let
1
through enough air for effective combustion, then the filter has to be
replaced. The filter indication measures the vacuum pressure on the
engine side of the filter. When the filter is clogged, the vacuum pres-
008040
sure increases and the indicator indicates that it’s time to replace filter.
Air cleaning system, overview

1. Dust reservoir As an option, the machine can be equipped with a high-position air in-
2. Air cleaner let with pre-cleaner. It consist of an extension of the inlet pipe to the air
3. Filter indication filter and a pre-cleaner that filters coarser particles by creating cy-
clones at the air inlet. The pre-cleaner does not have any parts that
need to be replaced. When operating in dirty conditions, this means
that less dusty air is drawn into the air cleaner, extending the service
life of the air filters.
1.6.3 Exhaust system

Exhaust system, description
page
–
The exhaust system is installed in the chassis. A heat shield is in-

stalled between the engine and the exhaust system to protect wiring,
etc. A flex pipe between the turbo and muffler absorbs the engine’s
1 movements. On the outside of the machine, there is a heat shield in-
stalled over the exhaust system.
WARNING
2 3
Hot exhaust system!
Risk of burn injuries!
Never touch the turbo, exhaust pipe, or muffler when

008041
the machine is running or just after it has been turned

1. End pipe off!
2. Silencer
3. Exhaust pipe

28 1 Engine – 1.6.4 Intercooler
1.6.4 Intercooler
Intercooler, description
page
–
The charge air is cooled by an air-air intercooler in the upper part of

4 the cooler unit.
See also Cooling system, description page 29.
5
3
6
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)

1 Engine – 1.7 Cooling system 29
1.7 Cooling system

Cooling system, description
page
–
The engine is water-cooled and has passages through which the cool-
ant from the radiator flows round a closed system.
Main parts of the cooling system:
• Coolant pump, located in the engine.
• Expansion tank, located in the engine compartment.
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Water cooler, part of cooling unit (middle).
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of cooling unit (lower).
• Intercooler, part of cooling unit (upper).
• Fuel cooler, located behind the radiator
Engine cooling work as follows:
1. Coolant is circulated through the cylinder head, engine block and
oil cooler by the coolant pump.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening tempera-
ture the thermostat directs it back through the engine.
When the coolant is warmer than the thermostat opening temper-
ature the thermostat directs it through the radiator and then back
to the coolant pump.
4. The expansion tank allows the coolant to expand without escap-
ing from the engine.

30 1 Engine – 1.7.4 Radiator and expansion tank
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description
page
–
Radiator for the engine is located in the cooling unit which is placed
4 behind the engine.
The function of the cooler unit is to cool:
• Engine coolant.
5
• Transmission oil (cooled in the lower part of the cooler unit), see
3
also section 2 Transmission, group 2.6.3 Oil cooler.
6
• Charge air (cooled in the upper part of the cooling unit), see also
Intercooler, description page 28.
2 See also Cooling system, description page 29.
For more information, see supplier documentation, engine.
1
010120
Radiator core
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank

1 Engine – 1.7.5 Cooling fan 31
1.7.5 Cooling fan

Drive belt, replacement
page
–
Drive belt, changing (engine alternative Volvo TAD760VE)

2 Slacken the belt tensioner and lock it in place with a drift or the
like (position 1).
1
007314
1. Drift
3 Remove the belt from the coolant pump first.
4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves, and that it is tensioned correctly.
1
007969
1. Coolant pump

32 1 Engine – 1.7.5 Cooling fan
Drive belt, changing (engine alternative Cummins QSB6.7)

1. Machine in service position, see section B Safety.
2. Turn the belt tensioner to remove the drive belt.
3. Turn the belt tensioner and fit the drive belt. If it is difficult to fit (the
belt seems too short), first position the belt on the grooved pulley.
Then continue holding up the belt tensioner and wriggle the belt
over the water pump pulley.
Loosen the belt tensioner and check that the belt is positioned cor-
rectly in the grooves and is correctly tensioned.
016043

1 Engine – 1.7.7 Coolant 33
1.7.7 Coolant
Changing coolant and cleaning the cooling system
page
–
(engine alternative Volvo)

Cooling performance is reduced due to deposits in the radiator and
cooling channels. Always clean the cooling system in connection with
coolant change.
WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
Risk or scalding or burn injuries!
Open the filler cap (position B) very carefully when

the engine is warm. Wait until the coolant has cooled
down before filling or topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, use safety gog-

gles and protective gloves. In case of skin contact,
wash the skin.
IMPORTANT
Machines with ECC or AC are equipped with a com-
bined heating and cooling unit, which can result in a
risk of freezing if the machine is operated with coolant
that has no anti-freeze properties.
Risk of freezing and damage to the heating and cool-

ing unit!
The electrical connections on the AC compressor

must be disconnected when cleaning the radiator
with water or agents without antifreeze properties.
NOTE
Read the safety instructions before starting work with the cooling
system, see section B Safety.

34 1 Engine – 1.7.7 Coolant
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block using the drainage hose.
The drain nipples are located under the radiator and on the en-
gine block’s right-hand side.
3 Check that all coolant drains out.
NOTE
There may be deposits inside the tap or the plug which must
be cleaned away, otherwise there is a risk that coolant may
remain and cause freezing damage.
007394
Let the drainage taps or plugs remain open and make sure that
TAD760VE the heating control is set to full heat while cleaning.
4 Check the condition of the hoses and clamps and check the radi-
ator for leaks. Replace as necessary.
5 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
6 If impurities remain after flushing for a long time, it’s possible to
clean with coolant. Otherwise, continue with step 10.
Cleaning with cleaning agent for the cooling system
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Only use cleaning agents approved by the engine
manufacturer.
Fill the system with a radiator cleaning agent approved by the en-
gine manufacturer.
Mix the radiator cleaning agent and clean the cooling system in
accordance with the engine manufacturer’s instructions.
7 Once the cleaning is completed fill the system with recommended
new coolant, see section F Technical data.

Filling point
8 When the cooling system is completely free from impurities, close
the drain valves.
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.
NOTE
Only use the recommended coolant, see section F Techni-
cal data.
9 Fill coolant so that the level is between the MIN and MAX mark-
ings. The engine must not be started until the system is bled and
completely filled.
10 Start the engine.
Check that the water valve is fully open in order to bleed the heat-
ing system.
11 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.

36 1 Engine – 1.7.7 Coolant
Changing coolant and cleaning the cooling system

page
–
(Cummins engine)
The cooling performance is reduced due to deposits in the radiator and
cooling channels. Clean the cooling system in connection with coolant
change.
WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
Risk or scalding or burn injuries!
Open the filler cap (position B) very carefully when

the engine is warm. Wait until the coolant has cooled
down before filling or topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, use safety gog-

gles and protective gloves. In case of skin contact,
wash the skin.
IMPORTANT
Machines with ECC or AC are equipped with a com-
bined heating and cooling unit, which can result in a
risk of freezing if the machine is operated with coolant
that has no anti-freeze properties.
Risk of freezing and damage to the heating and cool-

ing unit!
The electrical connections on the AC compressor

must be disconnected when cleaning the radiator
with water or agents without antifreeze properties.
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.

Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points.
Drain the coolant from the radiator and engine block. There is a
drain nipple under the radiator and a drain plug under the coolant
inlet on the engine block.
3 Check that all coolant drains out.
NOTE
There may be deposits inside the tap/plug, which must be
cleaned away, otherwise there is a risk that the coolant may
remain and cause freezing damage.
008020 Let the drain valves/plugs remain open and make sure that the
heating control is set to full heat while cleaning.
4 Check the condition of the hoses and clamps and check the radi-
ator for leaks. Replace as necessary.
Cleaning with cleaning agent for the cooling system
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Only use cleaning agents approved by the engine
manufacturer.
Fill the system with a radiator cleaning agent approved by the en-
gine manufacturer.
Mix the radiator cleaning agent and clean the cooling system in
accordance with the engine manufacturer’s instructions.
5 Once the cleaning is completed fill the system with recommended
new coolant, see section F Technical data.

38 1 Engine – 1.7.8 NO (normally open) switch, coolant level
Filling point
6 When the cooling system is completely free from impurities, close
the drain valves.
CAUTION
Risk of engine damage and damage to the cooling

system if different types of coolant are mixed.

NOTE
Only use the recommended coolant, see section F Techni-
cal data.
7 Fill coolant so that the level is between the MIN and MAX mark-
ings. The engine must not be started until the system is bled and
completely filled.
8 Start the engine.
Check that the water valve is fully open in order to bleed the heat-
ing system.
9 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.
1.7.8 NO (normally open) switch,

coolant level
NO (normally open) switch, coolant level, description
page
–
The coolant level NO switch is located on the expansion tank.
1.7.10 Engine heater

Engine heater, description
page
–
See supplier documentation, engine.

A start-inhibitor function is available as an option coupled with the en-
gine heater. The function is activated when the heater is running.

1 Engine – 1.9 Control system, engine 39
1.9 Control system, engine

1.9.1 Engine control unit
Control unit, engine, general
page
–
See section 11 Common electrics, group 11.5.3.10 Engine control unit

and supplier documentation, engine.

40 1 Engine – 1.11 Start/stop
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo)
page
–
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 batter-
ies. A relay on the starter motor (solenoid) is activated by the engine
control unit (D794).
Starter motor, description (engine alternative

page
–
Cummins)
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 batter-
ies. A relay on the starter motor (solenoid) is activated by the frame
control unit (D797-1).
1.11.2 Stopping device

Stopping device, description
page
–
The engines have electrically regulated injectors that stop delivering

fuel when the voltage is cut off, which means that the engine stops.
The engine can only be stopped by turning off the ignition via the igni-
tion key lock.
NOTE
The battery disconnector must not be used for emergency stop!
Start lock-out is available as an option, where a code has to be

entered via the display before the engine can be started.
Automatic engine shutdown is available as an option. This means

that the engine shuts off automatically after 3-10 minutes (depending
on customer setting) if the machine is idling without the operator in the
seat.

1
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 21
2.1.1 Gear selector and multi-function lever ................................................. 21
2.2 Torque converter/Clutch system .............................................................. 22
2.2.1 Flex plates ........................................................................................... 22
2.6 Lubrication system ................................................................................... 24
2.6.3 Oil cooler .............................................................................................. 27
2.7 Cooling system ......................................................................................... 28
2.7.3 Oil cooler .............................................................................................. 28
2.8 Control system, transmission ................................................................... 29
2.8.1 Transmission control unit ..................................................................... 29
2.8.2 Break contact (opening switch) declutch ............................................. 29
2.8.3 Transmission cable harness ................................................................ 30

2

2 Transmission 3
2 Transmission
mm mm mm mm mm mm
Transmission, general
page
–

tions that concern installation in the machine. For descriptions of and
instructions for the transmission’s components and systems, refer to
the supplier documentation.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.

4 2 Transmission
Transmission, function description

page
–

Sensor, operator-in-seat Operator in seat Section 9 Frame, body, cab and accessories, group 9.3.14 Operator-in-
seat sensor
F
D27 R
22 <˚ 1
27 Pa D1
5
D5
21 6,23,28 2, 7
D794 D790-1 D790-2
D793 D795 D797-1

10,16,18,20,26,29 19 25
D13
D8 D14
D9 D15 D22
9 D20
D12 ˚C D24 Pa
8 12 13 14 15
Pa ˚C 24
4 17
11
3
009864

1 The multi-function lever (S162) Forward, Conn. F: U = 24 V Gear selector and multi-function lever, de-
sends a voltage signal to the KIT Reverse, Conn. R: U = 24 V scription page 21
control unit (D790-2). D1: Diagnostic menu, see section 8 Control
system, group 8.4.7.2 TRANSM, menu 2
2 The KIT control unit (D790-2) trans- Checked by control sys- See section 11 Common electrics,
mits the selected direction of travel tem, error shown with error group 11.5.3.11 Control unit KIT (D790-2)
(forward or reverse) on the CAN bus. code.
3 The transmission’s oil pump pumps - -

oil when the engine is running.
4 The transmission’s oil filter cleans - -

the oil from impurities.

2 Transmission 5

5 The accelerator pedal transmits a U = 0.5-4.5 V See section 1 Engine, group 1.1.2 Accelerator
signal to Control unit, cab (D790-1). pedal
D5: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE menu 1
6 Control unit, cab (D790-1) transmits Checked by control sys- See section 11 Common electrics,
the desired throttle application on tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
the CAN bus. code.
7 Control unit KIT (D790-2) sends the Checked by control sys- See section 11 Common electrics,
selected shifting program on the tem, error shown with error group 11.5.3.11 Control unit KIT (D790-2)
CAN bus. code.
8 The oil pressure sensors sends a Checked by Control unit, D8: Diagnostic menu, see section 8 Control
voltage signal to the transmission transmission, error shown system, group 8.4.7.10 TRANSM menu 10
control unit (D793) if oil pressure is with error code.
too low.
9 The engine speed and oil tempera- Checked by Control unit, D9: Diagnostic menu, See Section 8 Control
ture sensor (B758/766) sends the transmission, error shown system, group 8.4.7.6 TRANSM, menu 6 and
transmission control unit (D793) a with error code. 8.4.7.10 TRANSM, menu 10
pulse signal with frequency propor-
tional to engine speed and a voltage
signal proportional to the transmis-
sion oil temperature.
10 The transmission control unit (D793) Checked by Control unit, Control unit transmission, general page 29
supplies voltage to valve block trans- transmission, error shown
mission control to obtain desired with error code.
function.
11 Solenoid valves for travel direction Checked by Control unit, -

and gear position in valve block transmission, error shown
transmission control activate gears with error code.
in the transmission and the engine’s
power is transmitted to the transmis-
sion’s output shaft.
12 Sensor, turbine speed (B751) sends Checked by Control unit, D12: Diagnostic menu, see section 8 Control
Control unit, transmission (D793) a transmission, error shown system, group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- with error code.
tional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit, D13: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error shown system, group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- with error code.
tional to drum speed.
14 The output shaft speed sensor Checked by Control unit, D14: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- transmission, error shown system, group 8.4.7.6 TRANSM, menu 6
trol unit (D793) a pulse signal with with error code.
frequency proportional to output
shaft speed.

6 2 Transmission

15 The torque converter temperature Checked by Control unit, D15: Diagnostic menu, see section 8 Control
switch (S221) sends the transmis- transmission, error shown system, group 8.4.7.10 TRANSM, menu 10
sion control unit (D793) a voltage with error code.
signal if oil temperature in the torque
converter becomes too high.
16 Control unit, transmission (D793) Checked by Control unit, Control unit transmission, general page 29
controls gear shifting according to transmission, error shown
selected shifting program. with error code.
17 The oil cooler cools the transmission - Oil cooler, description page 28
oil. A thermostat senses the oil’s
temperature and directs the oil back
to the transmission if the oil is cold.
18 Control unit, transmission (D793) Checked by control sys- Control unit transmission, general page 29
transmits temperature and speed tem, error shown with error
data on the CAN bus. code.
19 Control unit KID (D795) shows trans- Checked by control sys- See section 11 Common electrics,
mission information in operating tem, error shown with error group 11.5.3.12 KID control unit (D795)
menus. code.
20 If the signal from the output shaft - D20: Diagnostic menu, see section 8 Control
speed sensor (B758) indicates that system, group 8.4.7.6 TRANSM, menu 6
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine
speed reduction request on the CAN
bus.
21 Control unit, engine (D794) reduces - See section 11 Common electrics,

the engine speed. group 11.5.3.10 Engine control unit (D794)
22 If the clutch pedal (S220-1) is U = 24 V Section 9 Frame, body, cab and accessories,
pressed down, it sends a voltage group 9.1 Controls and instruments
signal to the cab control unit D22: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.7.1 TRANSM, menu 1
23 Control unit, cab (D790-1) transmits Checked by control sys- See section 11 Common electrics,
declutch drive on the CAN bus. tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
code.
24 Normally closed (NC) switch, disen- Brake pressure above Break contact (opening switch) declutch, de-
gagement (S220-2) sends the frame 0.2 MPa: scription page 29
control unit (D797-1) a voltage signal Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control
if brake pressure is high enough to system, group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
allow drive disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V

2 Transmission 7

transmits disengagement approved tem, error shown with error group 11.5.3.2 Frame control unit (D797-1)
on the CAN bus. code.
26 Control unit, transmission (D793) Checked by Control unit, Control unit transmission, general page 29
mission control so that drive is with error code.
declutched.
27 If the operator leaves the driver’s U = 24 V Section 9 Frame, body, cab and accessories,
seat, the operator-in-seat sensor group 9.3.14 Operator-in-seat sensor
(S230) sends a voltage signal to the D27: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system, group 8.4.7.1 TRANSM, menu 4
28 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics,
mits go to neutral on the CAN bus. tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
code.
29 The transmission control unit (D793) Checked by Control unit, Control unit transmission, general page 29
mission control so that the drive is with error code.
put in neutral three seconds after the
operator leaves the driver’s seat.

8 2 Transmission
Shifting transmission,
page
–
function description
7 9 11 13 15
RSP
25 5
Fwd 2 Rev 1/3
6
8
26 10 12 14 16
18
VFS 1/3
3 4
17
28
27
19
2
1 Fwd 2:nd Rev 1:st 3:rd
008240
29 20 21 22 23 24

1. Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2. The transmission’s oil pump 1 supplies the 92.1 l/min at 2420 rpm -
transmission with control pressure for control
of the transmission.
3. The oil filter cleans the oil. - -
4. The bypass valve in the filter bracket leads Opening pressure: -

the oil past the filter if the resistance through 390 kPa
the filter becomes too high.
5. The pressure governor releases pressure to Opening pressure: -

the torque converter if the pressure becomes 2500-2900 kPa
too high.
6. The pressure reducer reduces the feed pres- 1200 kPa -

sure to servo pressure.
7. Solenoid valve neutral position (RSP) - Diagnostic menu, see section 8 Control
(Y6066) controls Valve spool neutral position. system, group 8.4.7.7 TRANSM menu 7
8. Valve spool neutral position opens or closes - -

to allow control pressure to the transmission.
9. Solenoid valve drive forward (Y630) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster drive forward. system, group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9
10. Pressure booster forward increases the pres- 0-2000 kPa -

sure and pressurises Drive clutch forward.
11. Solenoid valve gear 2 (Y6069) controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster gear 2. system, group 8.4.7.8 TRANSM, menu 8
12. Pressure booster gear 2 increases the pres- 0-3000 kPa -

sure and feeds Valve spool gear selection 2.

2 Transmission 9

13. Solenoid valve drive reverse controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster drive reverse. system, group 8.4.7.8 TRANSM, menu 8
14. Pressure booster reverse increases the pres- 0-2000 kPa -

sure and pressurises Drive clutch reverse.
15. Solenoid valve 1/3 (Y6067) controls Pressure 0-1000 mA Diagnostic menu, see section 8 Control
booster gear 1/3. system, group 8.4.7.8 TRANSM, menu 8
16. Pressure booster gear 1/3 increases the pres- 0-2000 kPa -
sure and feeds Valve spool gear
selection 1/3 as well as.
17. Contact drive sends signal to the control unit - -

to verify that drive clutches for travel direction
and gear selection are activated when sole-
noid valve neutral position (RSP) (Y6066) is
activated.
18. Solenoid valve VFS 1/3 (Y6075) controls ser- 0-1000 mA Diagnostic menu, see section 8 Control
vo pressure to Valve spool gear selection 1/3. system, group 8.4.7.7 TRANSM menu 7
19. Valve spool gear selection 1/3 pressurises 0-2000 kPa -

Drive clutch gear 1 or Drive clutch gear 3.
20. Drive clutch forward locks transmission in for- 0-2000 kPa -
ward drive when the clutch is pressurised.
21. Drive clutch gear 2 locks transmission in gear 0-2000 kPa -

position 2 when the clutch is pressurised.
22. Drive clutch reverse locks transmission in re- 0-2000 kPa -

verse drive when the clutch is pressurised.

25. The safety valve leads the oil back to the Opening pressure: -
sump if the pressure to the torque converter 850 kPa
becomes too high.
26. The torque converter transmits the engine’s - -

power to the transmission.
27. The transmission oil cooler cools the oil. - -
28. The bypass valve torque converter leads the Opening pressure: -
oil past the torque converter if the pressure 400 kPa
becomes too high.
29. The oil is distributed to different lubrication - -

points in the transmission.

10 2 Transmission
Transmission, component location

page
–
3 4
6
2 7
14 13 12
15
8
16
9
17
10
004269
19 18 11
1. Valve block transmission control 11. Oil filter transmission

2. Radiator connection (out from transmission) 12. Radiator inlet
3. Oil pump transmission 13. Radiator outlet
4. Power take-off 14. Transmission oil cooler
5. Cooling unit 15. Radiator connection (from radiator to sump)
6. Thermostat 16. Temperature monitor torque converter (S221)
7. Breather filter transmission 17. Sensor turbine speed (B751)
8. Sensor, drum rpm (B752) 18. Sensor rpm output shaft (B758)
9. Engine speed and oil temperature sensor (B758/766) 19 Output shaft
10. Sensor oil pressure

2 Transmission 11
3 4 5
2
11
10 9b 9a 8
008057
1. Accelerator pedal (B690) 7. Declutch pedal (S220-1)
2. Multi-function lever (S162) 8. Control unit, transmission (D793)
3. Control unit KIT (D790-2) 9a. Control unit, Volvo engine (D794)
4. Control unit, KID (D795) 9b. Control unit, Cummins engine (D794)
5. Control unit, cab (D790-1) 10. Frame control unit (D797-1)
6. Sensor operator in seat (S230) 11. Switch (NC), disengagement (S220-2)

12 2 Transmission
Transmission (engine alternative

page
–
Volvo), replacement
DANGER
The transmission is very heavy.
Risk of crushing!
NOTE
Safety.
2 Remove the propeller shaft from the transmission.
NOTE

2 Transmission 13
4 Remove the screws holding the cover plate to the flywheel.
5 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
6 Attach the transmission to an overhead crane.
7 Support the engine from underneath with a jack.
NOTE
Secure the engine so that it does not tip over when the transmis-
sion is removed.
8 Remove the bolts holding the transmission to the transmission
mounting.

14 2 Transmission
9 Remove the bolts holding together the transmission and engine.
10 Carefully separate the transmission and engine.
NOTE
Check the balance of the transmission before lifting it.
NOTE
If the flex plates are damaged during transmission replacement,
they must be replaced.
11 Remove the transmission.
007780
Assembly
008301

2 Transmission 15
13 Insert two studs into the flywheel housing as a guide when the
transmission is installed.
14 Transfer the transmission bracket to the new transmission;
torque-tighten to 330 Nm (oiled screw).
007775
15 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
16 Lift the transmission into place. Make sure that the flywheel’s
studs come into correct alignment and do not damage the flex
plate.
17 Install the bolts that affix the transmission and engine, but do not
tighten the bolts fully. Leave about a millimetre between the en-
gine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.
NOTE
Make sure that the torque converter has bottomed in the fly-
007776
wheel before tightening the nuts for the flex plate.

16 2 Transmission
18 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 46-50 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
19 Tighten the bolts that attach the transmission and engine.
20 Measure and check that the transmission is centred in the frame.

21 Screw the transmission into the transmission mountings. Tighten
to 169 Nm (oiled screw). Refit the cover plate and propeller
shaft.
22 Remove the hoisting equipment from the transmission.
23 Remove the jack from underneath the engine.
24 Connect the requisite hoses and cables for the engine and trans-
mission. Check and fill fluids as necessary.
25 Calibrate the transmission; see Transmission, calibration
007973
page 29.

2 Transmission 17
Transmission (engine alternative

page
–
Cummins), replacement
DANGER
The transmission is very heavy.
Risk of crushing!
NOTE
Safety.
2 Remove the propeller shaft from the transmission.
NOTE
4 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314

18 2 Transmission
5 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be
removed.
6 Attach the transmission to an overhead crane.
7 Support the engine from underneath with a jack.
008315
NOTE
Secure the engine so that it does not tip over when the transmis-
sion is removed.
8 Remove the bolts holding the transmission to the transmission
mounting.
9 Remove the bolts holding together the transmission and engine.
10 Carefully separate the transmission and engine.
NOTE
Check the balance of the transmission before lifting it.
NOTE
008275
If the flex plates are damaged during transmission replacement,

11 Remove the transmission.
Assembly
008301

2 Transmission 19
13 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
14 Transfer the transmission bracket to the new transmission;
torque-tighten to 330 Nm (oiled screw).
007769
Transmission guide stud

15 Lift the transmission into place. Guide the stud through the fly-
wheel and out through the hole in the flywheel housing.
16 Install the screws which fix the transmission and engine, but do
not tighten the screws fully. Leave about a millimetre between the
engine and transmission to facilitate installation of the screws for
the flex plate/flywheel.
17 Remove the stud through the hole in the flywheel housing.
NOTE
008319
Make sure that the torque converter has bottomed in the fly-
wheel before tightening the nuts for the flex plate.
18 Fit the screws that fix the flex plates at the flywheel in two steps.
First fit the screws without tightening. Then rotate the flywheel
one more revolution and tighten the screws to 35 Nm (oiled
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
008315
The engine must be loosened from the engine mounts and sep-
arated from the transmission in order to remove a dropped bolt.
Secure the bolt in the socket when installing.
19 Torque-tighten the screws to 52 Nm (oiled screw).
008275

20 2 Transmission
20 Measure and check that the transmission is centred in the frame.

21 Screw the transmission into the transmission mountings. Tighten
to 169 Nm (oiled screw). Refit the cover plate and propeller
shaft.
22 Remove the hoisting equipment from the transmission.
23 Remove the jack from underneath the engine.
24 Connect the requisite hoses and cables for the engine and trans-
mission. Check and fill fluids as necessary.
25 Calibrate the transmission; see Transmission, calibration
007973
page 29.

2 Transmission – 2.1 Controls and instruments 21

2.1.1 Gear selector and multi-function
lever
Gear selector and multi-function lever, description
page
–
Selection of direction travel is made with the gear selector and multi-
F
function lever.
Selecting direction of travel:
• F – Forward
• N – Neutral
• R – Reverse
The switch is supplied voltage by and sends signals to the KIT control
unit (D790-2).
002209
R
section 8 Control system, group 8.4.7.2 TRANSM, menu 2.

22 2 Transmission – 2.2 Torque converter/Clutch system
2.2 Torque converter/

Clutch system
2.2.1 Flex plates
Flex plates, changing
page
–

2 Remove the transmission, see Transmission (engine alternative
Volvo), replacement page 12.
3 Remove the bolts holding the flex plate to the transmission.

007774
Fastening the flex plate (transmission alternative

TE17 with Volvo TAD760VE engine)

2 Transmission – 2.2.1 Flex plates 23
4 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
5 Fit the transmission, see Transmission (engine alternative
Volvo), replacement page 12.
6 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 29.
007773
Fastening the flex plate (other transmission and

engine alternatives)

24 2 Transmission – 2.6 Lubrication system
2.6 Lubrication system

Lubrication system, description
page
–
The transmission lubrication system has the following function:

• Lubricate gear wheels and bearings
• Apply the clutches in the transmission
• Cool down the torque converter and the transmission
• Clean the oil of any impurities with the oil filter
During operation of the engine, the oil pump draws oil from the trans-
mission’s oil sump through a strainer, and it then pumps it through the
oil filter to a control valve.
The control valve supplies oil at the correct pressure to the transmis-
sion’s valve housing to activate the clutch plates for FORWARD or
REVERSE and gear 1, 2 or 3. 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 re-
turns to the transmission for lubrication.
See also supplier documentation, transmission.
Oil and oil filter transmission, changing

page
–
NOTE
Safety.
NOTE
The transmission must not be over-filled!
1 Operate and warm up the transmission oil.
3 Place a receptacle under the transmission.
4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the sealing washer stays with the drain plug.
Draining transmission oil

2 Transmission – 2.6 Lubrication system 25
5 Clean the area around the oil filter.

6 Change oil filter.
Moisten the O-ring on the new oil filter with transmission oil.
Tighten until it makes contact and then another one-quarter of a
turn.
7 When the transmission oil has drained, fit the drain plug.
NOTE
Make sure that the seal washer for the drain plug is fitted
as well.
004331
8 Remove the transmission dipstick and fill new transmission oil

through the dipstick hole to the marking for low level on the
dipstick.
For volume and quality, see section F Technical data.
9 Turn the main current on and start the engine. Allow the engine
to idle for at least two minutes.
10 Check that the transmission oil drain plug is sealed.
11 Check the transmission oil level with the engine running at idle
A and top up to the marking for low level.
B
008054
A. Position of oil filling point and level check

B. Oil filling point and oil dipstick

26 2 Transmission – 2.6 Lubrication system
12 Warm up the transmission so that the display shows an oil tem-

perature between 60-65 C. Use the oil temperature operating
menu to check the transmission’s oil temperature.
a
13 Check the oil level. Fill to the MAX mark.
000356
b 14 Calibrate the transmission; see Transmission, calibration
page 29.
Operating menu oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature
Transmission oil level check

page
–
NOTE
Safety.
The transmission oil filler pipe and dipstick (position B) is located un-
der the hood.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 82-93 C). The
dipstick has two markings, MAX and MIN. The oil level should be
at MAX.
A
Wipe off the dipstick before checking.
B
NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if needed (for volume and grade,
see section F Technical data).
3 Fill – wait a moment – check the dipstick.
NOTE
008054
Work carefully when filling transmission oil to prevent other

fluids or particles from contaminating the oil. Other fluids or
particles in the transmission oil means a risk of transmission
A. Position of oil filling point and level check damage.
B. Oil filling point and oil dipstick

2 Transmission – 2.6.3 Oil cooler 27
2.6.3 Oil cooler

Oil cooler, description
page
–
The transmission oil is cooled in the lower section of the cooler unit.
4 A temperature-controlled thermostat, which only acts on the transmis-
sion oil cooling circuit, is located in a pipe on the underside of the cool-
er (engine side). The thermostat closes when the oil starts to reach
5 working temperature. This means that the oil reaches normal working
3 temperature more quickly.
6 The machine must not be operated if the thermostat is removed.
For more information, see supplier documentation, transmission.
2
1
010120
Radiator core
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
Thermostat transmission oil cooler, replacement

page
–
NOTE
Safety.

2 Drain the oil from the transmission, see Oil and oil filter transmis-
sion, changing page 24.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change if needed.
5 Install the new thermostat, and the cover plug.
IMPORTANT
007447
It is very important that the thermostat is turned with

the temperature bulb facing out as shown.
6 Fill with transmission oil; see Oil and oil filter transmission, chang-
ing page 24.
7 Start the engine and check for leaks.
8 Check the transmission oil level, see Transmission oil level check
page 26.

28 2 Transmission – 2.7 Cooling system
2.7 Cooling system

2.7.3 Oil cooler
Oil cooler, description
page
–
See Oil cooler, description page 27.

2 Transmission – 2.8 Control system, transmission 29
2.8 Control system, transmission

Transmission, calibration
page
–
See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
2.8.1 Transmission control unit

Control unit transmission, general
page
–
See section 11 Common electrics, group 11.5.3.9 Transmission con-

trol unit and Supplier documentation.
2.8.2 Break contact (opening switch)

declutch
Break contact (opening switch) declutch, description
page
–
The NC switch for disengagement detects if the wheel brakes are

pressurised. The NC switch is located on the distribution block for the
brake system, above the drive axle’s differential.
The sensor can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.7.1 TRANSM, menu 1.
1
10
2
1
3
3
4
5
5
9 6
8 7
009865
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to radiator
and tank
3. Brake cooling connection, to wheel brake
4. Brake cooling connection, from accumulator
charging valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. Switch (NC), declutch (S220)
8. NO switch, brake lights (S216)
9. Measurement connection, brake pressure
10. Measuring outlet, brake cooling back pressure

30 2 Transmission – 2.8.3 Transmission cable harness
2.8.3 Transmission cable harness

Transmission cable harness, description
page
–
See section E Diagrams.

3 Driveline/axle 1
3 Driveline/axle
Table of Contents 3 Power transmission

mm mm mm mm mm mm
3 Power transmission ....................................................................................... 3

3.2 Propeller shaft ............................................................................................ 3
3.3 Drive axle ................................................................................................... 4

2 3 Driveline/axle

3 Driveline/axle – 3 Power transmission 3
mm mm mm mm mm mm
3.2 Propeller shaft

Propeller shaft, description
page
–
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.
Propeller shaft, replacement

page
–

2 Clean the contact surfaces (cross-toothed) on the drive axle and
gearbox.
3 Fit the propeller shaft in position with the coupling upward.

4 Fit the propeller shaft’s attaching bolts.
Tightening torque 98 Nm (oiled screw). Retighten the attaching
bolts after 50 hours of operation.
005193

4 3 Driveline/axle – 3.3 Drive axle
3.3 Drive axle

Drive axle, general
page
–

tions that concern installation in the machine. For descriptions and in-
structions for the drive axle’s components and systems, refer to
supplier documentation.
References to supplier documentation are only used in exceptional
cases. If information about a component is missing, use the supplier
documentation.
Drive axle, replacement

page
–
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is not permissible to enter under a machine that has

been lifted by a jack, etc. For machine weights, please
refer to section F Technical data.
1 Remove the mast, see section 7 Load handling, group 7.2 Lifting/
lowering.
2 Park the machine with blocks behind the steering wheels.
3 Depressurise the hydraulic systems, See section B Safety.

3 Driveline/axle – 3.3 Drive axle 5
5 Insert wedges between the steering axle and the frame.
6 Detach the hydraulic hoses (position 1) and cable harness

(position 2) from the distribution block.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
1
004501
2
1. Hydraulic hoses
2. Cables
7 Remove the cover (position 3) on the parking brake.
3
004505
3. Cover, parking brake

8 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. Reinstall the cover on the
6 parking brake (position 3).
9 Detach the hydraulic hose (position 6) from the parking brake.
5 NOTE
4 system from impurities.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose parking brake
10 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
Securing the propeller shaft.

11 Lift the machine so that the wheels are off the ground.
12 Remove the drive wheels from the drive axle.
13 Support the drive axle under the hubs.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
Lifting machine

14 Remove the bolts that secure the drive axle in the frame.
15 Lift away the drive axle.
CAUTION
Crushing injury!
uncontrollably.
Attaching bolts drive axle
16 Undo the hydraulic hoses on the drive axle.
NOTE
17 Transfer the couplings from the old axle to the new axle.

18 Transfer the parking brake union to the new axle.
19 Undo the distribution block bracket and move it to the new axle.
20 Connect the hydraulic hoses from the distribution block to the
drive wheels.
21 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the drive axle’s underside.
22 Remove the nuts for attaching the drive axle, blow clean and refit
the nuts.
23 Lift the drive axle into place under the frame.
CAUTION
Crushing injury!
uncontrollably.
24 Lower the frame toward the drive axle.

25 Fit the new screws that fix the drive axle in the frame. Tighten to
26 Install the drive wheels on the new axle.
27 Rustproof the bolts with suitable paint.
28 Connect hydraulic hoses (position 1) and cables (position 2) to

the distribution block on the drive axle.
29 Connect the hydraulic hose to the parking brake, adjust the park-
ing brake.
30 Connect the propeller shaft to the drive axle; see Propeller shaft,
replacement page 3.
31 Check the oil level in the drive axle.
32 Start the machine and bleed the brakes, see section 4 Brakes,
1 group 4.3.9 Wheel brake.
33 Check for leaks.
004501


4 Brakes 1
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 6
4.3.1 Hydraulic oil pump ................................................................................. 9
4.3.2 Hydraulic oil filter ................................................................................. 11
4.3.3 Accumulator charging valve ................................................................. 12
4.3.4 Accumulator ......................................................................................... 15
4.3.5 Brake valve .......................................................................................... 19
4.3.6 Drive axle block ................................................................................... 23
4.3.7 Break contact (opening switch) brake pressure ................................... 24
4.3.8 Make-contact (closing switch) brake lights .......................................... 25
4.3.9 Wheel brakes ....................................................................................... 27
4.3.10 Pipes and hoses .................................................................................. 29
4.5 Parking brake system ............................................................................... 30
4.5.1 Hydraulic oil pump ............................................................................... 33
4.5.3 Solenoid valve parking brake ............................................................... 33
4.5.4 Parking brake unit ................................................................................ 34
4.5.5 Break contact (opening switch) parking brake ..................................... 37
4.5.6 Pipes and hoses .................................................................................. 37
4.8 Temperature control, cleaning and hydraulic oil ....................................... 38
4.8.1 Hydraulic oil tank ................................................................................. 38
4.8.4 Accumulator charging valve ................................................................. 39
4.8.5 Drive axle block ................................................................................... 39
4.8.6 Wheel brakes ....................................................................................... 39
4.8.8 Thermal bypass valve .......................................................................... 39
4.8.9 Cooling fan ........................................................................................... 39
4.8.10 Sensor hydraulic oil temperature ......................................................... 39
4.8.11 Breather filter hydraulic oil tank ........................................................... 39
4.8.13 Pipes and hoses .................................................................................. 39
4.8.14 Hydraulic oil ......................................................................................... 40

2 4 Brakes

4 Brakes 3
4 Brakes
mm mm mm mm mm mm

4.1.1 Brake pedal
Brake pedal, checking and adjustment
page
–
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal moves smoothly.
Stop screw for adjusting clearance between brake

pedal and brake valve. (The illustration shows a loose
brake pedal).
4 Lubricate the pedal hinge with "EP2" universal grease.
5 Check that the rubber pad on the brake pedal is intact and that
the tread pattern is not worn away. Change if needed.
6 Check the brake valve; see Brake valve, checking page 20.
Lubrication points, brake pedal. (The illustration

shows a loose brake pedal).

4 4 Brakes – 4.1.1 Brake pedal
Brake pedal, replacement

page
–
NOTE
Safety.
1 Switch off the engine and switch off the system voltage.
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cab’s underside and remove the
brake valve attaching bolt.
4 Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering
wheel shaft.
5 Detach the steering valve from the pedal assembly.

Secure the steering valve on the cab’s underside. Remove the
steering valve’s attaching bolts. Pull down the valve slightly so
that the steering shaft releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the clutch pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal’s attaching bolt and lift away the brake
pedal.
Mounting of steering wheel shaft and steering valve in 9 Transfer the pedal rubber to the new pedal.
pedal assembly.
10 Fit the new brake pedal.
Fit the pedal and fit the pedal’s attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.

4 Brakes – 4.1.1 Brake pedal 5
14 Close the drain valve on the accumulator charging valve.
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 3.

6 4 Brakes – 4.3 Power-assisted brake system
4.3 Power-assisted brake system

Power-assisted brake system, function
page
–
description
5
B
13 P
T
D790-2
D11
D797-1
10, 12 8 C
Pa
11
C 9 D9
D8
4 Pa
3
C ACC
7
B
P
6
2
008059
B
1 The hydraulic oil pump pumps oil See the pressure plate on Hydraulic oil pump, description page 9
from the oil tank. the left-hand frame beam.
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description page 39
3 The accumulator charging valve di- Charge: P = 20.50.5 MPa Accumulator charging valve, description
rects oil to charging of accumula- Cooling: P < 0.1 MPa page 12
tors or through the brake system’s
cooling circuit.
4 The accumulators store oil See the pressure plate on Accumulator, description page 15
pressure. the left-hand frame beam.
5 The brake valve directs pressure - Brake valve, description page 19

from the accumulators to the brake
cylinders proportional to pressing of
the pedal.
6 The brake cylinders compress the See the pressure plate on Wheel brakes, description page 27
discs in the brake unit. the left-hand frame beam.

4 Brakes – 4.3 Power-assisted brake system 7
7 The wheel brakes brake the - Wheel brakes, description page 27

machine.
8 Make-contact (closing switch), Brake pressure above Make-contact (closing switch) brake lights, de-
brake light (S216) closes the circuit 0.2 MPa: scription page 25
when the brake cylinders are pres- Conn. 1, U = 24 V D8: Diagnostic menu, see section 8 Control
surised. system, group 8.4.5.4 HYD, menu 4
Conn. 2, U = 24 V
0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
9 Brake pressure NC switch (S204) Brake pressure above Brake pressure NC switch, description page 24
opens the circuit if the pressure in 11.5 MPa: D9: Diagnostic menu, see section 8 Control
the accumulators is low. Conn. 1, U = 24 V system, group 8.4.5.4 HYD, menu 4
Conn. 2, U = 24 V
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
10 The frame control unit (D797-1) Controlled by control sys- Section 11 Common electrics,
transmits the brake light request on tem, error shown with error group 11.5.3.2 Frame control unit (D797-1)
the CAN bus. code.
11 The brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories,
H411R) are activated by the frame group 9.6.4 Brake lights
system, group 8.4.2.8 LIGHTS, menu 8
12 The frame control unit (D797-1) Controlled by control sys- Section 11 Common electrics,
transmits a warning about low tem, error shown with error group 11.5.3.2 Frame control unit (D797-1)
brake pressure on the CAN bus. code.
13 Control unit KIT (D790-2) activates Controlled by control sys- Section 11 Common electrics,
Warning lamp brake pressure. tem, error shown with error group 11.5.3.11 KIT control unit (D790-2)
code.
Hydraulic diagram, see section E Schematics group 10 Common hy-

draulics, Basic machine

8 4 Brakes – 4.3 Power-assisted brake system
Power-assisted brake system,

page
–
component positions
4
1 2
5 6
3 8
9
12
008061
11 10
1. Brake lights (H411L and H411R) 7. Brake pressure NC switch (S204)

2. Control unit KIT (D790-2) 8. Distribution block drive axle
3. Brake valve 9. Make-contact (closing switch) brake light (S216)
4. Frame control unit (D797-1) 10. Hydraulic oil filter
5. Wheel brakes 11. Hydraulic oil pump
6. Accumulator charging valve 12. Accumulators

4 Brakes – 4.3.1 Hydraulic oil pump 9
4.3.1 Hydraulic oil pump

Hydraulic oil pump, description
page
–
The brake system has a gear pump with fixed displacement. The hy-
1
2 draulic oil pump sits in the rear of the right main pump. The pump gen-
erates hydraulic power, which is stored in the accumulators for brake
force to the power-assisted brake and parking brake. It also generates
the oil flow used for cleaning and cooling. The switchover between
power generation and flow is regulated by the accumulator charging
valve, see Accumulator charging valve, description page 12.
For description of how a gear pump works, see section 10 Common
hydraulics, group 10.4.1 Gear pump with fixed displacement .
3
4
009967
1. Hydraulic oil pump for load handling.

2. Hydraulic oil pump for quick-lift.
3. Hydraulic oil pump for brake system, cooling and
filtering.
4. Hydraulic oil pump for steering and load handling.
Hydraulic oil pump, checking

page
–
NOTE
Safety.
Checking the pump pressure

1 Operate and warm up the machine so that the oil in the brake sys-
tem reaches operating temperature, at least 50 C.
4 Connect a pressure gauge (0–25 MPa) to the pressure check
connection for pump pressure on the accumulator charging
valve.
5 Start the engine and run it at idle.
008048
Measuring outlet, pump pressure

10 4 Brakes – 4.3.1 Hydraulic oil pump
6 Close the drain valve on the accumulator charging valve and

check the pump pressure during charging.
NOTE
Check that the accumulator drain valve is fully closed and
During charging the pressure should increase to 20.51.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
008049
7 Check the pressure during cooling.
Close the accumulator charging valve During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8 Turn off engine.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
NOTE
Checking the accumulator charging

connection for accumulator pressure on the accumulator charg-
ing valve.
008050
Measuring outlet, accumulator pressure

4 Brakes – 4.3.2 Hydraulic oil filter 11
NOTE
16 Check that the pressure increases slowly to 20.51.0 MPa.
17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 15.50.5 MPa.
008049
Close the accumulator charging valve
measuring outlet.
NOTE
Hydraulic oil pump, replacement

page
–
NOTE
Safety.
The hydraulic oil pump for the brake system, cooling and filtering and
the pump for load handling are replaced as a unit. See the
section 10 Common hydraulics, group 10.4.1 Gear pump with fixed
displacement.
4.3.2 Hydraulic oil filter

Hydraulic oil filter, general
page
–
See Hydraulic oil filter, description page 39.

12 4 Brakes – 4.3.3 Accumulator charging valve
4.3.3 Accumulator charging valve

Accumulator charging valve, description
page
–
The accumulator charging valve distributes oil from the hydraulic oil
3 4 5 6
pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is located on the left of the frame in the
area beside the transmission.
The accumulator charging valve stores pressure by guiding the oil to
the accumulators. The wheel brakes are cooled by oil being guided to
the drive axle cooling circuit and then on to the brake system cooler.
The accumulator charging valve prioritises charging of the accumula-
tors before cooling. A restriction of the charging means that a small
quantity of oil also flows to cooling during accumulator charging. At idle
speed the flow from the pump is so small that all oil flows to pressure
storage.
The drain valve (position 11) is used to relieve the pressure in the ac-
cumulators to the tank. The valve opens a connection between the ac-
cumulators and the wheel brake’s cooling circuit. The oil is drained
through the wheel brake to the tank.
2 1 13 12 11 10 9 8 7 There is a measuring outlet for measuring accumulator pressure (po-
sition 5) and pump pressure (position 4) on the accumulator charging
valve. The pressures are individual to each machine and are on the
pressure plate on the left-hand frame beam, see section 10 Common
hydraulics. On the accumulator charging valve, there is also a parking
brake solenoid valve (position 6), switch (NC) brake pressure (position
9) and switch (NC) parking brake (position 7).
• Solenoid valve parking brake, description page 33
• Make-contact (closing switch) brake lights, description page 25
009867
• Break contact (opening switch) parking brake, description

page 37
1. Safety valve
2. Connection from pump (P)
3. Connection, wheel brake (T)
4. Measuring outlet, pump pressure (P)
5. Measuring outlet, accumulator pressure (M)
6. Parking brake solenoid valve (Y642)
7. NC switch, parking brake (GHB) (S260)
8. Connection, accumulators (ACC)
9. NC switch, brake pressure (LB) (S204)
10. Connection, parking brake calliper (HB)
11. Drain valve
12. Main valve charging
13. Pressure limiting valve

4 Brakes – 4.3.3 Accumulator charging valve 13
Accumulator charging, checking and adjustment

page
–
NOTE
Safety.

2 Check the accumulator’s charging, see Hydraulic oil pump,
checking page 9.
3 If necessary, adjust the accumulator charging pressure on the
pressure limiting valve.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
4 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valves and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
008245
Adjusting screw accumulator charging pressure

14 4 Brakes – 4.3.3 Accumulator charging valve
Accumulator charging valve, replacement

page
–
NOTE
Safety.
3 Mark up hydraulic hoses and electric cables.
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator charg-
ing valve.
Remove the parking brake valve for easier access.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
6 Remove the accumulator charging valve.
7 Transfer the connection adapters and sensors to the new accu-
mulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in accord-
008244
ance with the marking.
Attaching bolts, accumulator charging valve

NOTE
Check that the O-rings are intact and in the correct position.
10 Fit the parking brake valve and parking brake NO switch.
11 Connect the wiring to the accumulator charging valve.
NOTE
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 13.
009868

4 Brakes – 4.3.4 Accumulator 15
4.3.4 Accumulator
Accumulator, description
page
–
The accumulators store pressure so that there is a pressure reserve

in the event of engine or brake system malfunction. The brake system
has two accumulators connected in parallel. These are located along
the frame beam on the left side of the machine.
The accumulators are of the diaphragm type. Each accumulator is di-
vided into two spaces by a diaphragm. One side of the diaphragm is
pressurised by nitrogen gas. The other side is pressurised by the hy-
draulic oil, which compresses the nitrogen gas.
At the top of the accumulator, there is a connection for checking nitro-
gen gas pressure (and for filling nitrogen gas using special filling
equipment).
When the accumulator is filled with hydraulic oil the diaphragm is
pressed up and the pressure of the nitrogen gas rises. When the hy-
draulic system requires supply from the accumulator, the diaphragm
forces the oil back into the system
Pressurised oil from the accumulator is used for the service and park-
009869
ing brake systems and for supplying the servo hydraulics’ reducing
valve (see section 4 Brakes and section 7 Load handling).
Brake system accumulators
NOTE
If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may cease to work.
Accumulator, checking
page
–
NOTE
Safety.
NOTE
A special tool for checking the accumulators can be ordered from
Cargotec. The procedure without use of the special tool is de-
scribed below.

3 The accumulators can be tested with separate test equipment or
in the machine. Primarily, separate test equipment should be
used since it is faster and more exact.
Test equipment can be ordered from Kalmar Industries AB.
• Test with test equipment: continue with step 4.
• Test in machine: continue with step 6.

16 4 Brakes – 4.3.4 Accumulator
Checking with test equipment

4 Remove the accumulators and test them with the test equipment
designed for the purpose.
The accumulators’ gas pressure must match with the pressure
plate.
5 Continue with step 17.
M Pa
009870
Pressure plate, gas pressure brake accumulators

Checking in the machine
3
2 6 Loosen one of the accumulators from the distribution block. Plug
1 the connection on the distribution block with a plug that can han-
dle high pressure. Plug the connection on the accumulator to pre-
vent contamination.
009871
1. Clamp
2. Bolt
3. Distribution block
connection for accumulator pressure on the accumulator charg-
ing valve.
9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
NOTE
10 Check that the plug seals properly.
11 Turn off engine.
12 Lower the pressure by means of braking carefully several times
004810
while checking the pressure on the pressure gauge.

4 Brakes – 4.3.4 Accumulator 17
When the pressure reaches approx. 10 MPa the pressure must

decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is turned off,
then the accumulator does not have any precharge pressure.
This indicates internal leakage and the accumulator must be
changed.
If the pressure can be reduced slowly to a pressure below
10 MPa then the pre-charge pressure is too low and the accumu-
lator must be replaced or given to authorised personnel for
maintenance.
14 Mark up and disconnect the tested accumulator. Plug the con-
nections. Connect one of the other accumulators to the distribu-
tion block.
15 Repeat steps 8 - 14 until all accumulators have been checked.
Installation and final checking

17 Connect both accumulators to the distribution blocks. If needed,
replace or fill defective accumulators.
NOTE
Check that the seals are intact and are fitted correctly.
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.

18 4 Brakes – 4.3.4 Accumulator
Accumulator, replacement
page
–
NOTE
Safety.
2 Switch off the engine and close the system voltage.
4 Detach the accumulator’s clamp and remove the bolt.
3
2 5 Detach the accumulator from the distribution block.
1
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
6 Bend the clamp away and remove the accumulator.
009871
7 Fit the new accumulator.
1. Clamp NOTE
2. Bolt Check that the seal is intact and in the correct position.
8 Secure the accumulator’s clamp and tighten the bolt.
11 Check that the accumulator’s connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking
page 15 steps 18-19.
009868

4 Brakes – 4.3.5 Brake valve 19
4.3.5 Brake valve

Brake valve, description
page
–
The brake valve, which is located on the underside of the cab under
3
the brake pedal, controls the hydraulic pressure to the brakes. A lever
2 transfers pedal force to the valve.
1
The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion to
brake pressure. This provides optimal pedal response and increased
safety as the operator senses if no brake pressure is being built up (no
resistance in the pedal).
009872
1. Inlet from accumulators [P]

2. Return connection [T]
3. Outlet to brake cylinders [B]

20 4 Brakes – 4.3.5 Brake valve
Brake valve, checking

page
–
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, at least 50 C.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
brake pressure on the distribution block on the front axle.
NOTE
6 Start the machine and run it at idle until the accumulators are
charged and the accumulator charging valve changes to cooling.
7 Press down the pedal completely and read off the pressure.
Compare to the pressure plate on the left frame member.
8 Turn off engine.
9 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.
10 Release the pedal, the brake pressure must decrease to 0 MPa
immediately. Otherwise the brake valve does not seal and can
cause the brakes to remain applied and then overheat during
operation.
Replace the brake valve if it is not sealed.
measuring outlet.
NOTE
009873


4 Brakes – 4.3.5 Brake valve 21
Brake valve, replacement

page
–
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the brake valve.
B
T NOTE
P Plug the connections immediately to protect the brake sys-
009875 4 Secure the brake valve under the cab.
5 Remove the brake valve’s attaching bolt.

6 Remove the brake valve.
7 Transfer the connection adapters to the new brake valve.
8 Install the new brake valve.
NOTE
Remember the spacer ring.
9 Connect the hydraulic hoses to the brake valve in accordance

B with the marking.
T
NOTE
P
Check that the O-rings are intact and are installed correctly.
10 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment page 3.
004795

22 4 Brakes – 4.3.5 Brake valve
NOTE
12 Turn on the system voltage and start the engine. Run the engine
at idle speed.
13 Test the brakes a couple of times.
14 Check that the brake valve’s connections are sealed tightly.
15 Bleed the wheel brakes’ brake cylinders, see Wheel brakes,
bleeding page 28.
009868

4 Brakes – 4.3.6 Drive axle block 23
4.3.6 Drive axle block

Drive axle block, description
page
–
The drive axle block distributes oil flow and brake pressure to the right
1
10 and left wheel brakes. The drive axle block is located on a bracket
2 above the drive axle’s differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake’s cooling circuit.
4
The drive axle block has a bypass valve which guides oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance in
9 the axle becomes too high. This protects the wheel brake seals, e.g.,
6
when the oil is cold.
8 7 There are two contacts in the drive axle block: brake light NO
switch (216), see Make-contact (closing switch) brake lights, descrip-
tion page 25 and disengagement NO switch, see section 2 Transmis-
sion, group 2.8.2 Normally closed (NC) switch, disengagement.
009876
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to radiator
3. Brake cooling connection, to wheel brake
4. Brake cooling connection, from accumulator charg-
ing valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. NO switch, declutch (S220)
8. NO switch, brake lights (S216)
9. Measurement connection, brake pressure
10. Measuring outlet, brake cooling back pressure

24 4 Brakes – 4.3.7 Break contact (opening switch) brake pressure

brake pressure
Brake pressure NC switch, description
page
–
The brake pressure NC switch (S204) detects the pressure in the ac-
cumulators. The NC switch is located on the accumulator charging
valve on the lifting beam in front of the transmission in the engine
compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s opening
pressure is chosen so that there is pressure for at least 8 brake appli-
cations without additional feed from the pump after the light has
gone off.
The brake pressure NC switch (S204) is supplied power by the frame
control module (D797-1). When the pressure increases above the cut-
off pressure, the voltage signal to frame control unit (D797-1) is cut off.
section 8 Control system, group 8.4.5.4 HYD, menu 4.
009877
Brake pressure NC switch, adjusting

page
–
NOTE
Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 C.
accumulator pressure on the accumulator charging valve.
NOTE
6 Start the engine and fully charge the accumulators (the accumu-
lator charging valve changes to cooling).
7 Stop the engine and turn the start key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
approx. 11.5 MPa.
004810

4 Brakes – 4.3.8 Make-contact (closing switch) brake lights 25
10 If necessary, adjust the warning level by turning the adjusting

screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
measuring outlet.
NOTE
4.3.8 Make-contact (closing switch)

brake lights
Make-contact (closing switch) brake lights,
page
–
description
The brake light NO switch controls brake light activation when the ma-
chine brakes. The switch is located on the drive axle block, which is
located on a bracket above the drive axle’s differential.
The brake light NO switch (S216) is supplied power by and sends a
voltage signal to the frame control unit (D797-1). When the pressure
increases above the closing pressure, a voltage signal is sent to the
frame control unit (D797-1).
009878
Make-contact (closing switch) brake light, checking

page
–
NOTE
Safety.
1 Operate and warm up the machine until the hydraulic oil reaches
operating temperature, at least 50 C.
3 Brake and check that the brake light is switched on.

26 4 Brakes – 4.3.8 Make-contact (closing switch) brake lights

brake pressure on the distribution block.
NOTE
7 Start the engine.
8 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYD 4(6) system, group 8.4.5.4 HYD, menu 4.
PRESSURE SWITCHES
BRAKE PRESSURE X BRAKE LIGHT PRESS. indicates status for the brake light
BRAKE LIGHT PRESS. X switch. 1 = Activated switch (brakes applied).
000144
DECLUTCH PRESSURE X 9 Press down the brake pedal slowly until the brake light is activat-
ed 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.
10 Turn off engine.
measuring outlet.
NOTE

4 Brakes – 4.3.9 Wheel brakes 27
4.3.9 Wheel brakes

Wheel brakes, description
page
–
The wheel brakes brake the machine during operation and are fitted
on the drive axle between the drive axle housing and hub reduction.
The wheel brake have so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
009879
The wheel brake has two main sections - disc pack and brake cylinder.
1 2
The disc pack performs the braking. The brake cylinder presses to-
gether the discs in the disc pack during braking.
000016
Wheel hub and brake, cross section

1. Disc pack
2. Brake cylinder

28 4 Brakes – 4.3.9 Wheel brakes
Wheel brakes, bleeding

page
–
NOTE
Safety.
IMPORTANT
Both brake cylinders must be bled after work where
the brake system is opened or after work on the wheel
brake.

2 Position a ring spanner on the bleed nipple and connect a trans-
parent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 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. Therefore, allow at least two litres of oil to pass through
the air bleeder nipple when bleeding to ensure that no air
pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub’s inner short side (left-hand side). 6 Move the wrench and hose and repeat steps 1–4 on the other
side.
7 Check the oil level in the brake system, fill if necessary.
Wheel brake, replacement

page
–
See supplier documentation, drive axle.

4 Brakes – 4.3.9.1 Disc pack 29
4.3.9.1 Disc pack

Disc pack, description
page
–
The disc assembly consists of several thin metal discs fixed alternately
to the wheel brake housing and to the hub reduction housing. The
discs are mounted on splines, which allows them to move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
Braking takes place by means of the brake cylinder pressing together
the discs. This creates friction between the discs that are fixed to the
axle and those fixed to the hub reduction.
000008
Disc pack
4.3.9.2 Brake cylinder

Brake cylinder, description
page
–
The brake cylinder is integrated in the wheel brake and consists of a

metal ring (cylinder) with two seal rings. The seals have lateral support
from a bevel on the cylinder and a bevel on the wheel brake housing.
The space between the seal rings is pressurised through a channel in
the wheel brake housing. The pressure moves the metal ring sideways
and compresses the disc pack.
000007
Brake cylinder
4.3.10 Pipes and hoses

Piped and hoses, description
page
–
See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

30 4 Brakes – 4.5 Parking brake system
4.5 Parking brake system

Parking brake system, function description
page
–
D5
5
6 12
D790-1 D790-2
D797-1
7 11
C D8 D10
4
8
Pa 10 9
C ACC
3
H
P
T
2
008060
B
1 The hydraulic oil pump pumps oil from P = 211 MPa Hydraulic oil tank, description page 38
the hydraulic oil tank. Hydraulic oil pump, description page 9
2 The hydraulic oil filter cleans dirt from - Hydraulic oil filter, description page 39
the oil.
3 The accumulator charging valve directs Charging: Accumulator charging valve, description
oil to charging of accumulators or through P = 20.50.5 MPa page 12
the brake system’s cooling circuit.
Cooling: P < 0.1 MPa
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 15
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
the parking brake. Conn. 1, U = 24 V ries, group 9.1 Controls and instruments
The switch uses two signals - one for ap- Conn. 7, U = 0 V D5: Diagnostic menu, see section 8 Con-
plied and one for released parking brake. trol system, group 8.4.5.5 HYD, menu 5
Switch in home position:
Both signals must be correct to enable re-
lease of the parking brake. Conn. 1, U = 0 V
Conn. 7, U = 24 V

4 Brakes – 4.5 Parking brake system 31
6 The cab control unit (D790-1) transmits Controlled by control sys- Section 11 Common electrics,
Activate parking brake on the CAN bus. tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
ror code.
7 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description
the parking brake solenoid valve (Y642). page 33
D7: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.5 HYD, menu 5
8 Solenoid valve parking brake (Y642) acts Pump pressure Solenoid valve parking brake, description
on the valve slide which drains pressure page 33
in the parking brake’s brake caliper to
tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description page 34
and the spring applies the parking brake.
10 The parking brake NC switch (S200) Applied parking brake: Break contact (opening switch) parking
closes the circuit when the pressure Conn. 1, U = 24 V brake, description page 37
increases. D10: Diagnostic menu, see section 8 Con-
Conn. 2, U = 0 V
trol system, group 8.4.5.5 HYD, menu 5
Released parking brake:
Conn. 1, U = 24 V
Conn. 2, U = 24 V
11 The frame control unit (D797-1) transmits Controlled by control sys- Section 11 Common electrics,
Parking brake applied on the CAN bus. tem, error shown with er- group 11.5.3.2 Frame control unit
ror code. (D797-1)
12 Control unit KIT (D790-2) activates indi- Controlled by control sys- Section 9 Frame, body, cab and accesso-
cator light, parking brake (508). tem, error shown with er- ries, group 9.1 Controls and instruments
ror code.
Hydraulic diagram, see section E Schematics, group 10 Common hy-


32 4 Brakes – 4.5 Parking brake system
Parking brake system, component positions

page
–
1 4
2 5 6
12
008062
11 10 9 8
1. Control unit, cab (D790-1) 7. Switch (NO), parking brake (S200)

2. Control unit KIT (D790-2) 8. Parking brake disc
3. Switch parking brake (S107) 9. Parking brake caliper
4. Frame control unit (D797-1) 10. Hydraulic oil filter
5. Accumulator charging valve 11. Hydraulic oil pump
6. Solenoid valve parking brake (Y642) 12. Accumulators


Hydraulic oil pump, general
page
–
See Hydraulic oil pump, description page 9.

Hydraulic oil filter, general
page
–
See Hydraulic oil filter, description page 39.
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
page
–
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the transmission in the engine
compartment, see Accumulator charging valve, description page 12.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. In-
stead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by the frame control unit
009880
(D797-1) at activation.
Solenoid valve parking brake, checking

page
–
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.
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake with switch parking brake and check
that the parking brake’s brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the switch for the parking brake
and check that the parking brake’s brake caliper is applied.

34 4 Brakes – 4.5.4 Parking brake unit
4.5.4 Parking brake unit

Parking brake unit, description
page
–
The parking brake unit keeps the machine stationary when parked.
3 1 2
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake caliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is ac-
tivated before the pressure drops so low that the parking brake is
applied. If the parking brake is applied while the machine is on the
move, the brake disc and brake pads must be checked and re-
placed if necessary.
009881
Parking brake unit, checking and adjusting

page
–
DANGER
The machine may start to roll.
Risk of crushing.

1 Start the engine and run up hydraulic pressure until the accumu-
lators are fully charged and the accumulator charging valve
switches to cooling.
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.

4 Brakes – 4.5.4.1 Parking brake caliper 35
6 Remove the cover from the brake calliper and check for oil inside
the cover. Oil inside the cover indicates internal leakage.
7 Loosen the lock nut.

8 Adjust the adjusting screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc is 0.50.1 mm.
10 Tighten the lock nut.
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.
4.5.4.1 Parking brake caliper

Brake caliper, description
page
–
The brake caliper has a spring section and a hydraulic section. The
1 2 3 4 5
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. In turn, this means that the machine is
braked if a serious malfunction occurs.
000020
1. Brake pads
2. Release cylinder
3. Application spring
4. Release screw
5. Adjusting washer

36 4 Brakes – 4.5.4.2 Parking brake pads
4.5.4.2 Parking brake pads

Brake pads, description
page
–
The brake pads consist of a metal plate with friction material (lining).
Brake pads, replacement (Kessler drive axle)

page
–
DANGER
The machine may start to roll.
Risk of crushing.

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

Safety.
2 Remove the cover from the brake caliper.
3 Loosen the lock nut.

4 Slacken the adjusting screw to release the brake pads.
5 Remove the split pin and undo the nut on one of the attaching
bolts holding the parking brake calliper in place.

4 Brakes – 4.5.4.3 Parking brake disc 37
6 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 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Fit new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjusting page 34.
4.5.4.3 Parking brake disc

Brake disc, description
page
–
The brake disc is mounted on the drive axle input shaft. The drive ax-
le’s gear ratio amplifies the braking force.

parking brake
Break contact (opening switch) parking brake,
page
–
description
The parking brake NC switch (S200) detects whether the parking
brake is applied or released. The NC switch is fitted on the accumula-
tor charging valve, which is fitted on the lifting beam in front of the
transmission in the engine compartment, see Accumulator charging
valve, description page 12.
Break-contact parking brake (S200) senses the pressure in the park-
ing brake circuit. When the pressure is so high that the parking brake
is released, the sensor opens an electric circuit. This is used to indi-
cate that the parking brake is released.
The parking brake NC switch (S200) is supplied power by and sends
a voltage signal to the frame control unit (D797-1). When the pressure
increases above the opening pressure, the voltage signal to the frame
control unit (D797-1) is cut off.
009882
NOTE
Gears cannot be engaged when the parking brake is applied.

page
–

38 4 Brakes – 4.8 Temperature control, cleaning and hydraulic oil
4.8 Temperature control,

cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page
–
C C
4
P T
2 5
3
002611
1 The hydraulic oil pump pumps oil from See pressure plate on left Hydraulic oil pump, description page 9
the hydraulic oil tank. frame beam. Section 10 Common hydraulics,
group 10.3.1 Tank
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description page 39
3 The accumulator charging valve directs Charging: Accumulator charging valve, description
oil to charging of accumulators or P = 20.50.5 MPa page 12
through the brake system’s cooling
Cooling: P < 0.1 MPa
circuit.
4 The oil cools the wheel brake. - Wheel brakes, description page 27
5 The bypass valve in the distribution - Drive axle block, description page 23
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.
Hydraulic diagram, see section E Schematics, group 10 Common hy-


page
–
component positions
Hydraulic oil pump, hydraulic oil filter, accumulator charg-
ing valve, drive axle block, wheel brakes
See Power-assisted brake system, component positions page 8.
4.8.1 Hydraulic oil tank

Hydraulic oil tank, description
page
–
See section 10 Common hydraulics, group 10.3.1 Hydraulic oil tank.


page
–
See Hydraulic oil pump, description page 9.
4.8.4 Accumulator charging valve

Accumulator charging valve, description
page
–
See Accumulator charging valve, description page 12.
4.8.5 Drive axle block

Drive axle block, description
page
–
See Drive axle block, description page 23.
4.8.6 Wheel brakes

Wheel brakes, description
page
–
See Wheel brakes, description page 27 and supplier documentation,

drive axle.
4.8.8 Thermal bypass valve

Thermal bypass valve, description
page
–
See section 10 Common hydraulic, group 10.6.5 Radiator bypass

valve.
4.8.9 Cooling fan

Cooling fan, description
page
–
See section 10 Common hydraulics, group 10.6.3 Cooling fan.
4.8.10 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
page
–
See section 10 Common hydraulics, group 10.6.4 Hydraulic oil tem-

perature sensor.
4.8.11 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
page
–
See section 10 Common hydraulics, group 10.6.6 Breather filter, hy-

draulic oil tank.

Hydraulic oil filter, description
page
–
See section 10 Common hydraulics, group 10.6.7 Hydraulic oil filter.

page
–

40 4 Brakes – 4.8.14 Hydraulic oil
4.8.14 Hydraulic oil

Hydraulic oil, description
page
–
See section 10 Common hydraulics, group 10.6.8 Hydraulic oil.

5 Steering 1
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5 Steering........................................................................................................... 3
5.2 Power assisted system ............................................................................... 3
5.2.1 Hydraulic oil pump ................................................................................. 4
5.2.2 Priority valve .......................................................................................... 6
5.2.3 Steering valve ........................................................................................ 8
5.2.4 Steering cylinder .................................................................................. 10
5.2.5 Steering axle cradle ............................................................................. 12
5.2.6 Link arm ............................................................................................... 12
5.2.7 Wheel spindle ...................................................................................... 12
5.2.8 Wheel hub ............................................................................................ 12
5.2.9 Shuttle valve ........................................................................................ 12
5.2.13 Pipes and hoses .................................................................................. 12

2 5 Steering

5 Steering 3
5 Steering
mm mm mm mm mm mm
5.2 Power assisted system

Power assisted system, function description
page
–
2
PP P
C
CF LS
T
5
P
LS T L R
3
1
6
008053
1 The hydraulic oil pump pumps oil to the See the pressure plate on Section 10 Common hydraulics,
priority valve. the left-hand frame beam. group 10.4.2 Axial piston pump with variable
displacement
2 The priority valve prioritises pressure Checked by control sys- Priority valve, description page 6
supply to the steering valve over the tem, error shown with er-
working hydraulics. The priority valve ror code.
also transmits a control signal to the hy-
draulic oil pump.
3 Shuttle valve control selects the strong- Checked by control sys- Section 10 Common hydraulics,
est load signal to the hydraulic oil pump tem, error shown with er- group 10.5.3 Shuttle valve
if hydraulic functions are activated at the ror code.
same time as the steering wheel is
turned.
4 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments

4 5 Steering – 5.2.1 Hydraulic oil pump

5 The steering valve pumps pressurised - Steering valve, description page 8
oil to the steering cylinder and transmits
a load signal to the main pump.
6 The steering cylinder turns the wheels. - Steering cylinder, description page 10

Power-assisted steering system, component

page
–
positions
4 6
5 7
1 014828
Hydraulic components
1. Hydraulic oil pump for steering and load handling 5. Steering valve
2. Shuttle valve 6.
Steering valve mini-wheel/joystick control
3. Priority valve 7. Steering axle with steering cylinder
4. Connection terminal, return oil

page
–
Steering is supplied oil by the hydraulic oil pump for steering and load
handling; see section 10 Common hydraulics, group 10.4 Pumps.

5 Steering – 5.2.1 Hydraulic oil pump 5
Control pressure, checking

page
–
NOTE
Safety.
es operating temperature, 50 C.
3 Connect the pressure gauge to the measuring outlet on the hy-
draulic oil pump for steering and load handling.
4 Start the engine and increase engine speed to approx. 1200 rpm.
009885
Measuring outlet on hydraulic oil pump for steering

and load handling
5 Turn the steering wheel fully and read pump pressure during the
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate.
measuring outlet.
009886

6 5 Steering – 5.2.2 Priority valve
5.2.2 Priority valve

Priority valve, description
page
–
1 2 The priority valve separates the oil flow from the hydraulic oil pump for
steering and load handling so that there is always oil to the steering
valve. The residual flow goes to the working hydraulics or the servo
circuit.
The priority valve is load-sensing and pilot pressure compensating.
Load-sensing means that the valve adapts the control signal to the
steering valve’s consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure-drop between the
3 priority valve and steering valve via a separate line.
6 4
5 The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signal’s pressure.
009884
1. Supply pressure from hydraulic oil pump (P)

2. Pilot pressure (PP), pressure drop to steering valve
3. Pressure to steering valve (CF)
4. Pressure to control valve, load handling (EF)
5. Load signal from steering valve (LS)
6. Tank draining (T)
Priority valve, replacement

page
–
NOTE
Safety.

5 Steering – 5.2.2 Priority valve 7
1 2 4 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
5 Remove the priority valve attaching bolts.
6 Disconnect the priority valve from control valve lift and lower.
3 7 Remove the priority valve.

6 4
5 8 Transfer the connection adapters to the new priority valve.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to control valve lift and lower.
CAUTION
009884
1. Supply pressure from hydraulic oil pump (P)

2. Pilot pressure (PP), pressure drop to steering valve Do not tighten the hydraulic connection between pri-
3. Pressure to control valve, load handling (EF) ority valve and collection block before all other con-
4. Load signal from steering valve (LS) nections and attaching bolts are fitted.
5. Tank draining (T) Stresses in the priority valve may result in incorrect
6. Pressure to steering valve (CF) function.
10 Fit the priority valve attaching bolts.

11 Connect the hydraulic hoses to the priority valve in accordance
with the marking.
12 Check that control valve lift and lower is not jammed against the
priority valve.
13 Tighten the hydraulic connection between priority valve and col-
lection block.
14 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
15 Check the steering pressure, see Control pressure, checking
page 5.

8 5 Steering – 5.2.3 Steering valve
5.2.3 Steering valve

Steering valve, description
page
–
The steering valve is a closed centre, non-reaction valve with load sig-
nal connection to the priority valve.
The load signal generates load-dependent control of oil flow from the
1 priority valve to the steering valve. Closed centre means that the steer-
ing valve is closed in its neutral position. This is necessary so that sig-
nal pressure can be connected to the steering valve.
2
5 The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
4 3
the gear pump to the distribution valve, which guides oil to the steering
cylinder. The gear pump ensures that the oil flow supplied to the cylin-
der is proportional to the steering wheel angle.
In the steering valve there are double shock and anti-cavitation valves.
The shock valves protect the hydraulics against pressure spikes which
can arise from impacts on the steering wheels. The anti-cavitation
valves (non-return valves) protect against vacuum on the piston’s rear
side, which otherwise can lead to cavitation.
009887
Steering valve, replacement

page
–
NOTE
Safety.
1. Water valve
2. Steering valve

5 Steering – 5.2.3 Steering valve 9
4 Detach the steering valve from the brake pedal.

Remove the steering valve’s attaching bolts and lower the control
valve.
5 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
6 Remove the steering valve.
7 Transfer the connection adapters to the new steering valve.
NOTE
mixed up.
8 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
Check that the O-rings are intact and are fitted in the correct
position.
9 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. Install the
attaching bolts.
10 Turn on the main electric power and start the engine.
11 Check that the connections on the steering valve are sealed
tightly.
12 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.

10 5 Steering – 5.2.4 Steering cylinder
5.2.4 Steering cylinder

Steering cylinder, description
page
–
The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 ing cylinder is a double-acting hydraulic cylinder.
4
009888
1. Steering cylinder
2. Shaft
3. Lock bolt
4. Attaching bolt (locked with locking fluid)
Steering cylinder, replacement

page
–
NOTE
Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
3 Depressurise the brake and hydraulic systems, see section B
Safety.
4 Detach the link arms from the steering cylinder.

5 Steering – 5.2.4 Steering cylinder 11
5 Mark up and detach the hydraulic hoses from the steering

cylinder.
NOTE
6 Remove the steering cylinder’s attaching bolts.
7 Change the steering cylinder. Lift aside the steering cylinder.
1. Hydraulic connection
NOTE
2. Link arm mounting The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
9 Lubricate and install the steering cylinder’s attaching bolts. Tight-
en the bolts crosswise a few times with increasing torque to
680 Nm.
10 Transfer parts to the new steering cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
11 Connect the link arms to the steering cylinder, lubricate the shafts
for the link arms.
12 Connect the hydraulic hoses to the steering cylinder.
NOTE
position.
13 Close the drain valve on the accumulator charging valve. See
section B Safety.
Hydraulic cylinders, repairs

page
–
See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

12 5 Steering – 5.2.5 Steering axle cradle
5.2.5 Steering axle cradle

Steering axle cradle, general
page
–
See section 6 Suspension, group 6.2.1 Steering axle cradle.
5.2.6 Link arm

Link arm, description
page
–
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,
The link arms must be turned to the right direction, otherwise they can
1 be damaged by the rims with large wheel angles.
008854
1. Link arm
5.2.7 Wheel spindle

Wheel spindle, general
page
–
See section 6 Wheel suspension, group 6.2.2 Wheel spindle.
5.2.8 Wheel hub

Wheel hub, general
page
–
See section 6 Suspension, group 6.2.3 Wheel hub.
5.2.9 Shuttle valve

Shuttle valve, description
page
–
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.

page
–

6 Suspension 1
6 Suspension
Table of Contents 6 Wheel suspension

mm mm mm mm mm mm
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 3
6.2.1 Steering axle cradle ............................................................................... 4
6.2.2 Wheel spindle ........................................................................................ 6
6.2.3 Wheel hub .............................................................................................. 8
6.3 Tyres and rims .......................................................................................... 13
6.3.1 Tyres .................................................................................................... 15
6.3.2 Rim ...................................................................................................... 16
6.3.3 Nut, washer and clamp ........................................................................ 17

2 6 Suspension

6 Suspension 3
6 Suspension
mm mm mm mm mm mm
6.2 Suspension
Bushing steering axle mounting, changing
page
–
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is not permissible to go enter a machine which has

been lifted by a jack or similar. For machine weights,
please refer to the section F Technical data.

3 Support under the steering axle so that it cannot fall over.
4 Attach hoisting equipment to the rear of the machine and take up
the slack so that the steering axle’s mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
5 Remove the pins holding the steering axle.
6 Lift the machine so that the frame is off the steering axle.
7 Support the machine under the frame.
8 Move the steering axle so that the mountings can be accessed.
NOTE
If necessary, disconnect the cable harness for the sensors
on the steering axle.
009890
The illustration shows rear mounting

4 6 Suspension – 6.2.1 Steering axle cradle
9 Remove the washers that hold the bushing in place.

2 10 Press out the bushing.
1 11 Clean the bearing surfaces on the steering axle.

12 Press in the new bushing. Grease the bushing to facilitate
installation.
13 Fit the washers that hold the bushing in place.
14 Move the steering axle into place under the frame.
15 Lubricate and fit the pins at the steering axle’s mounts.
3
16 Remove the lifting equipment from the machine.
4
010121
1. Steering axle mounting

2. Rubber bushing
3. Washers
4. Screw
6.2.1 Steering axle cradle

Steering axle cradle, description
page
–
The oscillating steering axle has a double-acting steering cylinder. The

1 2 3 4 5 6
design has a minimum of moving parts for fewer service points and
simpler maintenance. Suspension in the chassis is performed with
maintenance-free pads.
008047
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. King pin/bearing
Steering axle cradle, replacement

page
–
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is not permissible to go enter a machine which has

been lifted by a jack or similar. For machine weights,
please refer to the section F Technical data.

6 Suspension – 6.2.1 Steering axle cradle 5
1 Clean the steering axle and its surrounding area.

5 Connect the lifting equipment to the rear section of the machine.
6 Tension the lifting equipment, do not lift so much that the wheels
are off the ground.
7 Support the machine’s rear section.
8 Detach the hydraulic hoses from the steering cylinder.
NOTE
9 Remove the pins holding the steering axle.
10 Lift the machine up so that the frame is lifted away from the axle.
11 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.
12 Adjust the support so that the machine is secured in the new

position.
13 Lift the steering axle into place under the frame.
14 Remove the support under the frame.
15 Lower the rear section of the machine.
16 Fit the pins at the steering axle mountings.
17 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact and that they are fitted
correctly.
18 Remove the lifting equipment from the machine.

6 6 Suspension – 6.2.2 Wheel spindle
6.2.2 Wheel spindle

Wheel spindle, description
page
–
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
3
2
4
5
1 6
8 7
9
009780
11 10
1. Wheel spindle
2. Seal ring
3. Bearing (upper)
4. Guard ring
5. Seal ring
6. Bearing (lower)
7. Circlip
8. Shim
9. Bearing cage
10. Bolt
11. Grease nipple
Spindle bolt bearing, replacement

page
–

2 Lift the machine under the steering axle at the wheel in question.
Support the steering axle in a suitable way.
3 Remove the steering wheel in question.
4 Clean the wheel spindle and its surrounding area.
5 Detach the link arm from the wheel spindle.
6 Remove the wheel hub and wheel bearing; see Wheel bearing,
replacement page 8.

6 Suspension – 6.2.2 Wheel spindle 7
7 Remove the six screws holding the bearing cage to the wheel
spindle.
8 Detach the bearing cage by screwing a screw into the removal

hole.
9 Remove the bearing cage and shim from the wheel spindle.
10 Remove the wheel spindle.
11 Remove the three screws on the top of the steering axle cradle.
Press out the outer bearing race of the upper bearing by screwing
three screws (approx. 90 mm long) into the holes.
12 Remove the inner bearing races of the upper and lower bearings
from the wheel spindle.
13 Remove the outer bearing race of the lower bearing from the
bearing cage.
002419
14 From underneath, tap in the outer bearing race of the upper bear-
ing into the steering axle cradle. Use a pipe of a suitable diameter
so as not to damage the bearing race.
15 Refit the three screws on the top of the steering axle cradle.
16 Fit upper bearing’s inner bearing race, seal ring, guard ring and
seal ring as well as the lower bearing’s inner bearing race and cir-
clip on the wheel spindle.
17 Fit the wheel spindle.
18 Tap the lower bearing’s outer bearing race into the bearing cage.
Use a pipe of a suitable diameter so as not to damage the
bearing race.
19 Fit the bearing cage. Use a shim to get it in the right position.
Tighten the screws.
20 Check that the wheel spindle rotates smoothly and that there is
no play in the spindle bearing arrangement. Correct with shims as
necessary.
NOTE
The correct number of shims have been used when it takes at
least 200 Nm to move the bearing arrangement to move laterally.
If it takes more than 400 Nm for the bearing arrangement to
move, it is too hard and the number of shims must be corrected.
21 Lubricate the wheel spindle bearings via the grease nipples.

8 6 Suspension – 6.2.3 Wheel hub
22 Fit the wheel hub and wheel bearing; see Wheel bearing, re-
placement page 8.
23 Connect the link arm to the wheel spindle.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
26 Test-run the machine and test the steering. Check also that the
machine feels stable when operating straight ahead.
6.2.3 Wheel hub

Wheel hub, description
page
–
The wheel hub holds the wheel in place and allows the wheel to rotate.
3 2
1
4
5
6
7
8
9
10 11
008595
1. Wheel hub
2. Wheel bolt
3. Wheel nut
4. Hub cap
5. Spacer
6. Nut
7. Washer
8. Bearing
9. Bolt
10. Bearing
11. Seal ring
Wheel bearing, replacement

page
–
1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
2 Remove the steering wheel in question.

6 Suspension – 6.2.3 Wheel hub 9
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe off grease from hub cover and hub nut. Handle it as envi-
ronmentally hazardous waste.
6 Secure the hub with a lifting strap.

Route the lift sling over the hub and around a wheel bolt. Install a
clamp and nut to secure the lift sling. Use manual forklift, pallet
forks or similar to lift the hub.
7 Bend up the locking washer’s tabs, remove the lock nut and lock-
ing washer.
8 Tension the lifting equipment so that the hub is unloaded.
9 Remove the hub nut.
10 Lift the hub out from the spindle.

Remove the outer bearing’s inner race and pull the hub from
the axle.

11 Remove the inner bearing from the wheel spindle.
12 Remove the seal from the hub.

13 Remove the bearings’ outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and line the inside with universal grease "EP2".
15 Fit new outer races in the hub.
Use a drift and press in the bearing races. Never use directly on
the bearings.
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 Install the inner bearing’s inner race and rollers on the wheel
spindle. Pack the bearing with universal grease "EP2".

6 Suspension – 6.2.3 Wheel hub 11
18 Fill the empty space in the hub with universal grease "EP2".
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut.

Pack the bearing with grease and fit the bearing.
Fit the washer and hub nut with the smooth surface in towards the
hub.
21 Remove the lifting equipment.
22 Tighten the bearing nut in the following stages.

A. Lubricate the thread and the side of the nut facing the bear-
ing with oil (SAE 80W/140).
B. Tighten the nut to 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle-tighten the nut 45.
E. Rotate the hub 10 revolutions.
F. Angle-tighten the nut 45.

23 Apply grease onto the locking washer and fit it.

24 Fit the lock nut and tighten to at least 250 Nm (oiled screw) or
as hard as necessary to engage the locking washer in the closest
groove. Lock the bearing nut and lock nut with the locking
washer.
25 Fill the bearing casing with grease and fit it.

26 Grease the wheel bearing with grease through the lubricant
nipple.
Lift the seal ring’s lip with a small screwdriver to facilitate the es-
cape of air. Lubricate until grease comes out at the seal.
27 Fit the wheel.
28 Remove the support and lower the steering wheel.

6 Suspension – 6.3 Tyres and rims 13
6.3 Tyres and rims

Tyres and rims, safety
page
–
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.
Deflate the tyre before removal. Otherwise the lock

ring and lock lugs may release and shoot out when
the pressure is changed. With tandem wheels, both
tyres must be deflated!
The air should always be released via the valve. If this

is not possible — drill a hole in the tread to deflate.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflat-

ing or inflating. The lock ring or lock lugs may release
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 select-

ed for each machine type so that maximal wheel loads
and travel speeds are not exceeded. For this reason it
is forbidden to change tyre dimension, tyre brand,
tyre type, rim type, or rim brand without approval from
Cargotec.

14 6 Suspension – 6.3 Tyres and rims
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 oper-

ating hours.
Always follow the tyre manufacturer’s or other ap-

proved instructions when changing tyres.
Never use a steel hammer to install or removerim

components. Instead, use a lead, brass or plastic
mallet.
Keep the tyre pressures at the prescribed level. Insuf-

ficient 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.

6 Suspension – 6.3.1 Tyres 15
6.3.1 Tyres
Tyres, description
page
–
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.
Spare and replacement tyres must be from a manufacturer approved
by Cargotec.
009892
Front wheels
009893
Rear wheels
Tyres, changing
page
–
DANGER
Changing tyres is complicated and dangerous work.
EXTREME DANGER!
Leave tyre work to authorised personnel/tyre

company.
The rims must be checked when tyres are changed. See Maintenance
manual DCF 90-100.

16 6 Suspension – 6.3.2 Rim
6.3.2 Rim
Rim, description
page
–
The rim is split to make it possible to fit a tyre, and the rim consists of
1 2 3 4
the following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring
5
009899
1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt

6 Suspension – 6.3.3 Nut, washer and clamp 17
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
page
–
The rim is attached to the wheel hub with nuts.

1 2 3 4
As an option, the rim can be equipped with nut protection.
5
009899
1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt

18 6 Suspension – 6.3.3 Nut, washer and clamp
Wheel bolt, replacement

page
–

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel; see Maintenance manual
DCF 90-100.
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.

7 Load handling 1
7 Load handling
Table of Contents 7 Load handling

mm mm mm mm mm mm
7 Load handling................................................................................................. 3
7.1.1 Control levers ......................................................................................... 5
7.1.2 Switch, lock twistlock/lock tongue .......................................................... 7
7.1.3 Switch, spreading 20'-40' ....................................................................... 7
7.1.4 Switch, stop at 30' .................................................................................. 8
7.1.13 Switch, automatic spreading .................................................................. 8
7.2 Lift and lower .............................................................................................. 9
7.2.2 Servo filter ............................................................................................ 12
7.2.3 Pressure reducer ................................................................................. 13
7.2.4 Accumulator servo circuit ..................................................................... 14
7.2.5 Control valve, lift and tilt ....................................................................... 15
7.2.6 Shuttle valve ........................................................................................ 17
7.2.7 Lift cylinder ........................................................................................... 17
7.2.8 Sensor hydraulic pressure lift cylinder ................................................. 17
7.2.9 Mast ..................................................................................................... 19
7.2.10 Mast position sensor ............................................................................ 28
7.2.11 Trolley .................................................................................................. 29
7.2.12 Valve block quick-lift ............................................................................ 36
7.2.13 Pipes and hoses .................................................................................. 36
7.4 Side shift ................................................................................................... 37
7.4.2 Control valve, attachment .................................................................... 39
7.4.3 Side shift cylinder ................................................................................. 44
7.4.4 Shuttle valve ........................................................................................ 44
7.4.5 Trolley .................................................................................................. 44
7.4.6 Valve block, main pump relief .............................................................. 48
7.4.7 Relief valve, attachment ...................................................................... 48
7.4.8 Pipes and hoses .................................................................................. 48
7.5 Spreading (positioning) ............................................................................ 49
7.5.2 Control valve, attachment .................................................................... 57
7.5.3 Spreading cylinder ............................................................................... 58
7.5.4 Spreader beam .................................................................................... 59
7.5.5 Main beam, side lift attachment ........................................................... 64
7.5.6 Position sensor, spreading .................................................................. 74
7.5.7 Buzzer, automatic spread 20’-40’ ........................................................ 75
7.5.8 Pipes and hoses .................................................................................. 75
7.7 Tilt ............................................................................................................. 76
7.7.2 Accumulator ......................................................................................... 78
7.7.3 Pressure reducer ................................................................................. 78
7.7.4 Servo filter ............................................................................................ 78

2 7 Load handling
7.7.5 Control valve, lift and tilt ....................................................................... 78

7.7.6 Load holding valve ............................................................................... 79
7.7.7 Tilt cylinder ........................................................................................... 79
7.7.8 Mast ...................................................................................................... 80
7.7.9 Pipes and hoses ................................................................................... 80
7.8 Levelling .................................................................................................... 81
7.8.1 Hydraulic oil pump ................................................................................ 83
7.8.2 Control valve, attachment ..................................................................... 83
7.8.3 Levelling cylinder .................................................................................. 84
7.8.4 Trolley ................................................................................................... 84
7.8.5 Valve block, main pump relief .............................................................. 84
7.8.6 Pipes and hoses ................................................................................... 84
7.9 Load carrier ............................................................................................... 85
7.9.1 Twistlocks ............................................................................................. 85
7.9.2 Lifting hook ........................................................................................... 98
7.10 Other functions ........................................................................................ 111
7.10.1 Container counter ............................................................................... 111

7 Load handling 3
7 Load handling
mm mm mm mm mm mm
Position sensor
page
–
3
1
4
009906
The illustration depicts a machine with a twistlock attachment
1. Sensor, hydraulic pressure in the lift cylinder (B768-L1), see Sen-
sor hydraulic pressure lift cylinder, description page 17.
2. Mast position sensor (B7211-2), see Position sensor, adjusting
page 4.
3. Sensor alignment
(Twistlock B7203L and B7203R), see Alignment sensor, checking
and adjusting page 95,
(Lifting hook B7203LL, B7203LU-2, B7203RL and B7203RU-2),
see Alignment sensor, checking and adjusting page 108.
4. Sensor, locked twistlocks/lock tongues (B7205LL and B7205RL),
see Twistlocks sensor, checking and adjusting page 97 or Lock
tongue sensor, checking and adjusting page 110.
5. Detection sensor, upper container (ultrasound) for attachment
with lifting hook (B7203LU and B7203RU), see Detection sensor,
upper container, checking page 109.
6. Damping sensor (B769L, B769R, B777L and B777R), see Posi-
tion sensor, adjusting page 4.

4 7 Load handling
Position sensor, adjusting

2 Check that the sensor in question is free of damage and dirt.
C-C
3 Check that the distance between the sensor and the indicator is
5±1 mm
51 mm.
4 Adjust if necessary.
009632
5±1 mm
Adjusting position sensor - indicator

7 Load handling – 7.1 Controls and instruments 5

7.1.1 Control levers
Control levers for electric servo, description
page
–
The load handling functions are controlled with fingertip-controlled lin-

ear levers.
The control levers are supplied voltage by and send a signal to the cab
a. Lift/lower (R8071-P1).
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
The lowering speed can only be varied through lever movement -
engine speed has no impact.
b. Tilt (R8072-P2).
IN - pull the lever backwards.
d OUT - push the lever forwards.
c
b
a c. Side shift (R8073-P3).
e LEFT - move lever forward.

RIGHT - pull the lever backwards.
It is not possible to use side shift on the side lift attachment if the
attachment is in its max or min position.
d. Levelling (R8075-1-P5) .
RIGHT side up - push lever forwards.
LEFT side up - pull lever backwards.
e. Emergency stop switch
f. Opening of locked twistlocks/lock tongues, attachment (S1002)
Pull the switch sideways.
f
008110

6 7 Load handling – 7.1.1 Control levers
Control lever, description

page
–
The control lever (S815) is used to control the mast and attachment.
2 3
1 The lever sends voltage signals to the cab control unit (D790-1).
4 The control lever has four potentiometer-controlled functions and six
on/off functions.
5
Lift and lower
6
Lifting and lowering are controlled by moving the control lever forward
7 (lower - position 10) or rearward (lift - position 12). See Lifting/lower-
ing, function description page 9.
8
12 9 section 8 Control system, group 8.4.8.1 ELSERV, menu 1.
Spreading (positioning)
009711
11 10 When the switch is pressed at position 5, spreading out is activated.

1. Not used When the switch is pressed at position 4, spreading in is activated.
2. Not used See Spreading, function description page 49.
3. Side shift (S815-P3) The signal can be checked via the diagnostic menu. See
4. Spreading in (S815-T1.2) section 8 Control system, group 8.4.9.3 ATTACH, menu 3.
5. Spreading out (S815-T1.1)
6. Lock/open twistlocks or lock tongues (S815-T2) at Side shift
full contact
When the potentiometer (position 3) is pressed on the left side, side
7. Not used
shift left is activated. When the right side is pressed, side shift right is
8. Pistol trigger (S815-T4): Changes the function of
activated. See Side shift, function description page 37.
side shift to levelling (S815-P3) The signal can be checked via the diagnostic menu. See
9. Tilt out section 8 Control system, group 8.4.9.1 ATTACH, menu 1.
10. Lift
11. Tilt in Levelling
12. Lower
If the pistol trigger (position 8) is pressed in at the same time as the

potentiometer (position 3) is pressed on the left side, levelling left is ac-
tivating. If the right side is pressed, levelling right is activated. See Ac-
tive levelling, function description page 81.
section 8 Control system, group 8.4.9.1 ATTACH, menu 4.
Tilt
Tilt is controlled by moving the lever to the right (tilt out - position 10)
or the left (tilt in - position 12). See Tilt, function description page 76.
section 8 Control system, group 8.4.8.1 ELSERV, menu 1.

7 Load handling – 7.1.2 Switch, lock twistlock/lock tongue 7
Open twistlocks or lock/open lock tongues

When the switch at position 6 is activated, the twistlocks open or the
lock tongues lock/open every other time if the conditions for such are
fulfilled.
7.1.2 Switch, lock twistlock/lock tongue

Switch, lock twistlock/lock tongue, description
page
–
Switch (green) for locking twistlock/lock tongue (S1003). The switch

has a return-spring action in position 2.
Position 1 - Twistlock/lock tongue locked automatically when contact
is made with load. Parking brake must be OFF.
Position 0 - Twistlock locking not activated.
Position 2 - Twistlock locked manually. Button has a return-spring
009907
action.
Twistlocks are opened with the switch on the control lever, see Control
levers for electric servo, description page 5.
The switch is supplied power by and sends a voltage signal to the cab
7.1.3 Switch, spreading 20'-40'

Switch, spreading 20’-40’, description
page
–
Switch (green) for spreading 20’ to 40’ (S1012). The spreader remains
in the position it held when the switch was released. The switch has a
return spring.
This function is used to adapt the attachment to the width of the
containers.
009910
Position 0 - Spreading not activated.

Position 1 - Spreading out activated. The outer end position of the
spreader is at 40’.
Position 2 - Spreading in activated. The inner end position of the
spreader is at 20’.

8 7 Load handling – 7.1.4 Switch, stop at 30'
7.1.4 Switch, stop at 30'

Switch, stop at 30’, description
page
–
The switch (green) for spreading stop for the attachment at 30’
(S1004) activates the 30-foot stop. When the switch is depressed, the
35 function changes from spreading from 20’–40’ to stop at 30’.
30-
009909
7.1.13 Switch, automatic spreading

Switch automatic spreading, description
page
–
Switch (green) for automatic spreading between 20’ and 40’ (S1004).
When the switch is depressed, spreading automatically goes to the
next position (20, 30 or 40 feet) if spreading is activated with the con-
trol lever.
This switch is used to activate automatic spreading.
009908
Position 0 - Automatic spreading not activated.

Position 1 - Automatic spreading activated. Spreading is activated with
the switch for spreading 20’-40’.
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.
WARNING
Risk of crushing and damage to the product!
Automatic spreading is stopped by activating spread-

ing in the opposite direction or deactivating the func-
tion with the switch.

7 Load handling – 7.2 Lift and lower 9
7.2 Lift and lower

Lifting/lowering, function description
page
–

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Twistlocks/lock Locked or unlocked, not in- Twistlocks, description page 85 or Lifting hook, description page 98
tongues termediate position
Alignment Mast down: no contact Sensor, alignment, description page 94 or Alignment and detection
sensor, description page 108
Bypassed or lift height lower Section 8 Control system, group 8.2.4 Height limitation
Height limitation
than height limitation
2,4 5
D790-1 D794
D1
D21 D15
D797-1
3,16,22
˚<
21
1b 1a
D16 6 6
D3
7
LS
15
17 P
A2
13 B2
14 P PS
8,20,23
12
C
P EF
9
LS
11
19 C C
009367
18 10

10 7 Load handling – 7.2 Lift and lower

1a The lifting/lowering control lever U = 0.5-4.5 V Control levers for electric servo, description
(R8071-P1) sends the cab control Lower: U = <2.5 V page 5
unit (D790-1) a voltage signal pro- D1: Diagnostic menu, see section 8 Control
Lift: U = >2.5 V
portional to lever movement. system, group 8.4.8.1 ELSERV, menu 1
0.5 V is the fastest lowering
speed and 4.5 V is the fastest
lift speed. Lower voltages than
0.5 V and higher voltages than
4.5 V are used to detect mal-
functions in cabling and
controls.
1b The control lever (S815-P1) sends US815-P1 = 0.5-4.5 V Control lever, description page 6
the cab control unit (D790-1) a volt- Lower: US815-P1 = <2.5 V D1: Diagnostic menu, see section 8 Control
age signal proportional to lever system, group 8.4.8.1 ELSERV, menu 1
movement. Lift: US815-P1 = >2.5 V
0.5 V is the fastest lowering

speed and 4.5 V is the fastest
lift speed. Lower voltages than
0.5 V and higher voltages than
4.5 V are used to detect mal-
functions in cabling and
controls.
2 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics,
sends the frame control unit error shown with error code. group 11.5.3.1 Cab control unit (D790-1)
(D797-1) a lift/lower request via the
CAN bus.
3 The frame control unit (D797-1) I = 380–650 mA Section 11 Common electrics,

sends current proportional to the le- group 11.5.3.2 Frame control unit (D797-1)
ver movement to the lift mast sole- D3: Diagnostic menu, see section 8 Control
noid valve (Y6005) or the lower system, group 8.4.8.3-ELSERV, menu 3
mast solenoid valve (Y6004). and 8.4.8.4 ELSERV, menu 4
4 Control unit, cab (D790-1) trans- Checked by control system, Section 11 Common electrics,
mits a request for increased engine error shown with error code. group 11.5.3.1 Cab control unit (D790-1)
5 Control unit, engine (D794) in- Checked by control system, Section 11 Common electrics,
creases the engine speed. error shown with error code. group 11.5.3.10 Engine control unit (D794)
6 The lift solenoid valve (Y6005) or - Control valve, lift and tilt, description
the lower solenoid valve (Y6004) page 15
pressurises the control valve’s lift
spool with servo pressure.
7 The control valve’s lift spool chang- - Control valve, lift and tilt, description
es position and pressurises the lift page 15
cylinders and sends a load signal to
the hydraulic oil pumps.
8 The lift cylinders are pressurised - Lift cylinder, description page 17

and the mast is lifted or lowered.

7 Load handling – 7.2 Lift and lower 11

9 The steering shuttle valve sends - Section 10 Common hydraulics,
the load signal on to the steering group 10.5.3 Shuttle valve
hydraulic pump and load handling.
10 The steering hydraulic oil pump and See the pressure plate on the Section 10 Common hydraulics,
load handling pump oil from the hy- left-hand frame beam. group 10.4.2 Axial piston pump with varia-
draulic oil tank to the priority valve ble displacement
and pressure reducer.
11 The priority valve leads feed pres- - Section 5 Steering, group 5.2.2 Priority
sure to Control valve, lifting/ valve.
lowering.
12 The pressure reducer reduces the See the pressure plate on the Pressure reducer, description page 13
oil pressure from the steering hy- left-hand frame beam.
draulic pump and load handling to
servo pressure for the control
valve.
13 The accumulator stores servo pres- See the pressure plate on the Accumulator servo circuit, description
sure. The non-return valve in the left-hand frame beam. page 14
pressure reducer makes it possible
to store the pressure when the en-
gine is turned off.
14 The servo filter cleans the servo oil - Servo filter, description page 12
before Control valve lift and lower.
15 Quick-lift UB768-L1/1 = 5 V Sensor hydraulic pressure lift cylinder, de-

The hydraulic pressure sensor, left scription page 17
UB768-L1/2 = 0 V
lift cylinder (B768-L1) sends the D15: Diagnostic menu, see section 8 Con-
UB768-L1/5 = 0.5-4.5 V
frame control unit (D797-1) a volt- trol system, group 8.4.5.6 HYD, menu 3 or
age signal proportional to oil group 8.4.10.1 OLS, menu 1.
pressure.
16 The frame control unit (D797-1) U = 24 V Section 11 Common electrics, group

supplies voltage to the quick-lift so- 11.5.3.2 Frame control unit (D797-1)
lenoid valve (Y6062) if the condi- D16: Diagnostic menu, see section 8 Con-
tions for quick-lift are fulfilled. trol system, group 8.4.5.6 HYD, menu 6.
Conditions for quick-lift when
lifting
• Pressure in lift cylinders
• Transmission in neutral
position
• Engine speed over 1200 rpm
• Damping inactive
17 The quick-lift solenoid valve - Valve block quick-lift, description page 36

(Y6062) conducts a load signal to
the hydraulic oil pump for quick-lift.

12 7 Load handling – 7.2.1 Hydraulic oil pump

18 The quick-lift hydraulic oil pump See the pressure plate on the Section 10 Common hydraulics,
pumps oil from the hydraulic oil tank left-hand frame beam. group 10.4.2 Axial piston pump with varia-
to lifting/lowering control valve. ble displacement
19 The pressure limiting valve pre- - Section 10 Common hydraulics,

vents the pressure from becoming group 10.2.4 Pressure limiting valve
too high to Control valve lift and
lower.
20 Lift speed increases. - Lift cylinder, description page 17
21 Damping UB771/1 = 5 V Mast position sensor, description page 28

When the mast is approx. 50 cm UB771/2 = 0 V Section 11 Common electrics,
from its topmost position, damping group 11.5.3.3 Frame control unit (D797-1)
UB771/3 = 0.5-4.5 V
is activated. D21: Diagnostic menu, see section 8 Con-
The mast position sensor trol system, group 8.4.8.15 ELSERV,
(B7211-2) sends the frame control menu 15.
unit (D797-1) a voltage signal pro-
portional to the lift height. The con-
trol unit then transmits a damping
request on the CAN bus.
22 The frame control unit (D797-1) de- - Section 11 Common electrics, group
activates quick-lift and reduces the 11.5.3.2 Frame control unit (D797-1)
control current to the lift solenoid D3: Diagnostic menu, see section 8 Control
valve (Y6005) or the lower solenoid system, group 8.4.5.6 HYD, menu 6
valve (Y6004).
23 Lift speed decreases. - Lift cylinder, description page 17
Hydraulic diagram, see section E Schematics 10 Common hydraulics,

Hydraulic diagram DCF 90-100, electric servo

page
–
See section 10 Common hydraulics, group 10.4.2 Axial piston pump

with variable displacement.
7.2.2 Servo filter

Servo filter, description
page
–
The servo filter prevents the control valve’s servo circuits from contam-
inants. The servo filter sits on the hydraulic plate in front of the trans-
mission, to the right of the servo pressure accumulator.
The servo filter is a low-pressure filter with removable filter insert. The
oil is cleaned when it passes through the filter insert’s filter material.
The filter insert is pressed against the upper section of the filter hous-
ing by a spring. Rubber gaskets seal between the insert and filter
housing. If the back pressure through the filter is too great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
009161
is viscous (cold or incorrect viscosity) or if the filter insert is clogged.

7 Load handling – 7.2.3 Pressure reducer 13
7.2.3 Pressure reducer

Pressure reducer, description
page
–
The pressure reducer reduces the pressure from the hydraulic oil
1
pump which supplies the servo circuit for control valve servo pressure.
2 The pressure reducer is located on the hydraulic plate in front of the
3 transmission, mounted together with the servo pressure accumulator.
Servo pressure is stored in an accumulator for quicker start-up and for
emergency reduction of load. An integrated non-return valve prevents
pressure leakage from the accumulator when the machine is not in
use.
7
6
5
4 009911
1. Accumulator servo pressure

2. Pressure reducer
3. Measuring outlet
4. Pressure supply from servo filter
5. Return to tank
6. Servo pressure to control valve
7. Adjusting screw, servo pressure
Servo pressure, inspection and adjustment

page
–
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil is at
operating temperature, at least 50 C. As an alternative, operate
until the cooling fan is activated.
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the
pressure reducer.
009912

14 7 Load handling – 7.2.4 Accumulator servo circuit
5 Start the engine and check the servo pressure. Compare with the
pressure plate.
M Pa Turn the steering wheel or activate a load handling function to ac-
tivate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
6 If the pressure does not match the value specified on the pres-
sure plate, adjust the servo pressure adjusting screw until the
right pressure is obtained; see Pressure reducer, description
page 13. Slacken the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function
009913 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 turned off between the checks.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
measuring outlet.
7.2.4 Accumulator servo circuit

Accumulator servo circuit, description
page
–
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator sits on
the hydraulic plate in front of the transmission, on top of the pressure
reducer.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
009914
Accumulator servo circuit

7 Load handling – 7.2.5 Control valve, lift and tilt 15
Accumulator servo circuit, replacement

page
–
NOTE
Safety.
3 Detach the accumulator from its mounting.
4 Replace the accumulator.
6 Check the oil level and fill with hydraulic oil as necessary.
7.2.5 Control valve, lift and tilt

Control valve, lift and tilt, description
page
–
4 7
3
8
2
5
1 6
14 11
13 12 10
009915
1 Solenoid valve, lift (Y6005) 8 Connection, rod side, right lift cylinder (B1)
2 Solenoid valve, lower (Y6004) 9 Connection, piston side, tilt cylinder (A1)
3 Connection, piston side, left lift cylinder (A2) 10 Connection, rod side, tilt cylinder (B1)
4 Connection, rod side, left lift cylinder (B2) 11 Connection return to tank (T)
5 Connection, feed from hydraulic oil pump (P) 12 Connection, piston side, tilt cylinder (A1)
6 Connection, feed from priority valve (P) 13 Solenoid valve, tilt out (Y6010)
7 Connection, piston side, right lift cylinder (A1) 14 Solenoid valve, tilt in (Y6011)

16 7 Load handling – 7.2.5 Control valve, lift and tilt
The control valve controls speed and direction of lift and tilt. The con-
trol valve is located on the hydraulic plate in front of the transmission.
The valve has two sections - one for the lift function and one for the tilt
function. The sections have many similarities, but are described sep-
arately under the respective function. For tilt, see Control valve, lift and
tilt, description page 78. Electric control valves control the flow from
the valve.
The control valve is proportionally controlled by solenoid valves. This
means that both volume and direction of the flow from the valve can
be adjusted and that the valve can also send a control signal to the
variable pumps.
Electrically controlled pressure reducing valves (solenoid valves) con-
vert electrical current into a low hydraulic pressure that is proportional
to the current, known as servo pressure. The servo pressure acts on
the spring-centred control slides in the control valve for the function in
question and thereby controls the main flow.
The speed of the function is controlled by means of the flow being reg-
ulated in proportion to the lever movement.
Lift slide
The lift slide controls the direction and flow of the oil to the lift cylinder.
Lift solenoid valve

The valve is controlled electrically by the lift solenoid valve (Y6005),
which is activated by the frame control unit (D797-1). The servo valve
guides servo pressure to the lift spool. This pressure is proportional to
the control current to the solenoid valve.
The signals can be checked from the diagnostic menu, see
Lower solenoid valve

The valve is controlled electrically by the lower solenoid valve
(Y6004), which is activated by the frame control unit (D797-1). The
servo valve guides servo pressure to the lift spool. This pressure is
proportional to the control current to the solenoid valve.

7 Load handling – 7.2.6 Shuttle valve 17
7.2.6 Shuttle valve

page
–
7.2.7 Lift cylinder

Lift cylinder, description
page
–
The lift cylinders lift and lower the inner mast, which runs inside the
outer mast. The lower parts of the lift cylinders are fixed to the outer
mast, while their upper parts are fixed to the inner mast - one on the
right and one on the left of the mast.
A sensor that measures hydraulic pressure in the lift cylinder is situat-
ed on the left lift cylinder.
The lift cylinder is fastened in the mast with nuts in the bottom and a
washer and screw in the top.
The lift cylinders are connected in parallel and fed from lift and tilt con-
trol valve, see Control valve, lift and tilt, description page 15.
009916

page
–
7.2.8 Sensor hydraulic pressure lift

cylinder
Sensor hydraulic pressure lift cylinder, description
page
–
The lift cylinder hydraulic pressure sensor (B768-L1) measures the

pressure in the lift cylinders and is located on the left lift cylinder.
Pressure is measured to determined whether quick-lift can be ena-
bled. A sensor measures the pressure on the left lift cylinder.
The sensor is supplied power by and sends a voltage signal propor-
tional to hydraulic oil pressure to the frame control unit (D797-1).
The signal can be checked with the diagnostic menu, see
section 8 Control system, group 8.4.5.3 HYD, menu 3 or
group 8.4.10.1 OLS, menu 1.
009917
Sensor, hydraulic pressure lift cylinder, piston side, left

(B768-L1)

18 7 Load handling – 7.2.8 Sensor hydraulic pressure lift cylinder
Sensor, hydraulic pressure lift cylinder, replacement

page
–
NOTE
Safety.
3 Disconnect the cable harness from the sensor for hydraulic pres-
sure lift cylinder.
4 Remove the sensor for hydraulic pressure lift cylinder.
NOTE
5 Fit the new sensor.
NOTE
6 Connect the cable harness to the sensor for hydraulic pressure.
009188
7 Clamp the cable harness as before.

Sensor hydraulic pressure lift cylinder
9 Activate the lift carefully.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the low-

est possible speed a couple of times to avoid
cadvitation.
10 Check that there are no leaks at hydraulic connections and that

lifting/lowering works properly.

7 Load handling – 7.2.9 Mast 19
11 Check the oil level in the hydraulic oil tank with the attachment ful-
ly lowered and the mast tilted in. The oil level should be at the top
of the level glass. Top up as necessary.
CAUTION
Overfilling of oil.
Leakage and environmental damage.
Check the hydraulic oil level with all hydraulic cylin-

ders fully retracted.
12 Check pressure and signals with the diagnostic menu; see sec-
tion 8 Control system, group 8.4.5.3 HYD, menu 3 or
group 8.4.10.1 OLS, menu 1.
7.2.9 Mast
Mast, description
page
–
The mast, which is a free-view mast, lifts the load. The trolley runs
1 along the mast. This, in turn, holds the side lift attachment.
The lower part of the mast is fixed to the frame by two shafts in two
double lugs on the front of the frame. The mast is also fixed to the
2
frame by two tilt cylinders.
The mast consists of an outer mast and an inner mast, made from high
strength steel, with a minimum number of welds for highest strength.
3 The inner mast runs inside the outer mast, and is lifted and lowered by
the lift cylinders. Mast wheels and slide plates between the inner and
outer masts guide the inner mast in the outer mast and reduce friction
between the two parts of the mast.
4 The lower parts of the lift cylinders are fixed to the outer mast, while
their upper sections are fixed to the inner mast. When oil is forced into
the lift cylinders, the piston rods in the cylinders are forced out and the
inner mast is lifted. The chain which is fixed to the carriage (and the
outer mast), runs over sprockets at the top of the inner mast. This also
lifts the carriage at the same time as the inner mast.
Hydraulic hoses and cables for the trolley and side lift attachment func-
tions run along the left side.
009918
1. Inner mast
2. Lifting eye
3. Outer mast
4. Lift cylinder

20 7 Load handling – 7.2.9 Mast
Mast, removing
page
–
NOTE
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.
1 Remove the side lift attachment; see Side lift attachment, remov-
ing page 64.
2 Remove the trolley; see Trolley, removing page 30.
3 Connect the lifting equipment to the lifting lugs at the top of the
mast in a secure manner.
4 Start the engine and tilt the mast forwards as far as possible.
5 Turn off engine.
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
009974
8 Mark up and disconnect the hydraulic connections of the lift

cylinders.
NOTE
9 Mark up and detach the electrical connections of the mast.
009980
10 Mark and detach the mast’s hydraulic connections on the front

panel. Let the oil run out.
NOTE
009981

11 Undo the electrical connectors for the mast.

Undo the connectors and protect the terminals by lubricating
them with contact grease. Then loosely insert the connectors.
12 Fasten one of the tilt cylinders in the lifting equipment (overhead

crane).
13 Release the tilt cylinder from the mast.
Remove the cylinder shaft. If necessary, use the threaded hole
and a puller to press the shaft out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the mast. Switch off the engine.
Save the circlips. Refit the shaft in the tilt cylinder.
Lower the cylinder onto a block of wood. Then slacken and re-
move the lifting equipment (overhead crane).
Repeat the procedure for the other cylinder.
009984
14 Undo the nuts and bolts and remove the shafts which fix the mast
to the frame.
009979

15 Release the mast from the chassis.
WARNING
The mast can swing out when it is released from the
machine.
This can cause personal injury!
Stand in the mast!
009983
16 Lift aside the mast.

009985
17 Place the mast on the ground and detach the lifting equipment
(overhead crane).
009975

Mast, installing
page
–
NOTE
Safety.
1 Turn off engine.
4 Connect lifting equipment to the mast in a secure manner so the
mast does not tip when lifted.
009975
5 Before mast is installed, check shafts and bearing surfaces for

deep cracks or scratches and check that the bearings have no fi-
bres that shoot out from the surface. If the shaft/bearing shows
sign of damage it must be replaced.
NOTE
The mast is attached to the machine’s frame with strong
shafts which run in maintenance-free bearings.
It is most important that bearing surfaces are absolutely
clean when the mast is installed.
009977
The shafts and bearings mentioned above must NEVER be

lubricated with oil or grease.
Check that seals are intact and clean.
6 Lift the mast into place. It is important that the lifting equipment is
connected to the mast’s lifting lugs in a secure manner.
009976

7 Suspend the mast vertically. Align the mast and position the
shafts in the mast mountings.
009978
8 Fasten the shafts with bolts and lock nuts.

9 Start the engine and tilt the mast forwards as far as possible.
10 Turn off engine.
009979
13 Lift the tilt cylinders with lifting equipment (overhead crane) and
align the tilt cylinders with the mast.
009982
14 Connect the tilt cylinders to the mast.

If necessary, adjust the cylinders’ stroke so that the cylinders pull
the mast straight. This is done by slackening the screws and turn-
ing the piston with a hook spanner. Tighten the screws to
136 Nm.
Fit the shafts and lock with circlips.
009996

15 Grease the connectors with contact grease and join them up.
16 Remove the plugs and connect the mast’s hydraulic hoses on the
machine’s front panel.
009981
17 Remove the plugs and connect the hydraulic hoses to the lift
cylinders.
18 Turn on the power supply and start the engine.
19 Check that the hydraulic connections are sealed tightly.
20 Check the mast functions.
21 Fit the trolley; see Trolley, installing page 31.
22 Fit the side lift attachment; see Side lift attachment, installing
page 67.
009980
Flanges on outer and inner mast beam

page
–
Flanges on outer and inner mast beam, description

The mast and its constituent parts are made of high-strength material
and are tested under extreme operating conditions and environments
to ensure a long and problem-free life.
Despite these efforts, problems can arise due to neglected mainte-
nance, improper handling, malfunction or damage to a mast wheel,
mast or trolley.
For example, lamination or pitting could occur on the mast beam
flange. This most often occurs on the inner mast, but could also occur
on the outer mast.

Flanges on outer and inner mast beam, repair

If the surface of flanges has started to break down in small flakes, this
can be remedied so as to keep the mast in use. This is remedied by
first grinding down the affected areas and then "running in" the surface
layer.
NOTE
Safety.
3 Removing the mast, please refer to Mast, removing page 20.
4 Separate the outer and inner mast.
5 Clean the mast components.
6 Grind the affected surfaces with a band grinder until the surface
is smooth and bare. Start with grain size 36-40 and finish with
60-80.
Grind in the longitudinal direction of the beam.
250 mm
Check the internal measurement between the beam’s front and

rear flange. If the measurement exceeds 252 mm for a beam that
is supposed to be 250 mm, contact Kalmar Industries.
010127C
7 Apply a thin layer of slide grease to the sliding surfaces of the out-
er mast and reassemble the inner and outer masts.
Mast beam size 250 mm. 8 Apply a thin layer of slide grease to the sliding surfaces of the in-
ner mast and fit the mast on the machine; see Mast, installing
page 23.
10 Lift and lower the mast as follows to check its function.
Lift and lower the mast 20 times with 50% of the maximum load
at the right centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load
at the right centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
right centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Kalmar
Industries.

Slide plates in inner mast, adjusting

page
–
NOTE
If the slide plate extends less than 3 mm from the holder, replace
it.
1 Lubricate the inner sliding surfaces of the outer mast with a thin
layer of slide grease.
2 Lift the inner mast 200 mm.
3 Adjust the slide plate in the bottom part of the outer mast so that
it lies against or has no more than 0.5 mm play to the outer mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
4 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010152
Slide plates in outer mast, adjusting

page
–
NOTE
If the slide plate extends less than 3 mm from the holder,
replace it.
1 Lubricate the outer sliding surfaces of the inner mast with a thin
2 Lower the inner mast to its bottom position.
3 Lift the inner mast 200 mm.
4 Adjust the slide plate in the top part of the outer mast so that it lies
against or has no more than 0.5 mm play to the inner mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
5 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010130

28 7 Load handling – 7.2.10 Mast position sensor
Mast wheel, adjusting

page
–
1 Use a drift to tap out the spring pin (position 4).

1
NOTE
Check that the cover washer (position 3) is centred on the clamp-
2
ing screw.
3
2 Screw in the clamping screw (position 5) so that the wheel is
completely locked.
4
NOTE
5 Rotate the mast wheel while tightening the clamping screw.
3 Slacken the clamping screw until the wheel can be rotated some-
what sluggishly. Turn the clamping screw to engage the spring
6 pin in the closest hole.
7
NOTE
Check that there is clearance between the mast wheel and the
mast beam.
4 Lock the clamping screw with the spring pin.
010126
1. Impeller
2. Circlip
3. Cover washer
4. Spring pin
5. Clamping screw
6. Inner bearing
7. Outer bearing
7.2.10 Mast position sensor

Mast position sensor, description
page
–
The mast position sensor (B7211-2) activates damping during lift. The
position sensor is used to deactivate the hydraulic oil pump for quick-
lift so that lifting is decelerated when the mast approaches its upper
end position.
For checking and adjusting, see Position sensor, adjusting page 4.
The position sensor sends a signal to the frame control unit (D797-1).
The signal can be checked from the diagnostic menu; see

7 Load handling – 7.2.11 Trolley 29
7.2.11 Trolley
Trolley, description
page
–
The trolley holds via hydraulic cylinders in the side lift attachment and
runs along the inner mast with slide plates and mast wheels.
2 The following functions are controlled via the trolley cylinders:
• Side shift - the attachment can be shifted to the side  600 mm.
1
• Mechanical levelling - the attachment can be levelled  3°.
• Active levelling - the attachment can be levelled  3°.

3
The trolley also houses the control valve for the hydraulic functions of
the trolley and side lift attachment.
See also Side shift cylinder, description page 44 and Levelling cylin-
der, description page 84.
4
013589
3
Trolley
1. Side shift cylinder
2. Control valve attachment
3. Slide plates
4. Mast wheels
5. Levelling cylinders
1 2
3
5 4
5
014791
Trolley with levelling

1. Side shift cylinder
2. Control valve attachment
3. Slide plates
4. Mast wheels
5. Levelling cylinders

30 7 Load handling – 7.2.11 Trolley
Trolley, removing
page
–
NOTE
Safety.
1 Remove the side lift attachment; see Side lift attachment, remov-
ing page 64.
2 Connect lifting equipment to the trolley in a secure manner.
3 Disconnect the main power supply.
4 Disconnect the trolley cable by undoing the lock plate screws.
009995
5 Mark up and disconnect the carriage’s hydraulic connections. Let

the oil run out.
NOTE
6 Raise the carriage with the lifting equipment (overhead crane) to
slacken the chains.
009987
7 Undo the nuts and remove the chain tensioners.

8 Start the engine and tilt the mast rearwards.
9 Raise the mast enough for the carriage to release from the mast.
10 Lower the mast again.
11 Lift aside the trolley. Put it on blocks and supports to prevent
damage to the cylinders.
12 Undo the lifting equipment (travelling crane).
013591

009986
Trolley, installing
page
–
NOTE
Safety.
1 Park the machine with the mast vertical.
2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.
3 Lower the mast so that the carriage fastens in the inner mast.
Stop the mast in a position where the chains can be fastened to
the carriage. Fit the chain tensioners and adjust and fasten with
the nuts.
4 Lower the carriage as far as possible.
5 Turn off engine.
013591
009986

8 Remove the plugs and connect the mast’s hydraulic hoses and
the carriage wiring.
009987
9 Connect the trolley cable.

Grease the connectors with contact grease and join them up.
Fasten the wiring with the lock plate.
10 Fit the side lift attachment; see Side lift attachment, installing
page 67.
13 Check the trolley functions.
009995

Slide plates in trolley, adjusting and, if necessary,

page
–
replacing
NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.
2 If the slide plate extends less than 3 mm from the holder,
A replace it.
3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.
B
013593
Measure the interior width of the inner mast (A and B)

4 Use a sliding calliper to measure the external measurements be-
tween the trolley slide plates.
D
013648
Measure the exterior measurements between the

trolley slide plates (C and D).

5 Adjust trolley clearance by removing the screws (position 1) and

adding or removing shims (position 2).
a) If the width at A and B is the same:
2
Adjust C and D to be equal to or max. 0.5 mm more than A.
1
b) If A is greater than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm more than B.
c) If A is less than B:
Adjust D to be equal to or max. 0.5 mm less than B.
1 013648 6 Lubricate the inner sliding surfaces of the inner mast with a thin
2
1. Screws
2. Shim
8 Lift the trolley all the way up and check that the slide plates do not
clamp too hard against the sliding surfaces.
Slide plates in the trolley with levelling, adjusting

page
–
and, if necessary, replacing
NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.
A 2 If the slide plate extends less than 3 mm from the holder,
replace it.
3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.
B
010123
Measure the interior width of the inner mast (A and B)

4 Use a sliding calliper to measure the external measurements be-

tween the trolley slide plates.
D
010124
Measure the exterior measurements between the

trolley slide plates (C and D).
5 Adjust trolley clearance by removing the screws (position 1) and
adding or removing shims (position 2).
2 a) If the width at A and B is the same:
1 Adjust C and D to be equal to or max. 0.5 mm more than A.

b) If A is greater than B:
Adjust D to be equal to or max. 0.5 mm more than B.
c) If A is less than B:
Adjust D to be equal to or max. 0.5 mm less than B.
010125
1
2 6 Lubricate the inner sliding surfaces of the inner mast with a thin
1. Screws layer of slide grease.
2. Shim 7 Fit the trolley; see Trolley, installing page 31.
8 Lift the trolley all the way up and check that the slide plates do not
clamp too hard against the sliding surfaces.
Mast wheel, adjusting

page
–
For mast wheel adjustment, see Mast wheel, adjusting page 28.

36 7 Load handling – 7.2.12 Valve block quick-lift
7.2.12 Valve block quick-lift

Valve block quick-lift, description
page
–
The quick-lift valve block regulates engagement of the quick-lift hy-

draulic oil pump, see section 10 Common hydraulics, group 10.4.2 Ax-
ial piston pump with variable displacement. When the solenoid valve
for quick-lift connection (Y6062) is connected, the valve block guides
a load signal to the quick-lift hydraulic oil pump, which supplies extra
oil to the lift and tilt control valve. The valve block sits on the hydraulic
plate in front of the transmission.
The solenoid valve for quick-lift connection (Y6062) is supplied voltage
from the frame control unit (D797-1) upon activation.
009922 The signal can be checked from the diagnostic menu, see
Valve block quick-lift

page
–

7 Load handling – 7.4 Side shift 37
7.4 Side shift

Side shift, function description
page
–

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
1b 1a D1
2
D790-1
D797-1 D791-1
3 8 D8
D3 11
9
C
P1 A
4
T1 B
10
5
C
6
7
014798
1a The side shift control lever U = 0.5-4.5 V Control levers for electric servo, description
(R8073-P3) sends the cab control Left: U = <2.5 V page 5
unit (D790-1) a voltage signal propor- D1: Diagnostic menu, see section 8 Control
Right: U >2.5 V
tional to lever movement. system, group 8.4.9.1 ATTACH, menu 1
0.5 V is the highest speed
for side shift left and 4.5 V
is the highest speed for
side shift right. Voltage
lower than 0.5 V and high-
er than 4.5 V is used to de-
tect defects in cable
harnesses and controls.

38 7 Load handling – 7.4 Side shift

1b The control lever (S815-P3) sends US815-P3 = 0.5-4.5 V Control lever, description page 6
the cab control unit (D790-1) a volt- Right: US815-P3 = <2.5 V D1: Diagnostic menu, see section 8 Control
age signal proportional to lever system, group 8.4.9.1 ATTACH, menu 1
movement. Left: US815-P3 = >2.5 V

for side shift right and
for side shift left. Voltage
lower than 0.5 V and high-
er than 4.5 V is used to de-
tect defects in cable
harnesses and controls.
2 Control unit, cab (D790-1) transmits Checked by control sys- Section 11 Common electrics,
side shift left or right on the CAN bus. tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
code.
3 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics,

vates the solenoid valve for main group 11.5.3.2 Frame control unit (D797-1)
pump relief (Y6062-2). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump re- - Valve block, main pump relief, description
lief (Y6062-2) routes a relieved con- page 48
stant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
5 The attachment shuttle valve sends - Section 10 Common hydraulics,

the load signal on to the hydraulic oil group 10.5.3 Shuttle valve
pump for load handling or the cab tilt
shuttle valve.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics,
load signal on to the hydraulic oil group 10.5.3 Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See the pressure plate on Section 10 Common hydraulics,
dling pumps oil from the hydraulic oil the left-hand frame beam. group 10.4.2 Axial piston pump with variable
tank. displacement
8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics,

activates the solenoid valve for side group 11.5.3.5 Attachment control unit
shift left (Y6020) or the solenoid valve (D791-1)
for side shift right (Y6021). D8: Diagnostic menu, see section 8 Control
system, group 8.4.9.11 ATTACH, menu 11
and group 8.4.9.12 ATTACH, menu 12
9 The solenoid valve for side shift left - Attachment control valve, description page 39
(Y6020) or the solenoid valve for side
shift right (Y6021) pressurises the
side shift spool in the attachment
control valve.

7 Load handling – 7.4.1 Hydraulic oil pump 39

10 The control valve’s side shift slide - Attachment control valve, description page 39
changes position and pressurises the
side shift cylinders.
11 The side shift cylinders push in the - Side shift cylinder, description page 44
main beam sideways in relation to the
trolley.


page
–

7.4.2 Control valve, attachment

Attachment control valve, description
page
–
1 2 3 6 9 12 16
014782
5 4 8 7 11 10 13 14 15 17
1 Connection return to tank (T) 10 Solenoid valve spreading out left (Y6018L)
2 Connection, feed from hydraulic oil pump (P) 11 Connection to spreading cylinder left
3 Solenoid valve, side shift right (Y6021) 12 Solenoid valve spreading in right (Y6019R)
4 Solenoid valve, side shift left (Y6020) 13 Solenoid valve spreading out right (Y6018R)
5 Connection to side shift cylinder 14 Connection to spreading cylinder right
6 Solenoid valve, lock twistlock (Y6040) 15 Solenoid valve, levelling right (Y6035)
7 Solenoid valve, open twistlock (Y6039) 16 Solenoid valve, levelling left (Y6036)
8 Connection to lock cylinders 17 Connection to levelling cylinders
9 Solenoid valve spreading in left (Y6019L)
The attachment control valves controls hydraulic functions on the at-

tachment. The control valve is located at the top of the trolley. Electric
solenoid valves control the flow from the valve.

40 7 Load handling – 7.4.2 Control valve, attachment
The control valve is an electro-hydraulically controlled, proportional

and pressure-compensated directional valve. Electrically controlled
solenoid valves convert current to servo pressure. The servo pressure
controls the spring-centred valve spools, which control pressure and
flow for the function in question. The valve spools have a flow limit so
that several functions can be used simultaneously. This enables them
to control main flow.
The control valve has built-in supply of pilot pressure. This means that
the valve has a built-in pressure reduction which converts feed pres-
sure to servo pressure for the various functions. Supply of pilot pres-
sure is common for all functions. This reduces pressure variations due
to long hoses and reduces the number of hoses to the valve.
The control valve has the following sections:
• Levelling
• Spreading right extension beam
• Spreading left extension beam
• Twistlocks/lock tongues
• Side shift
Side shift slide

The valve slide controls the direction and speed of side shift.
The valve spool is controlled by a solenoid valve for side shift right and
a solenoid valve for side shift left.
Solenoid valve, side shift left

The solenoid valve for side shift left controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.
The solenoid valve for side shift lift (Y6020) is controlled electrically
and is activated by the attachment control unit (D791-1). The solenoid
valve guides servo pressure to the side shift spool in proportion to the
control current to the solenoid valve.
Solenoid valve, side shift right

The solenoid valve for side shift right controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.
The solenoid valve for side shift right (Y6021) is controlled electrically
and is activated by the attachment control unit (D791-1). The solenoid
valve guides servo pressure to the side shift spool in proportion to the
control current to the solenoid valve.

7 Load handling – 7.4.2 Control valve, attachment 41
Control valve attachment, replacement

page
–
NOTE
Safety.
3 Remove the attaching bolts and lift away the plate fitted over the
control valve.
4 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
5 Mark and disconnect the cable harness from the control valve.
013595
6 Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
7 Transfer the connection adapters to the new control valve.
NOTE
position.
NOTE
013596
mixed up.
8 Mark up the solenoid valves on the new control valve.
9 Lift the valve into place and fit the attaching bolts.
10 Connect the cable harness to the control valve according to the
marking.
11 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
13 Check that the valve's hydraulic connections are sealed.

42 7 Load handling – 7.4.2 Control valve, attachment
14 Check that the attachment is working.
CAUTION
product damage.
Activate the functions carefully and operate at the

lowest possible speed a couple of times to avoid
cavitation.
15 Check the hydraulic oil level with all hydraulic pistons fully retract-
ed. The oil level should be at the top of the level glass. Top up as
necessary.
CAUTION
Do not overfill!

Control valve attachment, checking hydraulic

page
–
pressure
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

operating temperature, at least 50 C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Turn off engine.
˚C
000475
Operating menu, hydraulic oil temperature

4 Connect a pressure gauge to pressure measuring outlet LS on

the attachment control valve.
5 Start the engine and let it idle. Check the pressures in the attach-
ment’s different functions by letting each function go to its end-
position, then read off the pressure gauge.
The pressures should be:
Function Pressure
Side shift 13.0 MPa
Spreading right extension 13.0 MPa

beam
Spreading left extension 13.0 MPa

013597 beam
20.0 MPa
Levelling
Pressure check connection, control valve attachment
Twistlocks/lock tongues Same as feed pressure.
measuring outlet.

44 7 Load handling – 7.4.3 Side shift cylinder
7.4.3 Side shift cylinder

Side shift cylinder, description
page
–
The side shift cylinder sits between the trolley and the side lift attach-
ment. It shifts the main beam laterally in relation to the trolley.
013598
Side shift cylinder

009923
Side shift cylinder, on the trolley with levelling

page
–
7.4.4 Shuttle valve

page
–
7.4.5 Trolley
page
–
See Trolley, description page 29.

Slide plates between trolley and attachment,

page
–
adjustment/replacement
1 Park the machine with the attachment lowered as far as possible
and spreading run all the way in.
1
2 Switch off the engine and switch off the main electric power.
3 Clean and measure the thickness of the lower slide plates.
NOTE
The thickness of the slide plate must be at least 10 mm.
4 Replace the lower slide plates, if necessary, by loosening the at-
tachment’s mounting.
5 Unload the tension from the slide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the side lift attachment or inserting wedges to alter
the position of the side lift attachment in the trolley.
6 Remove the slide plate and fit a new one. Repeat with the rest of
the lower slide plates (4 pcs).
3 7 Reassemble the attachment’s mounting.
2
013681
3
The illustration shows slide plates between
attachment and trolley.
1. Upper slide plates
2. Lower slide plates
3. Attachment mounting

8 Clean and measure the thickness of the upper slide plates.

1 2 3
The upper slide plates can be replaced and adjusted using shims
when the attachment is in position in the trolley.
NOTE
The thickness of the slide plate must be at least 10 mm.
9 Remove the counterhold.
10 Loosen the slide plate’s attaching bolt slightly so that the slide
4 plate releases from the carriage.
11 Insert the required number of shims to remove the play between
attachment and carriage. Alternatively replace the slide plate.
12 Refit the counterhold and tighten the attaching bolt that secures
the slide plate.
013682
13 Check the clearance between the side lift attachment and the trol-
ley. Clearance should be less than 1 mm with all slide plates
The illustration shows slide plates between fitted.
attachment and trolley. Use more shims to adjust any play.
1. Upper slide plates
2. Lower slide plates
3. Attachment mounting
NOTE
3. Screw Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
NOTE
Check that the attaching bolts for all slide plates are
tightened.
14 Check that the sliding surface is clean and lubricate the sliding
surface on the side lift attachment.
15 Start the machine and side shift the attachment to both of its end
positions. Check that the clearance between trolley and attach-
ment is sufficient along the whole of the attachment and that
there is no metallic contact. Adjust with shims if necessary.

Slide plates in the trolley with mechanical levelling,

page
–
adjusting/replacing

outer edge of the side lifting attachment or inserting wedges to al-
ter the position of the side lifting attachment in the lifting beam.
4 Remove the attaching bolts for the slide plate’s bracket.
1 5 Remove the slide plate’s guide screw.
6 Pull out the slide plate with spacer plate and bracket.
7 Measure the thickness of the slide plate. Replace if necessary.
NOTE
The thickness of the slide plate should be at least 10 mm.
8 Place the slide plate in the correct position.
Check the clearance between the side lift attachment and the trol-
ley. Clearance should be less than 1 mm with all slide plates
fitted.
Use a spacer plate to adjust the clearance.
1
NOTE
2 In general, the upper slide plates on the front of the lifting
carriage and the lower slide plates on the rear of the car-
riage are adjusted with shim plates.
NOTE
009190
Do not use adjustment shims that are too thick. Inadequate

The illustration depicts slide and roller plates on a
lifting carriage with mechanical levelling. NOTE
1. Slide and roller plates
2. Attaching bolts and guide screws for slide and roller
tightened.
plates
9 Fit the slide plate bracket.
10 Fit the slide plate’s guide screw.
surface on the side lift attachment.
12 Start the machine and check the function of the side lifting attach-
ment. Try lifting a container and then recheck the side lifting at-
tachment’s clearance in the lifting carriage.

48 7 Load handling – 7.4.6 Valve block, main pump relief
7.4.6 Valve block, main pump relief

Valve block, main pump relief, description
page
–
The valve block for the main pump relief is an electrically regulated
valve that uses relieved constant pressure as a load signal, sending it
to the hydraulic oil pump for load handling when attachment functions
are activated. The valve block sits on the hydraulic plate in front of the
transmission in the engine compartment.
When the solenoid valve is activated, pressure is routed from the hy-
draulics’ supply through a shuttle valve to the hydraulic oil pump for
load handling. A restriction before the valve block ensures that pres-
sure for control of the hydraulic oil pump does not become too high.
009955
When the solenoid valve is not activated, the load signal is drained to
the tank and the inlet from the control valve’s supply is closed.
Valve block, main pump relief
The valve is regulated electrically by the solenoid valve for main pump
relief (Y6062-2), which is activated by the frame control unit (D797-1).
7.4.7 Relief valve, attachment

Relief valve attachment, description
page
–
The attachment relief valve opens the connection between the attach-
ment’s pressure supply and the tank. This is used to drain the pressure
in the attachment hoses prior to work on the hydraulic system. The re-
lief valve sits on the spacer block at the hydraulic oil pump for load
handling.
009961
The illustration depicts an open valve

page
–

7 Load handling – 7.5 Spreading (positioning) 49
7.5 Spreading (positioning)

Spreading, function description
page
–

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description page 85 or Lifting hook, description page 98
activated Section 8 Control system, group 8.2.2 Bypass
D1
1b
1a
2
D790-1
D797-1 D791-1 8,9,17,18

3
D8 D9
D3 10,19 11,20
C
P1 12
4 21
T1
A B A B
D15 D16
5 15 16
C
6 13,22 14,22
7
014799

1a The switch for spreading 20’-40’ U = 24 V Switch, spreading 20’-40’, description page 7
(S1012) sends a voltage signal to D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1). system, group 8.4.9.3 ATTACH, menu 3
1b The control lever (S815-T1.1 and Spreading (positioning): Control lever, description page 6
S815-T1.2) sends a voltage signal US815-T4 = 24 V D1: Diagnostic menu, see section 8 Control
to the cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 3
Out: US815-T1.2 = 24 V
In: US815-T1.1 = 24V
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics,
mits spreading in or out on the CAN tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
bus. code.

50 7 Load handling – 7.5 Spreading (positioning)

3 The frame control unit (D797-1) ac- U = 24 V Section 11 Common electrics,
tivates the solenoid valve for main group 11.5.3.3 Frame control unit
4 The solenoid valve for main pump - Valve block, main pump relief, description
relief (Y6062-2) routes a relieved page 48
constant pressure to the hydraulic
oil pump for load handling. This
serves as a load signal.

shuttle valve.
7 The hydraulic oil pump for load han- See the pressure plate on Section 10 Common hydraulics,
dling pumps oil from the hydraulic oil the left-hand frame beam. group 10.4.2 Axial piston pump with variable
tank to the attachment control valve. displacement
8 The attachment control unit I = 350–600 mA Section 11 Common electrics,

(D791-1) activates the solenoid group 11.5.3.5 Attachment control unit
valve for spreading out left (Y6018L) (D791-1)
or the solenoid valve for spreading D8: Diagnostic menu, see section 8 Control
in left (Y6019L). system, group 8.4.9.17 ATTACH, menu 17 and
8.4.9.18 ATTACH, menu 18
9 The attachment control unit I = 350–600 mA Section 11 Common electrics,

(D791-1) activates the solenoid group 11.5.3.5 Attachment control unit
valve for spreading out right (D791-1)
(Y6018R) or the solenoid valve for D9: Diagnostic menu, see section 8 Control
spreading in right (Y6019R). system, group 8.4.9.19 ATTACH, menu 19 and
10 The solenoid valve for spreading out - Attachment control valve, description page 39
left (Y6018L) or the solenoid valve
for spreading in left (Y6019L) pres-
surises the left spreader spool in the
attachment’s control valve.
11 The solenoid valve for spreading out - Attachment control valve, description page 39
right (Y6018T) or the solenoid valve
for spreading in right (Y6019T) pres-
surises the right spreader spool in
the attachment’s control valve.
12 The control valve’s spreader spools - Attachment control valve, description page 39
change position and direct pressure
to the spreader cylinders.


13 Left spreader cylinder pushes left - Spreading cylinder, description page 58
spreader beam in or out in the
attachment
14 Right spreader cylinder pushes right - Spreading cylinder, description page 58

spreader beam in or out in the
attachment.
15 The sensor for end position 20’-40’ Sensor directly opposite Position sensor spreading, description page 74
left (B769L) sends a voltage signal indicator plate: U > 24 V D15: Diagnostic menu, see section 8 Control
to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1).
16 The sensor for end position 20’-40’ Sensor directly opposite Position sensor spreading, description page 74
right (B769R) sends a voltage signal indicator plate: U = 24 V D16: Diagnostic menu, see section 8 Control
to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1).
17 The attachment control unit - Section 11 Common electrics,

(D791-1) reduces the control cur- group 11.5.3.5 Attachment control unit
rent to the solenoid valve for (D791-1)
spreading out left (Y6018L) or the D8: Diagnostic menu, see section 8 Control
solenoid valve for spreading in left system, group 8.4.9.17 ATTACH, menu 17 and
(Y6019L). 8.4.9.18 ATTACH, menu 18
18 The attachment control unit - Section 11 Common electrics,

(D791-1) reduces the control cur- group 11.5.3.5 Attachment control unit
rent to the solenoid valve for (D791-1)
spreading out right (Y6018R) or the D9: Diagnostic menu, see section 8 Control
solenoid valve for spreading in right system, group 8.4.9.19 ATTACH, menu 19 and
(Y6019R). 8.4.9.20 ATTACH, menu 20
19 The solenoid valve for spreading out - Control valve attachment, replacement
left (Y6018L) or the solenoid valve page 41
for spreading in left (Y6019L) reduc- D8: Diagnostic menu, see section 8 Control
es the pressure to the left spreader system, group 8.4.9.17 ATTACH, menu 17 and
spool in the attachment’s control 8.4.9.18 ATTACH, menu 18
valve.
20 The solenoid valve for spreading out - Control valve attachment, replacement
right (Y6018R) or the solenoid valve page 41
for spreading in right (Y6019R) re- D9: Diagnostic menu, see section 8 Control
duces the pressure to the right system, group 8.4.9.19 ATTACH, menu 19 and
spreader spool in the attachment’s 8.4.9.20 ATTACH, menu 20
control valve.
21 The control valve’s spreader spools - Attachment control valve, description page 39
change position and reduce the
pressure to the spreader cylinders.
22 Spreader speed decreases. - Position sensor spreading, description page 74


30-foot stop, function description

page
–

voltage
Twistlocks/Lock tongues Unlocked or by- Twistlocks, description page 85 or Lifting hook, description page 98
pass activated Section 8 Control system, group 8.2.2 Bypass
D1 D2
2b 2a 1
35
30-
3
D790-1
D791-1
4,7,9,11 D5
D8 30' 30'
009346
014803
4,7 4,7 5 6 8 10

1 The switch for stop at 30’ (S1004) Switch in on position: Switch, stop at 30’, description page 8
sends a voltage signal to the cab con- Conn. 1: U = 0 V D1: Diagnostic menu, see section 8 Control
trol unit (D790-1). system, group 8.4.9.2 ATTACH, menu 3
Conn. 5: U = 24 V
Switch in off position:
Conn. 1: U = 24 V
Conn. 5: U = 24 V
2a The switch for spreading 20’-40’ U = 24 V DC Switch, spreading 20’-40’, description

(S1012) sends a voltage signal to the page 7
cab control unit (D790-1). D2: Diagnostic menu, see section 8 Control
2b The control lever (S815-T1.2) sends a Spreading (positioning): Control lever, description page 6
voltage signal to the cab control unit US815-T4 = 24 V D2: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
Out: US815-T1.2 = 24 V
In: US815-T1.1 = 24V


3 Control unit, cab (D790-1) sends Checked by control sys- Section 11 Common electrics,
spreading 30’ on the CAN bus. tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
ror code.
4 Spreading is activated in the same way - Spreading, function description page 49

as the normal spreading steps 3–14.
5 When the left spreader beam ap- Sensor directly opposite Position sensor spreading, description
proaches the 30’ mark, the sensor for indicator plate: page 74
30’ end position left (B777L) sends a U = 24 V D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
6 When the right spreader beam ap- Sensor directly opposite Position sensor spreading, description
proaches the 30’ mark, the sensor for indicator plate: page 74
30’ end position left (B777R) sends a U = 24 V D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
7 The attachment control unit (D791-1) - Spreading, function description page 49

dampens the speed the same way as in
steps 17–22 of normal spreading.
8 When the left spreader beam is at the Sensor directly opposite Position sensor spreading, description
30’ mark, the sensor for 20’-40’ end po- indicator plate: page 74
sition (B769L) sends a voltage signal to U = 24 V D8: Diagnostic menu, see section 8 Control
the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
9 The attachment control unit (D791-1) U=0V Attachment control valve, description
cuts off the current to the solenoid valve page 39
for spreading out left (Y6018L) or the
solenoid valve for spreading in left
(Y6019L).
10 When the right spreader beam is at the Sensor directly opposite Position sensor spreading, description
30’ mark, the sensor for 20’-40’ end po- indicator plate: page 74
sition (B769R) sends a voltage signal to U = 24 V D8: Diagnostic menu, see section 8 Control
the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
11 The attachment control unit (D791-1) U=0V Attachment control valve, description
cuts off the current to the solenoid valve page 39
for spreading out right (Y6018R) or the
solenoid valve for spreading in right
(Y6019R).


Automatic spreading 20-40 foot,

page
–

voltage
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description page 85 or Lifting hook, description page 98
activated
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
2
D1 D2
1b 1a
3 7
D790-1 D795
D791-1 D9
D10 D8 D11 4, 5, 8 9 D13 D12
10 8 11 6 13 9 12
009347
D5

1a. The switch for spreading 20’-40’ U = 24 V DC Switch, spreading 20’-40’, description page 7
(S1012) sends a voltage signal to D2: Diagnostic menu, see section 8 Control
1b The control lever (S815-T1.1 and Spreading (positioning): Control lever, description page 6
S815-T1.2) sends a voltage signal to US815/T4 = 24 V D1: Diagnostic menu, see section 8 Control
Out: US815/T1.2 = 24 V
In: US815/T1.1 = 24 V
2 The switch for automatic spreading Switch in on position: Switch automatic spreading, description
20’-40’ (S1012-2) sends a voltage US199-2/2 = 0 V page 8
signal to the cab control unit D2: Diagnostic menu, see section 8 Control
(D790-1). US199-2/5 = 24 V
Switch in off position:
US199-2/2 = 24 V
US199-2/5 = 24 V


3 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics,
mits "automatic spreading out" or tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
"automatic spreading in" on the CAN code.
bus.
4 The attachment control unit - Spreading, function description page 49

(D791-1) activates spreading the
same way as in steps 3-14 of normal
spreading.
5 The attachment control unit Buzzer active: Buzzer automatic spreading 20’-40’, descrip-
(D791-1) activates the automatic U = 24 V tion page 75
spreading buzzer (H9003). D5: Diagnostic menu, see section 8 Control
6 Buzzer automatic spreading Buzzer active: Buzzer automatic spreading 20’-40’, descrip-
(H9003) generates acoustic warning U = 24 V tion page 75
signal.
7 When automatic spreading is active, - Section 11 Common electrics,

the KID control unit (D795) activates group 11.5.3.12 KID control unit (D795)
the Automatic Spreading event
menu.
8 When the left spreader beam ap- Sensor directly opposite Spreading, function description page 49
indicator plate:
proaches the 20’, 30’ ( ) or 40’ 30-foot stop, function description page 52
mark, the sensor for 20’-40’ end po- U = 24 V
sition left (B769L) sends a voltage
signal to the attachment control unit
(D791-1), which activates damping
for the left spreader beam the same
way as in steps 16-22 of normal
spreading.
9 When the right spreader beam ap- Sensor directly opposite Spreading, function description page 49
indicator plate:
proaches the 20’, 30’ ( ) or 40’ 30-foot stop, function description page 52
mark, the sensor for 20’-40’ end po- U = 24 V
sition right (B769R) sends a voltage
signal to the attachment control unit
(D791-1), which activates damping
for the right spreader beam the
same way as in steps 16-22 of nor-
mal spreading.
10 When the left spreader beam is at Sensor directly opposite Position sensor spreading, description page 74
indicator plate: D10: Diagnostic menu, see section 8 Control
the 20’, 30’ ( ) or 40’ mark, the
sensor for end position 30’ left U = 24 V system, group 8.4.9.6 ATTACH, menu 6
(B777L) sends a voltage signal to
the attachment control unit
(D791-1).


11 The attachment control unit I = 0 mA Section 11 Common electrics,
(D791-1) cuts off the current to the group 11.5.3.5 Attachment control unit
solenoid valve for spreading out left (D791-1)
(Y6018L) or the solenoid valve for D11: Diagnostic menu, see section 8 Control
spreading in left (Y6019L). system, group 8.4.9.17 ATTACH, menu 17 and
12 When the right spreader beam is at Sensor directly opposite Position sensor spreading, description page 74
indicator plate: D12: Diagnostic menu, see section 8 Control
the 20’, 30’ ( ) or 40’ mark, the
sensor for end position 30’ right U = 24 V system, group 8.4.9.6 ATTACH, menu 6
(B777R) sends a voltage signal to
the attachment control unit
(D791-1).
13 The attachment control unit I = 0 mA Section 11 Common electrics,

(D791-1) cuts off the control current group 11.5.3.5 Attachment control unit
the solenoid valve for spreading out (D791-1)
right (Y6018R) or the solenoid valve D13: section 8 Control system,
for spreading in right (Y6019R). group 8.4.9.19 ATTACH, menu 16 and


page
–



page
–
Spreading is regulated by a separate section in the attachment’s con-

trol valve. For a more detailed description of the valve and component
locations, see Attachment control valve, description page 39.
Spreader slide
The valve spool controls the direction and speed of spreading. The
valve spool is controlled by a solenoid valve for spreading out and a
solenoid valve for spreading in.
Solenoid valve for spreading out

The solenoid valve for spreading out controls pressure to the spreader
spool so that it opens and pressurises the spreader cylinder.
The servo valve is controlled electrically by the solenoid valve for
spreading out left (Y6018L) or the solenoid valve for spreading out
right (Y6018R) which are activated by the attachment control unit
(D791-1). The servo valve routes servo pressure to the spreader spool
in proportion to the control current to the solenoid valve.
The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.13 ATTACH, menu 17
• Right: section 8 Control system, group 8.4.9.15 ATTACH,
menu 19
Solenoid valve for spreading in

The solenoid valve for spreading in controls pressure to the spreader
spool so that it opens and pressurises the spreader cylinder.
The servo valve is controlled electrically by the solenoid valve for
spreading in left (Y6019L) or the solenoid valve for spreading in right
(Y6019R) which are activated by the attachment control unit (D791-1).
The servo valve routes servo pressure to the spreader spool in propor-
tion to the control current to the solenoid valve.
The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.14 ATTACH, menu 18
• Right: section 8 Control system, group 8.4.9.16 ATTACH,
menu 20

page
–
See Control valve attachment, replacement page 41.

58 7 Load handling – 7.5.3 Spreading cylinder
7.5.3 Spreading cylinder

Spreading cylinder, description
page
–
The spreader cylinders pull the spreader beams in and out of the at-
tachment’s main beam. The attachment control unit (D791-1) sends a
signal to the attachment control valve, which pressurises the spreader
cylinders.
The spreader cylinders are fastened in the spreader beams and the
main beam.
Openings in the sides of the spreader beams and the attachment’s
main beam make it possible to access the spreader cylinders for main-
tenance purposes.
014816
Spreader cylinders
009925
Spreader cylinders, attachment with levelling

7 Load handling – 7.5.4 Spreader beam 59
7.5.4 Spreader beam

Spreader beam, description
page
–
The spreader beams are the part of the attachment that grip the con-
tainers. Two spreader beams run along the main beam. The spreader
beams are extended and retracted with hydraulic cylinders.
The spreader beam houses twistlocks, see Twistlocks, function de-
scription page 86 or Lifting hook, description page 98.
014737
Spreader beams
009926
Spreader beams, attachment with levelling

60 7 Load handling – 7.5.4 Spreader beam
Spreader beam slide plates, adjusting/replacing

page
–

1000 mm 013683
3 Unscrew the nuts and bolts (position 1) that secure the slide
plates.
outer edge of the spreader beam or inserting wedges to alter the
position of the spreader beam in the attachment’s main beam.
1
013684

4 Remove the slide plates and shims from the main beam
Lift the extension section slightly so that the slide the plates are
unloaded.
013685
Right side
013686
Left side

62 7 Load handling – 7.5.4 Spreader beam
5 Refit the slide plates, add a sufficient number of shims under the
slide plates so that the play between slide plates and main beam
is 1-3 mm both laterally and vertically. This corresponds to the di-
mensions X + (1-3) mm and Y + (1-3) mm.
NOTE
Do not use adjustment shims that are too thick. Inadequate
NOTE
tightened.
6 Start the machine and check the function of the spreader. Try lift-
ing a container and then recheck the spreader beam’s clearance
in the attachment’s main beam.
013687
Right side
013688
Left side

Slide plates spreader beam for attachment with

page
–
levelling, adjusting/replacing

1
outer edge of the spreader beam or inserting wedges to alter the
position of the spreader beam in the attachment’s main beam.
4 Remove the attaching bolts for the slide plate’s bracket.
5 Remove the slide plate’s guide screw.
6 Pull out the slide plate with spacer plate and bracket.
7 Measure the thickness of the slide plate. Replace if necessary.
2
NOTE
The thickness of the slide plate should be at least 10 mm.
8 Place the slide plate in the correct position.
Check the clearance between the spreader beam and the slide
plate. Clearance should be less than 1 mm with all slide
plates fitted.
Use a spacer plate to adjust the clearance.
009189
1 NOTE
The illustration depicts the inner slide plates on the In general, the upper slide plates on the front of the spreader
side lifting attachment’s spreader beam. beam/main beam and the lower slide plates on the rear of
1. Slide plates the spreader beam/main beam are adjusted with shim
2. Attaching bolts and guide screws for slide plates plates.
NOTE
Do not add too many shims as this increases slide plate
wear.
NOTE
tightened.
9 Fit the slide plate bracket.
10 Fit the slide plate’s guide screw.
surface on the spreader beam.
12 Start the machine and check the function of the spreader. Try lift-
ing a container and then recheck the spreader beam’s clearance
in the attachment’s main beam.

64 7 Load handling – 7.5.5 Main beam, side lift attachment
7.5.5 Main beam, side lift attachment

Side lift attachment’s main beam, description
page
–
The side lift attachment’s main beam is fastened in the trolley with hy-
draulic cylinders. The main beam houses equipment for spreading
(spreader beams, hydraulic cylinders, slide plates and sensors).
014817
Main beam
009927
Main beam, attachment with levelling
Side lift attachment, removing

page
–
NOTE
Safety.
NOTE
If the trolley will also be removed, e.g. to make it possible to re-
place or service the mast, it is a good idea to remove the trolley
and the side lift attachment as a unit.
1 Park the machine with the mast vertical and the attachment in its
lowest position.
2 Turn off engine.

7 Load handling – 7.5.5 Main beam, side lift attachment 65
3 Connect lifting equipment (overhead crane) to the attachment in

a secure manner.
4 Start the engine and lift slightly with the lifting equipment (over-
head crane). Let the machine run with the ignition on for a little bit.
5 Turn off engine.
014819
6 Detach the side shift cylinder from the attachment.
Remove the cylinder shaft from the mounting on the trolley. If
necessary, used the threaded hole and a puller to press out the
shaft.
from the mounting in the trolley. Switch off the engine.
Save the circlips. Refit the shaft in the cylinder.
013654
7 Fasten the side shift cylinder.

009997
10 Mark up and detach hydraulic connections from the side lift at-
tachment and the side shift cylinder.
NOTE
009952

11 Detach the cable harness of the attachment from the attachment

control unit.
Remove the cable harness clamping ring.
12 Loosen the attachment’s mounting unit in the trolley.

13 Lift aside the side lifting attachment. Position it so that the twist-
locks/lock tongues are not damaged.
013680

Side lift attachment, installing

page
–
NOTE
Safety.
2 Lower the trolley to its lowest position.
3 Turn off engine.
6 Lift the side lift attachment into place.
7 Fit the lifting carriage’s front panels to fix the side lifting attach-
ment in position.
8 Check that the side lift attachment runs correctly in the trolley;
see Slide plates between trolley and attachment, adjustment/re-
placement page 45.
013680
9 Clean and apply a layer of lubricating grease to the side shift cyl-
inder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with the
circlips.
NOTE
Use an anti-recoil plastic or copper mallet.
If necessary, detach the hydraulic connections on the side shift
cylinder to make it possible to adjust cylinder length.
013654

11 Attach the cable harness of the attachment to the attachment

control unit.
Fasten the wiring with clamps.
12 Remove plugs and connect hydraulic hoses for the side lift at-
tachment and side shift cylinder using the markings as a guide.
15 Check the functions of the side lift attachment.
009952
necessary.
CAUTION
Do not overfill!


Side lift attachment with levelling, removing

page
–
NOTE
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment as
one unit.
1 Park the machine with the mast vertical and the attachment in its
lowest position.
2 Turn off engine.
3 Connect lifting equipment (overhead crane) to the attachment in
a secure manner.
4 Start the engine and lift slightly with the lifting equipment (over-
head crane). Let the machine run with the ignition on for a little bit.
5 Turn off engine.
009998
6 Detach the side shift cylinder from the attachment.

Remove the cylinder shaft from the mounting on the trolley. If
necessary, used the threaded hole and a puller to press out
the shaft.
from the mounting in the trolley. Switch off the engine.
Save the circlips. Refit the shaft in the cylinder.
009951

7 Fasten the side shift cylinder.

009997 10 Mark up and detach hydraulic connections from the side lift at-
tachment and the side shift cylinder.
NOTE
009952
11 Detach the cable harness of the attachment from the attachment

control unit.
Remove the cable harness clamping ring.

12 Detach the front panels’ upper mounting in the lifting carriage.

Use a lifting device to lower them forward and release the side lift-
ing attachment.
009953
13 Lift aside the side lifting attachment. Position it so that the twist-
locks/lock tongues are not damaged.
009999
Side lift attachment with levelling, installing

page
–
NOTE
Safety.
2 Lower the trolley to its lowest position.
3 Turn off engine.

6 Lift the side lift attachment into place.
009999
7 Fit the lifting carriage’s front panels to fix the side lifting attach-
ment in position.
8 Check that the side lift attachment runs correctly in the trolley;
see Slide plates between trolley and attachment, adjustment/re-
placement page 45.
010000
9 Clean and apply a layer of lubricating grease to the side shift cyl-
inder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with the
circlips.
NOTE
Use an anti-recoil plastic or copper mallet.
If necessary, detach the hydraulic connections on the side shift
cylinder to make it possible to adjust cylinder length.
009951

11 Attach the cable harness of the attachment to the attachment

control unit.
Fasten the wiring with clamps.
12 Remove plugs and connect hydraulic hoses for the side lift at-
tachment and side shift cylinder using the markings as a guide.
15 Check the functions of the side lift attachment.
009952
necessary.
CAUTION
Do not overfill!


74 7 Load handling – 7.5.6 Position sensor, spreading
7.5.6 Position sensor, spreading

Position sensor spreading, description
page
–
The spreading position sensors indicates the position of the spreader

3 4 5
beams. The position sensors are used to control spreading so that the
twistlocks/lifting hooks fit the container. The position sensors are locat-
ed under the protective plate on the back of the attachment’s main
beam.
The sensor for end position 20’ and 40’ (B769R and B769L) indicate
the end position for a 20-foot and 40-foot container. The sensor de-
1 2 tects the end positions of the spreader beams through two indicator
plates on the top of the spreader beam. The sensor is used to activate
5 4 3 damping.
With the 30-foot stop option, two extra sensors are mounting - sensor
for end position 30’ (B777R and B777L) - along with two additional in-
dicator plates. The sensor is used to activate the 30-foot stop.
The sensors are supplied power by and send as 24 V signal to the at-
tachment control unit (D791-1) when the indicator plates pass the sen-
013676
sor. Indicator plates on the spreader units are mounted so that the
2 1
sensors generate a signal when the spreader unit passes the sensor.
1. Sensor for end position 20’ and 40’ The indicator plates and the position of the sensors are designed so
2. Sensor for end position 30’ that the distance between the spreaders becomes 20’ (30’) and 40’.
3. Indicator plate 20’ The signals can be checked from the diagnostic menu, see section 8
4. Indicator plate 30’ Control system, group 8.4.9.6 ATTACH, menu 6.
5. Indicator plate 40’
3 4 5
2
1
2
1
009928
4 3
5
Attachment with levelling

1. Sensor for end position 20’ and 40’
2. Sensor for end position 30’
Position sensor, checking and adjustment

page
–
See Position sensor, adjusting page 4.

7 Load handling – 7.5.7 Buzzer, automatic spread 20’-40’ 75
7.5.7 Buzzer, automatic spread 20’-40’

Buzzer automatic spreading 20’-40’, description
page
–
The buzzer for automatic spread 20’-40’ (H9003) sits on the underside
of the trolley on machines with automatic spreading 20’-40’. The buzz-
er is activated during automatic spreader movement.

page
–

76 7 Load handling – 7.7 Tilt
7.7 Tilt
Tilt, function description
page
–

voltage
D5
5b 5a 6
D790-1
10
D797-1 11
7
D7
8
10
11
P A1
B1
T1
P PS 9
3
4
EF
C P
1 1
009957

1 The hydraulic oil pumps pump oil from See the pressure plate on Section 10 Common hydraulics,
the hydraulic oil tank. the left-hand frame beam. group 10.4.2 Axial piston pump with variable
displacement
2 The pressure reducer reduces the pres- See the pressure plate on Pressure reducer, description page 13
sure from one of the hydraulic pumps to the left-hand frame beam.
servo pressure.
3 The accumulator stores servo pressure. See the pressure plate on Accumulator servo circuit, description
The non-return valve in the pressure re- the left-hand frame beam. page 14
ducer makes it possible to store the
pressure when the engine is turned off.
4 The servo filter cleans the oil upstream - Servo filter, description page 12
of the lift and tilt control valve.

7 Load handling – 7.7 Tilt 77

5a The tilt control lever (R8072-P2) sends U = 0.5-4.5 V Control levers for electric servo, description
the cab control unit (D790-1) a voltage Out: U = <2.5 V page 5
signal proportional to lever movement. D5: Diagnostic menu, see section 8 Control
In: U = >2.5 V
system, group 8.4.8.1 ELSERV, menu 1
0.5 V is the fastest speed
for tilt out and 4.5 V is the
fastest speed for tilt in.
Voltages lower than 0.5 V
and voltages higher than
4.5 V are used to detect
malfunctions in cables
and controls.
5b The control lever (S815-P2) sends the US815-P2 = 0.5-4.5 V Control lever, description page 6
cab control unit (D790-1) a voltage sig- In: US815-P2 <2.5 V D5: Diagnostic menu, see section 8 Control
nal proportional to lever movement. system, group 8.4.8.1 ELSERV, menu 1
Out: US815-P2 = >2.5 V

for tilt in and 4.5 V is the
highest speed for tilt out.
Voltage lower than 0.5 V
and voltage higher than
4.5 V is used to detect de-
fects in cables and
controls.
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics,
tilt in or tilt out on the CAN bus. tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
ror code.

vates the servo valve for tilt in (Y6011) group 11.5.3.2 Frame control unit (D797-1)
or the servo valve for tilt out (Y6010). D7: Diagnostic menu, see section 8 Control
system, group 8.4.8.5 ELSERV, menu 5 and
8.4.8.6 ELSERV, menu 6
8 The solenoid valve for tilt in (Y6011) or - Control valve, lift and tilt, description
the solenoid valve for tilt out (Y6010) page 15
pressurises the tilt spool in the lift and tilt
control valve.
9 The control valve’s tilt spool changes - Control valve, lift and tilt, description
position and pressurises the load reten- page 78
tion valve.
10 The load retention valve opens and di- - Load holding valve, description page 79
rects the pressure on to the tilt cylinders.
11 The tilt cylinders angle the mast in rela- - Tilt cylinder, description page 79
tion to the frame. Mast, description page 19



page
–

7.7.2 Accumulator
Accumulator, description
page
–
See section 10 Common Hydraulics, group 10.3.2 Accumulator.
7.7.3 Pressure reducer

Pressure reducer, description
page
–
See Pressure reducer, description page 13.
7.7.4 Servo filter

Servo filter, description
page
–
See Servo filter, description page 12.
7.7.5 Control valve, lift and tilt

Control valve, lift and tilt, description
page
–
Tilt is controlled by a separate section of the lift and tilt control valve.
See also Control valve, lift and tilt, description page 15.
For more information about tilting, see Tilt, function description
page 76.
Tilt slide
When the solenoid valves are activated, the tilt spool is pressurised
and controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.
Solenoid valve, tilt out

On machines with electric servo, the solenoid valve for tilt out is con-
trolled electrically by the solenoid valve for tilt out (Y6010), which is ac-
tivated by the frame control unit, option (ECU D797-1). The solenoid
valve directs the servo pressure to the tilt spool. This pressure is pro-
portional to the control current to the solenoid valve.
Solenoid valve, tilt in

On machines with electric servo, the solenoid valve for tilt in is control-
led electrically by the solenoid valve for tilt in (Y6011), which is activat-
ed by the frame control unit, option (ECU D797-1). The solenoid valve
directs the servo pressure to the tilt spool. This pressure is proportion-
al to the control current to the solenoid valve.

7 Load handling – 7.7.6 Load holding valve 79
7.7.6 Load holding valve

Load holding valve, description
page
–
The load retention valves are mounted on the tilt cylinders, by the hy-
draulic connection to the rod side. The load retention valve prevents
the tilt cylinders from moving faster than the pressure applied from the
load handling control valve. This prevents unwanted tilting forwards,
which can occur if there is a heavy load or high lift height. The load re-
tention valve also makes the tilting movement more controlled.
009929
Load holding valve
7.7.7 Tilt cylinder

Tilt cylinder, description
page
–
The tilt cylinders sit between the mast and the frame and angle the
mast in relation to the machine.
2
009930
1. Tilt cylinder
2. Mast
3. Lower mast anchorage on frame


page
–
7.7.8 Mast
Mast, description
page
–
See Mast, description page 19.

page
–

7 Load handling – 7.8 Levelling 81
7.8 Levelling
Mechanical levelling, function description
page
–
Mechanical levelling is possible because the attachment’s main beam

is movably suspended over the slide plates in the main beam. A lateral
clearance allows for mechanical levelling ±3°. Mechanical levelling
means that the attachment is in a float position and adapts to the angle
of the container to be lifted.
Active levelling, function description

page
–

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
1b 1a
D1
2 11
+ D790-1
D797-1 D791-1
3 8 D3
D2
9 11
C
P1 A
4
T1 B
10
5
C
6
7
014800

1a The levelling control lever (R8075-1- U = 0.5-4.5 V Control levers for electric servo, description
P5) sends a voltage signal to the cab Left: U = <2.5 V page 5
Right: U >2.5 V

82 7 Load handling – 7.8 Levelling

1b Control lever S815-P3 transmits a US815-P3 = 0.5-4.5 V Control lever, description page 6
voltage signal proportional to lever Left: US815-P3 <2.5 V D1: Diagnostic menu, see section 8 Control
movement while control lever system, group 8.4.9.1 ELSERV, menu 1
S815-P4 sends voltage to the cab Right: US815-P3 = >2.5 V
control unit (D790-1). US815-T4 = 24 V
2 Control unit, cab (D790-1) transmits Checked by control sys- Section 11 Common electrics,
side shift left or right on the CAN bus. tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
ror code.
vates the solenoid valve for main group 11.5.3.2 Frame control unit (D797-1)
4 The solenoid valve for main pump re- - Valve block, main pump relief, description
lief (Y6062-2) routes a relieved con- page 48
stant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
shuttle valve.
7 The hydraulic oil pump for load han- See the pressure plate Section 10 Common hydraulics,
dling pumps oil from the hydraulic oil on the left-hand frame group 10.4.2 Axial piston pump with variable
tank. beam. displacement
8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics,
activates the solenoid valve for level- group 11.5.3.5 Attachment control unit
ling right (Y6035) or the solenoid valve (D791-1)
for levelling left (Y6036). D8: Diagnostic menu, see section 8 Control
and 8.4.9.14 ATTACH, menu 14
9 The solenoid valve for levelling right - Attachment control valve, description page 39
(Y6035) or the solenoid valve for level-
ling left (Y6036) pressurises the level-
ling spool in the attachment control
valve.
10 The control valve’s levelling slide - Attachment control valve, description page 39
changes position and pressurises the
levelling cylinders.
11 The levelling cylinders push in the side - Levelling cylinder, description page 84
lifting attachments sideways in rela-
tion to the lifting carriage.


7 Load handling – 7.8.1 Hydraulic oil pump 83

page
–


page
–
Levelling is regulated by a separate section in the attachment control

valve. For a general description of the valve and component locations,
see Attachment control valve, description page 39.
Levelling slide
The valve slide controls the direction and speed of attachment
levelling.
The valve spool is controlled by a solenoid valve for levelling right
(Y6035) and a solenoid valve for levelling left (Y6036).
Solenoid valve, levelling right

The solenoid valve for levelling right controls pressure to the levelling
spool so that it opens and pressurises the levelling cylinders.
The solenoid valve for levelling right is regulated electrically by the so-
lenoid valve for levelling right (Y6035), which is activated by the at-
tachment control unit (D791-1). The solenoid valve directs servo
pressure to the levelling spool.
Solenoid valve, levelling left

The solenoid valve for levelling left controls pressure to the levelling
spool so that it opens and pressurises the levelling cylinders.
The solenoid valve for levelling left is regulated electrically by the so-
lenoid valve for levelling left (Y6036), which is activated by the attach-
ment control unit (D791-1). The solenoid valve directs servo pressure
to the levelling spool.

page
–

84 7 Load handling – 7.8.3 Levelling cylinder
7.8.3 Levelling cylinder

Levelling cylinder, description
page
–
The levelling cylinders sit between the lifting carriage and the side lift-
ing attachment. They change the angle of the side lifting attachment in
relation to the machine.
009924
Levelling cylinders

page
–
7.8.4 Trolley
page
–
Se Trolley, description page 29
7.8.5 Valve block, main pump relief

page
–
Se Valve block, main pump relief, description page 48

page
–

7 Load handling – 7.9 Load carrier 85
7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, description
page
–
The container is held in place on the side lift attachment with two
twistlocks.
Twistlocks are controlled with the twistlock switch. A section of the at-
tachment control valve pressures two hydraulic cylinders connected in
parallel on opposite sides of the side lift attachment. Each hydraulic
cylinder actuates a linkage that rotates a twistlock. Four positions sen-
sors (two on each side of the side lift attachment) detect the position
of the linkage and indicate whether the twistlocks are open or locked.
The status of the twistlocks is shown by indicator lights on the side lift
attachment and in the cab as well as a mechanical indicator on the
side lift attachment.
A contact pin and a sensor at each twistlock indicate when the attach-
ment is in contact with the container. This is used to control when the
twistlocks can be activated. An indicator light on the side lift attach-
ment and another one in the cab indicate when the side lift attachment
has full contact. An event menu shows which twistlocks have contact
(1-2). Both twistlocks must have contact for them to be activated.

86 7 Load handling – 7.9.1 Twistlocks
Twistlocks, function description

page
–

switch voltage
Alignment Full alignment or bypass activated Twistlocks, description page 92

Section 8 Control system, group 8.2.2 Bypassing
2b 1 D1
20
2a
8 7,22
D2 5,23
D790-1 D790-2 D795
D6 D20
D797-1 D791-1 D3
4,6,14, 21
9
D14
D9 19
15 D19 18 3
P1 A
D10
10 B
T1
17
16
11 18 3
19
D6
13 12
014801

1 The switch for locking the twistlocks U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1003) (automatic mode) sends a voltage tion page 7
signal to the cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control

7 Load handling – 7.9.1 Twistlocks 87

2a The switch for opening the twistlocks U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1002) sends a voltage signal to the cab tion page 7
control unit (D790-1) for twistlock opening. D2: Diagnostic menu, see section 8 Control
If the "lock twistlocks" switch (S1003) is in system, group 8.4.9.5 ATTACH, menu 5
the manual position, a signal from the "open
twistlocks" switch (S1002) is not needed to
open the twistlocks.
2b The control lever (S815-T2) sends a voltage US815/T2 = 24 V Control lever, description page 6
signal to the cab control unit (D790-1) for D2: Diagnostic menu, see section 8 Control
twistlock opening. system, group 8.4.9.3 ATTACH, menu 3
If Switch, lock twistlocks (S1003) is in man-
ual position then no signal is required from
the control lever to open twistlocks.
3 The alignment left sensor (B7203L) and Sensor directly oppo- Sensor, alignment, description page 94
alignment right sensor (B7203R) detect po- site indicator plate: D3: Diagnostic menu, see section 8 Control
sition and send a voltage signal to the at- U = 24 V system, group 8.4.9.6 ATTACH, menu 6
tachment control unit (D791).
4 The attachment control unit (D791-1) trans- Checked by control Section 11 Common electrics,
mits alignment on the CAN bus. system, error shown group 11.5.3.5 Attachment control unit
with error code. (D791-1)
5 Control unit KID (D795) activates the event - Section 11 Common electrics,
menu for alignment. group 11.5.3.12 KID control unit (D795)
6 The attachment control module (D791) acti- U = 24 V D6: Diagnostic menu, see section 8 Control
vates the alignment indicator light on the system, group 8.4.9.10 ATTACH, menu 10
mast light panel.
7 Control unit KID (D790-2) activates the indi- - Section 11 Common electrics,
cator light for alignment on the cab’s light group 11.5.3.11 KIT control unit (D790-2)
panel.
8 Control unit, cab (D790-1) transmits "open Checked by control Section 11 Common electrics,
twistlocks" or "lock twistlocks" on the CAN system, error shown group 11.5.3.1 Cab control unit (D790-1)
bus. with error code.
9 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics,

the solenoid valve for main pump relief group 11.5.3.2 Frame control unit (D797-1)
(Y6062-2). D9: Diagnostic menu, see section 8 Control
10 The solenoid valve for main pump relief - Valve block, main pump relief, description
(Y6062-2) routes a relieved constant pres- page 48
sure to the hydraulic oil pump for load han- D10: Diagnostic menu, see section 8 Control
dling. This serves as a load signal. system, group 8.4.5.6 HYD, menu 6
11 The attachment shuttle valve sends the - Section 10 Common hydraulics,

load signal on to the hydraulic oil pump for group 10.5.3 Shuttle valve
load handling or the cab tilt shuttle valve.

88 7 Load handling – 7.9.1 Twistlocks

12 The cab tilt shuttle valve sends the load sig- - Section 10 Common hydraulics,
nal on to the hydraulic oil pump for load group 10.5.3 Shuttle valve
handling.
13 The hydraulic oil pump for load handling See the pressure Section 10 Common hydraulics,
pumps oil from the hydraulic oil tank. plate on the left-hand group 10.4.2 Axial piston pump with variable
frame beam. displacement
14 The attachment control unit (D791-1) acti- U = 24 V Section 11 Common electrics,

vates the "open twistlocks" solenoid valve group 11.5.3.5 Attachment control unit
(Y6039) or the "lock twistlocks" solenoid (D791-1)
valve (Y6040). D14: Diagnostic menu, see section 8 Control
15 The "open twistlocks" solenoid valve - Attachment control valve, description

(Y6039) or the "lock twistlocks" solenoid page 39
valve (Y6040) pressurises the twistlock D15: Diagnostic menu, see section 8 Control
spool with servo pressure. system, group 8.4.9.9 ATTACH, menu 9
16 The twistlock spool of the control valve - Attachment control valve, description
changes position and pressurises the lock page 39
cylinders via the overcentre valve.
17 The overcentre valve prevents the uncon- -

trolled opening or closing of the twistlocks.
18 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 104
19 The "unlocked twistlocks" sensor (B7204 L Sensor directly oppo- Sensor, twistlocks, description page 96
and R) or the "locked twistlocks" sensor site indicator plate: D19: Diagnostic menu, see section 8 Control
(B7205 L and R) sends a signal to the at- U = 24 V and monitoring system,
tachment control unit (D791). group 8.4.9.7 AT-TACH, menu 7
20 The attachment control unit (D791-1) sup- U = 24 V D20: Diagnostic menu, see section 8 Control
plies voltage to the "unlocked twistlocks" in- and monitoring system,
dicator light (H562) or the "locked group 8.4.9.10 ATTACH, menu 10
twistlocks" indicator light (H563) on the
mast light panel.
mits "twistlocks unlocked" or "twistlocks system, error shown group 11.5.3.5 Attachment control unit
locked" on the CAN bus. with error code. (D791-1)
22 Control unit KIT (D790-2) supplies voltage - Section 11 Common electrics,

to Indicator light "unlocked twistlocks" or In- group 11.5.3.11 KIT control unit (D790-2)
dicator light "locked twistlocks" on the cab
lamp panel.
23 Control unit KID (D795) activates event - Section 11 Common electrics,

menu twistlocks. group 11.5.3.12 KID control unit (D795)


7 Load handling – 7.9.1.1 Hydraulic oil pump 89
7.9.1.1 Hydraulic oil pump

page
–

7.9.1.2 Control valve, attachment

page
–
Twistlocks are controlled by a separate section in the attachment’s

control valve. For a general description of the valve and component lo-
cations, see Attachment control valve, description page 39.
Twistlocks slide, description

The valve spool controls the direction of the lock cylinder.
The valve spool is controlled by the "lock twistlocks" solenoid valve
(Y6040) and the "open twistlocks" solenoid valve (Y6039).
"Lock twistlocks" solenoid valve, description

The "lock twistlocks" solenoid valve directs pressure to the twistlock
spool so that the spool opens and pressurises the lock cylinders.
The "lock twistlocks" solenoid valve is regulated electrically with the
"lock twistlocks" solenoid valve (Y6040), which is activated by the at-
tachment control unit (D791-1). The solenoid valve then directs servo
pressure to the twistlock spool.
"Open twistlocks" solenoid valve, description

The "open twistlocks" solenoid valve directs pressure to the twistlock
spool so that the spool opens and pressurises the lock cylinders.
The "open twistlocks" solenoid valve is regulated electrically with the
"open twistlocks" solenoid valve (Y6039), which is activated by the at-
tachment control unit (D791-1). The solenoid valve then directs servo
pressure to the twistlock spool.

page
–

90 7 Load handling – 7.9.1.3 Twistlock overcentre valve
7.9.1.3 Twistlock overcentre valve

Twistlock overcentre valve, description
page
–
The overcentre valve prevents the uncontrolled opening or closing of

the twistlocks. The valve sits to the left of the attachment control valve
on the trolley.
014805
009931

7 Load handling – 7.9.1.4 Lock cylinder 91
7.9.1.4 Lock cylinder

Lock cylinder, description
page
–
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders connected in parallel - one in the right and
one in the left spreader beam - actuate a linkage that twists a twistlock.
014806
014811

page
–

92 7 Load handling – 7.9.1.5 Lock mechanism
7.9.1.5 Lock mechanism

Lock mechanism, description
page
–
The lock mechanism transfers the force of the lock cylinders to the
1
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism operates
3 2 in the corner box.
The lock mechanism consists of a rotary plate with a linkage bearing
at which the lock cylinder is attached. The rotary plate rotates the
twistlocks.
014807
1. Linkage bearing
2. Rotary plate
3. Lock cylinder mounting
7.9.1.6 Twistlocks
Twistlocks, description
page
–
1 2 3
WARNING
Dropped load.
Extreme danger!
Twistlocks hold the load during load handling and

therefore it is of the utmost importance that twist-
locks are checked according to instructions and are
replaced at the slightest sign of damage or wear.
014716
5 4
1. "Unlocked twistlock" sensor Twistlocks secure the load and are located out in the corners of the
2. Sensor contact spreader beam’s longitudinal section.
3. "Locked twistlock" sensor Twistlocks are manufactured from high-strength steel according to in-
4. Lift pin ternational standards. The lift pins are marked with serial numbers.
5. Contact pin
Twistlocks are connected via a linkage system to a hydraulic cylinder
which in turn is controlled via a section in the attachment’s control
valve. Inductive sensors send signals when the twistlocks are locked
and unlocked, respectively.

7 Load handling – 7.9.1.6 Twistlocks 93
Twistlock, replacement
page
–

3 Clean the twistlocks and the surrounding area.
4 Slacken the screws on the clamp holding the twistlocks in place.
5 Hold the twistlock while removing the clamp halves.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.

014821
6 Remove the clamp halves and lift away the twistlock.

7 Install a new twistlock and secure it with the clamp halves.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlock can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlock and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlock is working.
014821

94 7 Load handling – 7.9.1.7 Sensor, alignment
7.9.1.7 Sensor, alignment

Sensor, alignment, description
page
–
The alignment sensors (B7203L and B7203R) detect when the attach-
ment has contact with the container. Two inductive position sensors
are used to indicate contact.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located behind the pin. The position of the sensor can be adjusted
so that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied power and send a 24 V signal to the attach-
ment control unit (D791-1) when the indicator pin is pressed in.
014813
1 2
1. Alignment pin
2. Sensor alignment
014812
1 2

1. Contact pin
2. Sensor contact

7 Load handling – 7.9.1.7 Sensor, alignment 95
Alignment sensor, checking and adjusting

page
–
1 Check that the contact pins in the corner boxes can freely move
up and down. The contact pins must spring down when they are
not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the LED on the sen-
sor is unlit.
4 Lower the attachment onto a container and check that the align-
ment indicator light comes on.
5 Lift the container a little bit so that the alignment indicator light
goes out.
014717
1 2
6 With the container lifted, check how much alignment pin move-
Right side ment is needed to detect contact (LED on the sensor lights). The
1. Sensor alignment movement should be 3–4 mm.
2. Alignment pin
7 If necessary, slacken the lock nut and screw the sensor in/out un-
til the distance between the sensor and the alignment pin is
51 mm.
014718
2 1
Left side
1. Sensor alignment
2. Alignment pin

96 7 Load handling – 7.9.1.8 Sensor twistlocks
7.9.1.8 Sensor twistlocks

Sensor, twistlocks, description
page
–
The twistlocks sensors (B7204L, B7204R, B7205L and B7205R) de-

tect when the twistlocks are locked/unlocked. Four inductive position
sensors - two on each spreader beam - detect the position of the lock
mechanism.
Both sides function the same way independently of one another. An
indicator plate sits on the lock mechanism at the lock cylinder. When
the lock mechanism is in the position that locks the twistlocks, one of
the sensors sends a signal to the attachment control unit (D791-1).
When the lock mechanism is in the position that unlocks the twistlocks,
the other sensor sends a signal to the attachment control unit
(D791-1). No signals are sent if the lock mechanism stops midway.
The sensors are supplied power and send a 24 V signal to the
attachment control unit (D791-1) when the indicator plate is in front of
the sensor.
014809
1 2
1. "Locked twistlock" sensor
2. "Unlocked twistlock" sensor
014810
1 2


7 Load handling – 7.9.1.9 Valve block, main pump relief 97
Twistlocks sensor, checking and adjusting

page
–
1 Check that the sensors are free of damage and dirt.

2 Turn the start key to position I and check that the LED on the
"unlocked twistlock" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out un-
til the distance between the sensor and the indicator plate is
51 mm.
3 Check that the "twistlocks open" indicator light is lit.
4 Lower the attachment over a container and lock the twistlocks.
5 Check that the LED on the "locked twistlock" sensor is lit.
014719
1 2 If necessary, slacken the lock nut and screw the sensor in/out
until the distance between the sensor and the indicator plate is
Right side
51 mm.
2. "Locked twistlock" sensor 6 Check that the "twistlocks locked" indicator light is lit.
014720
2 1
Left side
7.9.1.9 Valve block, main pump relief

page
–
See Valve block, main pump relief, description page 48.
7.9.1.10 Pipes and hoses

page
–

98 7 Load handling – 7.9.2 Lifting hook
7.9.2 Lifting hook

Lifting hook, description
page
–
The container is held in place on the side lifting attachment with two
fixed lifting hooks that are positioned in the corner boxes of the con-
tainer (in the side holes on the long side) and two movable lock
tongues that are positioned in the corner boxes of the container (in the
side holes on the short side). These secure that side lifting attachment
to the container.
The lock tongues are controlled with the lock tongue switch. One sec-
tion in the attachment control valve pressurises two hydraulic cylinders
connected in parallel - one in each spreader boom. Each hydraulic cyl-
inder acts on a linkage that turns a lock tongue. Four position sensors
- two in each spreader boom - sense the position of the linkage and
indicate if the lock tongues are open or closed. Indicator lights on the
side lifting attachment and in the cab show the status of the lock
tongues.
The lock tongues are activated manually or automatically and can be
opened if the machine is driven at a speed below 5 km/h. If the lock
tongues are not locked when the attachment is carrying a load, the
speed of the machine’s hydraulic functions is limited and machine
speed is limited to max. 5 km/h.
Two detection sensors (one at each lifting hook) use ultrasound to de-
tect distance (and informs that system) if one or two containers will be
lifted. At each lifting hook, there is a sensor that indicates contact with
the lower container and another that indicates contacts with the upper
container.
Two indicator lights on the side lifting attachment and one in the cab
indicate when the side lifting attachment has full contact. An event
menu shows when the lifting hook has contact (1-2).
Contact by both of the lifting hooks is not required to activate the lock
tongues. But, unless there is contact and correct locking, the ma-
chine’s hydraulic functions and speed will be limited.

7 Load handling – 7.9.2 Lifting hook 99
Lifting hook, function description

page
–

switch voltage
Alignment Full alignment or bypass activated Lifting hook, description page 107
Section 8 Control system, group 8.2.2 Bypassing
2b 1
D1
2a
8,23 21
D2 9
6
D790-1 D790-2 D795
D4 D21
D797-1 D791-1
5,7,15,22
10
D15 4
D10 16 D20 D3 19 3
P1 A
18 20
11 B
T1
17
12 19 3
C 4
14 13
014802

1 The switch for locking the lock tongue U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1003) (automatic mode) sends a voltage tion page 7
signal to the cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control


2a The switch for opening the lock tongue U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1002) sends a voltage signal to the cab tion page 7
control unit (D790-1) for lock tongue D2: Diagnostic menu, see section 8 Control
opening. system, group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, a signal
from the "open lock tongue" switch
(S1002) is not needed to open the lock
tongues.
2b The control lever (S815-T2) sends a volt- US815/T2 = 24 V Control lever, description page 6
age signal to the cab control unit (D790-1) D2: Diagnostic menu, see section 8 Control
for lock tongue opening. system, group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, no sig-
nal is needed from the control lever to
open lock tongues.
3 The sensor for lower left alignment Sensor directly oppo- Alignment and detection sensor, description
(B7203LL), sensor for upper left alignment site indicator plate: page 108
(B7203LU-2), the sensor for lower right U = 24 V D3: Diagnostic menu, see section 8 Control
alignment (B7203RL) and the sensor for system, group 8.4.9.23 ATTACH, menu 23
upper right alignment (B7203RU-2) detect
position and send a voltage signal to the
attachment control unit (D791).
4 The sensor for upper container right detec- - Alignment and detection sensor, description
tion (B7203RU) and the sensor for upper page 108
container left detection (B7203LU) detect D4: Diagnostic menu, see section 8 Control
position and send a voltage signal to the system, group 8.4.9.22 ATTACH, menu 22
5 The attachment control unit (D791-1) Checked by control Section 11 Common electrics,
transmits alignment/detection on the CAN system, error shown group 11.5.3.5 Attachment control unit
bus. with error code. (D791-1)
6 Control unit KID (D795) activates the - Section 11 Common electrics,

event menu for alignment. group 11.5.3.12 KID control unit (D795)
7 The attachment control module (D791) ac- U = 24 V D6: Diagnostic menu, see section 8 Control
tivates the alignment indicator light (H564) system, group 8.4.9.10 ATTACH, menu 10
on the mast light panel.
8 Control unit KID (D790-2) activates the in- - Section 11 Common electrics,
dicator light for alignment on the cab’s light group 11.5.3.11 KIT control unit (D790-2)
panel.
9 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics,
"open lock tongue" or "lock lock tongue" on system, error shown group 11.5.3.1 Cab control unit (D790-1)
the CAN bus. with error code.

7 Load handling – 7.9.2 Lifting hook 101

10 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics,
the solenoid valve for main pump relief group 11.5.3.2 Frame control unit (D797-1)
(Y6062-2). D10: Diagnostic menu, see section 8 Control
11 The solenoid valve for main pump relief - Valve block, main pump relief, description
(Y6062-2) routes a relieved constant pres- page 48
sure to the hydraulic oil pump for load han-
dling. This serves as a load signal.
12 The attachment shuttle valve sends the - Section 10 Common hydraulics,

load signal on to the hydraulic oil pump for group 10.5.3 Shuttle valve
load handling or the cab tilt shuttle valve.
13 The cab tilt shuttle valve sends the load - Section 10 Common hydraulics,
signal on to the hydraulic oil pump for load group 10.5.3 Shuttle valve
handling.
14 The hydraulic oil pump for load handling See the pressure plate Section 10 Common hydraulics,
pumps oil from the hydraulic oil tank. on the left-hand frame group 10.4.2 Axial piston pump with variable
beam. displacement
15 The attachment control unit (D791-1) acti- U = 24 V Section 11 Common electrics,

vates the "open lock tongue" solenoid group 11.5.3.5 Attachment control unit
valve (Y6039) or the "lock lock tongue" so- (D791-1)
lenoid valve (Y6040). D15: Diagnostic menu, see section 8 Control
16 The "open lock tongue" solenoid valve - Attachment control valve, description
(Y6039) or the "lock lock tongue" solenoid page 39
valve (Y6040) pressurises the lock tongue
spool with servo pressure.
17 The lock tongue spool of the control valve - Attachment control valve, description
changes position and pressurises the lock page 39
cylinders via pilot-controlled non-return
valves.
18 Pilot-controlled non-return valves prevent - Pilot-controlled non-return valve for lock

the uncontrolled opening or closing of the tongue, description page 104
lock tongues.
19 The lock cylinders rotate the lock tongues. - Lock cylinder, description page 104
20 The "unlocked lock tongue" sensor (B7204 Sensor directly oppo- Sensor, twistlocks, description page 96
L and R) or the "locked lock tongue" sen- site indicator plate: D20: Diagnostic menu, see section 8 Control
sor (B7205 L and R) sends a signal to the U = 24 V system, group 8.4.9.8 ATTACH, menu 8
21 The attachment control unit (D791-1) sup- U = 24 V D21: Diagnostic menu, see section 8 Control
plies voltage to the "unlocked lock system, group 8.4.9.10 ATTACH, menu 10
tongues" indicator light (H562) or the
"locked lock tongues" indicator light
(H563) on the mast light panel.


22 The attachment control unit (D791-1) Checked by control Section 11 Common electrics,
transmits "lock tongues unlocked" or "lock system, error shown group 11.5.3.5 Attachment control unit
tongues locked" on the CAN bus. with error code. (D791-1)
23 The KIT control unit (D790-2) supplies - Section 11 Common electrics,

voltage to the "unlocked lock tongues" in- group 11.5.3.11 KIT control unit (D790-2)
dicator light or the "locked lock tongues"
indicator light on the cab light panel.


7 Load handling – 7.9.2.1 Hydraulic oil pump 103

page
–

7.9.2.2 Control valve, attachment

page
–
The lock tongues are regulated by a separate section in the attach-

ment’s control valve. For a general description of the valve and com-
ponent locations, see Attachment control valve, description page 39.
Lock tongue spool, description

The valve spool controls the direction of the lock cylinder.
The valve spool is controlled by the "lock lock tongue" solenoid valve
(Y6040) and the "open lock tongue" solenoid valve (Y6039).
"Lock lock tongue" solenoid valve, description

The "lock lock tongue" solenoid valve directs pressure to the lock
tongue spool so that the spool opens and pressurises the lock
cylinders.
The valve spool is regulated electrically by the "lock lock tongues" so-
lenoid valve (Y6040), which is activated by the attachment control unit
(D791-1). The solenoid valve then directs servo pressure to the lock
tongue spool.
"Open lock tongue" solenoid valve, description

The solenoid valve for lock tongue opening controls pressure to the
lock tongue spool so that it opens and pressurises the lock cylinders.
The valve spool is regulated electrically by the "open lock tongues" so-
lenoid valve (Y6039), which is activated by the attachment control unit
(D791-1). The solenoid valve then directs servo pressure to the lock
tongue spool.

page
–

104 7 Load handling – 7.9.2.3 Pilot-controlled non-return valve for lock tongue
7.9.2.3 Pilot-controlled non-return valve for

lock tongue
Pilot-controlled non-return valve for lock tongue,
page
–
description
Pilot-controlled non-return valves prevent the uncontrolled opening or
closing of the lock tongues. There is one non-return valve at each lock
cylinder on the side lifting attachment.
009938
7.9.2.4 Lock cylinder

Lock cylinder, description
page
–
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders connected in parallel - one in the right and
one in the left spreader beam - each actuate a lock tongue.
009939

page
–

7 Load handling – 7.9.2.5 Lock mechanism 105
7.9.2.5 Lock mechanism

Lock mechanism, description
page
–
The lock mechanism transfers the force of the lock cylinders to the lock
2 tongues. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the lock tongues. The lock mechanism oper-
ates in the corner box.
3
The lock mechanism consists of a lock cylinder that rotates the lock
tongue, which is fastened to the corner box with a shaft bolt.
1
009940
4

2. Lock cylinder
3. Shaft bolt
3. Lock tongue
7.9.2.6 Lock tongue

Lock tongue, description
page
–
WARNING
7
6 Dropped load.
5
Extreme danger!
4
3 Lock tongues together with lifting hooks hold the load
in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
2
or wear whatsoever.
009941
1
1. Sensor, locked lock tongue (B7205LL/RL) The lock tongues secure the load and are located in the corners of the
2. Lock tongue spreader beam’s longitudinal part.
3. Sensor, unlocked lock tongue (B7204L/R) The lock tongues are made of high-strength steel.
4. Alignment pin for alignment sensor, lower container
The lock tongues are connected via a linkage system to a hydraulic
(B7203LL/RL)
cylinder which in turn is controlled via a section in the attachment’s
5. Lifting hook
control valve. Inductive sensors send signals when the lock tongues
6. Alignment pin for alignment sensor, upper container
are locked and unlocked, respectively.
(B7203LU-2/RU-2)
6. Detection sensor, upper container (B7203LU/RU)

106 7 Load handling – 7.9.2.6 Lock tongue
Lock tongue, replacement

page
–

3 Clean the lock tongues and the area surrounding them.
4 Detach the lock cylinder mounting in the lock tongue (position 1).
5 Remove the shaft bolt (position 1), which acts like the lock
tongue’s hinge.
6 Hold the lock tongue while removing the shaft bolt.
2
1
009942
WARNING
Dropped component.
2. Shaft bolt for lock tongue Risk of pinch injury or product damage.
Lock tongues are heavy.
7 Remove the lock tongue.

8 Fit a new lock tongue. Apply lubricating grease to the shaft bolt.
9 Fit the shaft bolt with a new lock nut.
10 Fit the screw of the lock cylinder’s mounting in the lock tongue.
NOTE
Use a new lock nut and new washers.
Apply lubricating grease to the parts before fitting.
11 Check the positions of the parts and that the lock tongues can
move.
12 Apply lubricating grease to the lock tongue’s shaft bolt and the
lock cylinder mounting.
13 Check that the lock tongue mechanism can move.
15 Check that the lock tongues work properly and connect with and
secure the container correctly when lifting.

7 Load handling – 7.9.2.7 Lifting hook 107
7.9.2.7 Lifting hook

Lifting hook, description
page
–
WARNING
7
6 Dropped load.
5
Extreme danger!
4
3 Lock tongues together with lifting hooks hold the load
in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
2
or wear whatsoever.
009941
1
1. Sensor, locked lock tongue (B7205LL/RL) The lifting hooks secure the load and are located in the corners of the
2. Lock tongue spreader beam’s longitudinal part.
3. Sensor, unlocked lock tongue (B7204L/R) The lifting hooks are manufactured from high-strength steel according
4. Alignment pin for alignment sensor, lower container to international standards. The lifting hooks are marked with serial
(B7203LL/RL) number.
5. Lifting hook
6. Alignment pin for alignment sensor, upper container
(B7203LU-2/RU-2)
Lifting hook, replacing

page
–

3 Clean the lifting hooks and the area surrounding them.
4 Remove the lifting hook’s shaft bolt.
5 Hold the lift hook while removing the shaft bolt.
WARNING
1 Dropped component.
009948
2
Risk of pinch injury or product damage.
1. Lifting hook The lifting hook are heavy.

2. Shaft bolt for lifting hook
6 Lift away the lifting hook.

7 Position a new lifting hook in the guide pin.

108 7 Load handling – 7.9.2.8 Alignment and detection sensor
8 Place the lift pin and guide pin in the spreader beam. Place the
guide pin so that the grease cup is accessible through the holes
in the spreader beam.
NOTE
Use a new lock nut and new washers.
9 Check the positions of the parts and that the lifting hooks
can move.
11 Check that the lifting hooks are working.
7.9.2.8 Alignment and detection sensor

Alignment and detection sensor, description
page
–
Two detection sensors (B7203LU/RU) - one at each lifting hook - use

ultrasound to detect distance (and inform the system) if one or two
containers are to be lifted.
1 At each lifting hook, there is one sensor that indicates contact with the
lower container (B7203LL/RL) and one sensor that indicates contact
2 with the upper container (B7203LU-2/RU-2).
The alignment sensors sense the position of a spring pin which is
pressed in when the attachment has contact up against the container.
The sensor is located behind the pin. The position of the sensor can
be adjusted so that it gives a signal when the pin is pressed in and the
head is level with the lower edge of the spreader beam. The clearance
between the attachment and the container’s corner boxes means the
3 sensors stop sending signals when the attachment is lifted.
4 ment control unit (D791-1) when the indicator pin is pressed in.
009949
5 The signal can be checked via the diagnostic menu. See

1. Sensor, upper container alignment
(B7203LU-2/RU-2)
2. Sensor, lower container alignment (B7203LL/RL)
3. Alignment pin, upper container
5. Alignment pin, lower container
Alignment sensor, checking and adjusting

page
–
A 1 Check the alignment sensors and adjust as necessary. Check

the left side and right side the same way.
2 With an unactuated contact pin, the measurement (A) across the
contact pin for the upper container should be approx. 39 mm.
3 When the measurement (A) is reduced to 22 mm, the light (B1)
B for contact with the upper container should come on.
4 Adjusting:
Fix the contact pin so that the measurement (A) is 22 mm. Then
014724
move the sensor along the oval retaining hole and screw it into
the exact position that makes the light (B1) come on.

7 Load handling – 7.9.2.8 Alignment and detection sensor 109
5 With an unactuated contact pin, the measurement (B) across the

contact pin for the lower container should be approx. 30 mm.
B1 6 When the measurement (B) is reduced to 18 mm, the light (B2)
A C for contact with the lower container should come on.
B2 7 Adjusting:
009375
Fix the contact pin so that the measurement (B) is 18 mm. Then
move the sensor along the oval retaining hole and screw it into
Lights on the side lifting attachment
the exact position that makes the light (B2) come on.
A Green light Lock tongues locked
B1 Orange light Alignment (upper container)
B2 Orange light Alignment (lower container)
C Red light Lock tongues released
Detection sensor, upper container, checking

page
–
The sensors for upper container detection use ultrasound to detect

whether one or two containers will be handled. The sensors are acti-
vated when the attachment is 30-50 cm from the container. At that
time, the alignment event menu lights up on the display.
1 Drive the machine toward two containers and check that the
1 alignment event menu lights up on the display no later than when
the attachment is 30 cm from the container.
2 If the event menu for upper container alignment does not light up:
• Use a piece of paper or the like to determine which of the
sensors is not activated.
• Clean the sensor.
• Check the sensor and wiring for damage.
014035
3 Repeat the check from step 1 above. If the alignment event menu
remains unlit, replace the sensor.
1. Detection sensor, upper container

110 7 Load handling – 7.9.2.9 Lock tongue sensor
7.9.2.9 Lock tongue sensor

Lock tongue sensor, description
page
–
The lock tongue sensors (B7204L, B7204R, B7205LL and B7205RL)

detect when the lock tongues are locked/unlocked. Four inductive po-
sition sensors - two on each spreader beam - detect the position of the
lock mechanism.
Both sides function the same way independently of one another. An
1
indicator plate sits on the lock tongue at the lock cylinder. When the
2 lock mechanism is in the position that locks the lock tongues, one of
the sensors sends a signal to the attachment control unit (D791-1).
When the lock mechanism is in the position that unlocks the lock
tongues, the other sensor sends a signal to the attachment control unit
(D791-1). No signals are sent if the lock mechanism stops midway.
009377
3
ment control unit (D791-1) when the indicator plate is in front of the
Right side sensor.
1. Detection sensor, upper container (B7203LU/RU) The signal can be checked via the diagnostic menu. See
2. Sensor, unlocked lock tongue (B7204R/L) section 8 Control system, group 8.4.9.8 ATTACH, menu 8.
3. Sensor, locked lock tongue (B7205LL/RL), lower
Lock tongue sensor, checking and adjusting

page
–
1 Check that the sensors are free of damage and dirt.

2 Turn the start key to position I and check that the LED on the
"unlocked lock tongues" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out
51 mm.
3 Check that the "lock tongue open" indicator light is lit.
4 Insert the lifting hooks in the container and lock the lock tongues.
5 Check that the LED on the "locked lock tongues" sensor is lit.
If necessary, slacken the lock nut and screw the sensor in/out
51 mm.
6 Check that the indicator light for locked lock tongues is lit.
7 Check that the lock tongues lock correctly. Adjust the lock cylin-
ders if necessary.
7.9.2.9 Valve block, main pump relief

page
–
Se Valve block, main pump relief, description page 48
7.9.2.10 Pipes and hoses

page
–

7 Load handling – 7.10 Other functions 111
7.10 Other functions

7.10.1 Container counter
Container counter, description
page
–
The container counter counts the number of lifted containers. The

counter has two counter units that can be reset separately. With the
side lifting attachment equipped with lifting hooks, the system detects
whether one or two containers are being handled and adds the corre-
sponding number to the counter.
The container counter uses the alignment sensor and "locked twist-
locks/lock tongues" sensor to determine when a container is lifted. The
container counter counts a lift when alignment disappears with locked
twistlocks/lock tongue and the twistlocks/lock tongue are not reopened
within eight seconds.
Container counter, function description

page
–

switch voltage
D1
1, 4, 7
10
D790-1 D795
D797-1 D791-1
3,6,9 D5
D2
2,8 5 009956

1 The attachment is positioned over a container - Lifting/lowering, function description page 9
with the functions 7.2 Lifting/lowering, 7.4 Side shift, function description page 37
Side shift, 7.5 Spreading and 7.5 Levelling.
Spreading, function description page 49
Active levelling, function description page 81
system, group 8.4.8.1 ELSERV, menu 1 and
8.4.8.1 ELSERV, menu 2.

112 7 Load handling – 7.10.1 Container counter

2 If the side lifting attachment is equipped Sensor directly oppo- Sensor, alignment, description page 94 or
with twistlocks, the left and right alignment site indicator plate: Alignment and detection sensor, description
sensors (B7203L and B7203R) send a volt- U = 24 V page 108
age signal to the attachment control unit D2: Diagnostic menu, see section 8 Control
If the side lifting attachment is equipped with
lifting hooks, the left lower, left upper, right
lower and right upper alignment sensors
(B7203LL, B7203LU-2, B7203RL and
B7203RU-2) send a voltage signal to the at-
tachment control unit (D791-1).
3 Control unit, attachment (D791-1) sends Checked by control Section 11 Common electrics,
alignment on the CAN bus. system, error shown group 11.5.3.5 Attachment control unit
4 Twistlocks/Lock tongues are turned to the - Twistlocks, function description page 86 or
locked position and closed with the Lifting hook, function description page 99
function 7.9.1 Twistlocks/7.9.2 Lifting hook.
5 The sensor for locked twistlocks/lock tongue Sensor directly oppo- Sensor, twistlocks, description page 96 or
left (B7205L) and the sensor for locked twist- site indicator plate: Lock tongue sensor, description page 110
locks/lock tongue right (B7205R) send a volt- U = 24 V D5: Diagnostic menu, see section 8 Control
age signal to the attachment control unit system, group 8.4.9.8 ATTACH, menu 8
(D791-1).
mits "locked twistlocks/lock tongues" on the system, error shown group 11.5.3.5 Attachment control unit
CAN bus. with error code. (D791-1)
7 The container is lifted with the - Lifting/lowering, function description page 9
function 7.2 Lifting/lowering.
8 If the side lifting attachment is equipped U=0V Sensor, alignment, description page 94 or
with twistlocks, the left and right alignment Alignment and detection sensor, description
sensors (B7203L and B7203R) stop sending page 108
a voltage signal to the attachment control unit D2: Diagnostic menu, see section 8 Control
If the side lifting attachment is equipped with
lifting hooks, the left lower, left upper, right
lower and right upper alignment sensors
(B7203LL, B7203LU-2, B7203RL and
B7203RU-2) stop sending a voltage signal to
the attachment control unit (D791-1).
9 Control unit, attachment (D791-1) sends no Checked by control Section 11 Common electrics,
alignment on the CAN bus. system, error shown group 11.5.3.5 Attachment control unit
10 If the twistlocks/lock tongue remains locked - Section 11 Common electrics,
for 8 seconds, the cab control unit (D790-1) group 11.5.3.1 Cab control unit (D790-1)
adds one lift to the container counter.

8 Control system 1
8 Control system
Table of Contents 8 Control system

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.1.10 Error code menu .................................................................................... 4
8.2 Monitoring ................................................................................................... 7
8.2.1 Overload system .................................................................................... 7
8.2.2 Bypass ................................................................................................... 9
8.2.3 Speed limitation ................................................................................... 10
8.2.4 Service indicator .................................................................................. 10
8.2.6 Height limitation ................................................................................... 11
8.2.7 Height warning ..................................................................................... 11
8.4 Diagnostics ............................................................................................... 12
8.4.1 CAN/POWER ....................................................................................... 14
8.4.2 LIGHTS ................................................................................................ 30
8.4.3 CAB ..................................................................................................... 42
8.4.4 CLIMATE ............................................................................................. 50
8.4.5 HYD ..................................................................................................... 56
8.4.6 ENGINE ............................................................................................... 63
8.4.7 TRANSM .............................................................................................. 75
8.4.8 ELSERV ............................................................................................... 86
8.4.9 ATTACH, DCF360-450CSG .............................................................. 100
8.4.9 ATTACH, DCF 80-100 with lifting hook attachment .......................... 116
8.4.9 ATTACH, DCF 70 and DCF 80-100 with twistlock attachment .......... 132
8.4.10 OLS .................................................................................................... 146
8.4.11 EXTRA ............................................................................................... 148
8.5 Setup ...................................................................................................... 178
8.5.1 Initiation ............................................................................................. 178
8.5.2 Calibration .......................................................................................... 215

2 8 Control system

8 Control system 3
8 Control system
mm mm mm mm mm mm
Control system, general

page
–
The machine’s functions are electrically controlled in many cases. The

signals which control the machine are monitored to warn the operator
or limit the machine’s functions in certain dangerous situations or if
faults arise in the machine.
The control system function is divided into the following functions:
• Monitoring
• Error codes
• Diagnostics
• Setup
• Software
Monitoring functions describes the machine’s monitoring functions
that warn the operator or limit the machine’s functions in the event of
any dangerous situations.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

4 8 Control system – 8.1 Controls and instruments

8.1.10 Error code menu
Error code menu, description
page
–
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
D E • Field B: Error code level is shown with a symbol.

• Field C: Shows error code.
B
000389
• Field D: Shows type of error.
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator’s
manual.
Field B: Error code level

The control and monitoring system gives error code information in
three levels which are indicated with a symbol in the lower left
corner (B) on the display unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
The error code is shown automatically on the display.
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
D E the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
000352
menu for service.
Field C: Error code number

The control and monitoring system gives error codes from three sub-
systems:
• Machine:
C
Shown with error code number XXX on display.
D E
B
000389

8 Control system – 8.1.10 Error code menu 5
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal from battery.
7. Incorrect signal from spool.
8. Level too high/low
7 8 9 9. Incorrect signal to bulb.
10. Incorrect signal, for example, open circuit.
11. Incorrect signal to engine.
10 11
002058

6 8 Control system – 8.1.10 Error code menu
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift, attachment
4. Length adjustment attachment
4 5 6
5. Levelling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks
10 11 12 11. Rotation forks

12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15
15. Steering
16. Engine
17. Transmission
16 17 18
18. Central lubrication
19. Control unit
20. Hardware-related error
19 20 21 21. Cab
22. Air conditioning
23. Fuel system
22 23 24 24. Headlights
25. Windscreen wipers
26. Battery voltage
25 26 27 27. Bulb for lighting
010153

8 Control system – 8.2 Monitoring 7
8.2 Monitoring
8.2.1 Overload system
Overload system, function description
page
–
D790-1 5
D795
D797-2 D797-1 D3
6 4, 6, 7
Pa Pa
D2 2 3
A A A
C
P2
P1
011727
T1 B B B

1 Lift or tilt in is activated. - Section 7 Load handling, group 7.2 Lifting/
lowering
Section 7 Load handling, group 7.7 Tilt
2 Sensor, hydraulic pressure lift cylinder Conn 1: U = 5 V Sensor hydraulic pressure lift cylinder, de-
(B768-1) sends a voltage signal propor- Conn 2: U = 0 V scription page 8
tional to the pressure in the lift cylinders D2: Diagnostic menu, see section 8 Control
Conn 3: U = 0.5 - 4.5 V
to the Control unit, frame (D797-1). system group 8.4.10.1 OP, menu 1
3 Sensor, hydraulic pressure tilt cylinder Conn 1: U = 5 V Hydraulic pressure sensor, tilt cylinder, de-
(B768-2) sends a voltage signal propor- Conn 2: U = 0 V scription page 9
tional to the pressure in the tilt cylinders D3: Diagnostic menu, see section 8 Control
Conn 3: U = 0.5 - 4.5 V
to the Control unit, frame (D797-1). system group 8.4.10.1 OP, menu 1
4 The frame control unit (D797-1) calcu- Checked by the control Section 11 Common electrics,
lates the load based on the pressures. system, error indicated group 11.5.3.2 Frame control unit (D797-1)
If the load is high then the frame control with error code.
unit (D797-1) sends overload on the
CAN bus.
5 The KID control unit (D795) activates - Section 11 Common electrics,

the Event menu for overload, depending group 11.5.3.12 KID control unit
on the load situation.

8 8 Control system – 8.2.1.1 Sensor hydraulic pressure lift cylinder

6 If the load on the lift is high then the - Section 7 Load handling, group 7.2 Lifting/
frame control unit (D797-1) stops lifting lowering
the mast or the frame control unit option
(D797-2) stops lifting the trolley depend-
ing on which position the mast is in.
NOTE
Whatever the conditions that inter-
rupt (high load on the lift or tilt) the
system interrupts both tilt and lift.
7 If the load on tilt is high then the frame - Section 7 Load handling, group 7.7 Tilt
control unit (D797-1) interrupts tilt in.
NOTE
Whatever the conditions that inter-
rupt (high load on the lift or tilt) the
system interrupts both tilt and lift.
8.2.1.1 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, description
page
–
The sensor for hydraulic pressure, lift cylinder, measures the pressure
on the lift cylinders’ piston side. The sensor is fitted on the output for
the lift cylinders on the control valve for load handling.
The sensors are supplied with power by, and send a voltage signal
proportional to, the hydraulic oil pressure for the frame control unit
(D797-1).
section 8 Control system, group 8.4.10.1 OP, menu 1.

8 Control system – 8.2.1.2 Hydraulic pressure sensor, tilt cylinder 9
8.2.1.2 Hydraulic pressure sensor, tilt cylinder

Hydraulic pressure sensor, tilt cylinder, description
page
–
The hydraulic pressure sensor for the tilt cylinder measures the pres-
sure on the rod side of the tilt cylinders. The sensor is fitted on the load
retention valve of the left tilt cylinder.
The sensors are supplied with power by, and send a voltage signal
proportional to, the hydraulic oil pressure for the frame control unit
(D797-1).
section 8 Control system, group 8.4.10.1 OP, menu 1.
8.2.2 Bypass
Bypass, description
page
–
Bypassing is activated with the bypass switch.

By-passing the safety system allows:
• locking and opening of twistlocks without complete alignment
• 20’-40’ spreading with locked twistlocks
• lowering a load with alignment on top lift
• manual control of the recirculation damper for ECC or EHC
• release of parking brake in the event of parking brake switch
malfunction
• output signal to solenoid valves with active error codes
• engagement of a gear without the operator in the operator’s seat,
the machine can only move at reduced speed
DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
Extreme hazard to personal health and risk of proper-

ty damage!
Only use the bypass of safety systems in emergency

situations.

10 8 Control system – 8.2.3 Speed limitation
8.2.3 Speed limitation

Speed limitation, description
page
–
Speed limitation prevents the machine’s speed from exceeding the

preset value by limiting gear position and engine speed.
Machine speed is limited when:
• the emergency stop switch is activated.
• the cab is tilted.
• load is not in transport position during transport. Maximum speed
is 5 km/h .
• the reversible driver’s seat is not in position .
• constant speed limitation is set .

• Hydraulic oil temperature too high.
Speed limitation is set via the initiation menu; see section 8 Control
system, group 8.5.1.4 INIT DRIVE-TRAIN, menu 9.
8.2.4 Service indicator

Service indicator, resetting
page
–

2 Navigate first to the service menu and press Enter.
000056
3 Enter the code to reset the service indicator.

Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Serv-

ice, Diagnostic test, Initiation or Calibration).
4 Reset the service indicator by pressing Enter. NEXT SERVICE is
SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh
SERVICE INTERVALL To change duration of the service interval, set the desired interval
STORED XXXXh with the plus or minus key.
004908
PRESENT XXXXh

8 Control system – 8.2.6 Height limitation 11
8.2.6 Height limitation

Height limitation, description
page
–
Height limitation is part of the control system and prevents the ma-
chine lifting higher than a preset height without the operator being
informed.
Height limitation is controlled by the control system with signals from
Position sensor, mast. When Position sensor, mast indicates that the
permitted height is reached, lift is blocked. In addition, display informa-
tion for height limitation is activated.
For details about lifting and lowering, see section 7 Load handling,
group 7.2 Lifting/lowering.
The values of height limitation can be checked from the diagnostic
menu, see section 8 Control system, group 8.4.10.3 OLS, menu 3.
8.2.7 Height warning

Height warning, description
page
–
Height warning warns via the display menu when the set maximum lift
height is reached. The height warning can be adjusted according to
customer requirements.

12 8 Control system – 8.4 Diagnostics
8.4 Diagnostics
Diagnostic test, general
page
–
The machine has built-in functions for troubleshooting called diagnos-

DIAGNOSIS tic test. The diagnostic test consists of several menus shown on the
CAN/POWER LIGHTS CAB display. The menus are grouped for faster access. The following pag-
CLIMATE HYD ENGINE
es describe the menu figures content and which functions that can be
TRANSM ELSERV ATTACH
controlled.
005263
OLS EXTRA
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system, CAN/
POWER, description page 14.
• Lighting, LIGHTS, description page 30.
• Cab functions, CAB, description page 41.
• Air conditioning, CLIMATE, description page 48.
• Hydraulic functions, HYD, description page 54.
• Engine, ENGINE, description page 61.
• Transmission, TRANSM, description page 73.
• Functions for electric servo, ELSERV, description page 84.
• Attachment functions, ATTACH, description page 98.
• Overload protection, OLS, description page 144.
• Optional functions, EXTRA, description page 146.
– Reversible driver’s seat, VBFS, menu 1 page 146.
– Mini-wheel or lever steering, EL-STEERING, menu 1
page 154.
– External attachment, EXT-ATTACH, menu 1 page 158.
– Freelift, FREELIFT, menu 1 page 163.
– Tiltable cab and sliding cab, MOVE-CAB, menu 1 page 164.
– RMI, RMI, menu 1 page 173.

8 Control system – 8.4 Diagnostics 13
Diagnostic menu, description

page
–
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
7 DIAG CAB 2(X)

FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5
008873
FEEDBACK 0
1. DIAG = Diagnostic menus

2. Menu group
3. Menu number
4. Total number of menus in the loop. The number of
menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
5. Signal value
6. Variable
7. Menu heading
DIAG Indicates that diagnostic tests are selected.
CAB Indicates which menu group is selected, these groups are:

CAN/POWER, description page 14.
LIGHTS, description page 30.
CAB, description page 41.
CLIMATE, description page 48.
HYD, description page 54.
ENGINE, description page 61.
TRANSM, description page 73.
ELSERV, description page 84.
ATTACH, description page 98.
OLS, description page 144.
EXTRA, description page 146.
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
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: 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.

14 8 Control system – 8.4.1 CAN/POWER
Signal value Measurement value or status for 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-circuiting.
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-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.
8.4.1 CAN/POWER
CAN/POWER, description
page
–
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selections with function key for Enter.
005263
OLS EXTRA
8.4.1.1 CAN/POWER, menu 1

PRESENT REDCAN STATUS, COMMUNICATION MODE
page
–
Description: Indicates communications status for the redundant

DIAG CAN/POWER 1(X) CAN-bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: 11.6-1
NUMBERS OF UNITS X Contact: -
005266
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN bus
Signal value:
3 OK.
2 Segment check.
0 Error.

8 Control system – 8.4.1.1 CAN/POWER, menu 1 15
PRESENT REDCAN STATUS, NUMBER OF UNITS

page
–
Description: Indicates number of control units, excluding cab KCU

control unit (D790-1), which should be present on the machine in
question. The number depends on the options present.
Circuit diagram: Circuit 11.6-1
Contact: -
Signal value:
X Number of nodes that should be in the machine. Number of

nodes dependent on installed options.
PRESENT REDCAN STATUS, SEGMENT ERROR

page
–
Description: Indicates if there is open circuit on the redundant CAN

bus. And if there is, where the first open circuit is. If there is open cir-
cuit, it is indicated with a number that corresponds to the incorrect seg-
ment on the redundant CAN bus.
Contact: -
Signal value:
0 No open circuits.
>0 If X is separated from 0, the first segment is indicated

as missing contact. A 1 means that the first segment is
incorrect, that is, that contact between first and second
control unit is cut off.
To see which control units are installed on the machine
along with their order, use diagnostic menu CAN/
POWER, menu 2, see PRESENT REDCAN STATUS,
CONNECTED CITIES page 16.

16 8 Control system – 8.4.1.2 CAN/POWER, menu 2

PRESENT REDCAN STATUS, CONNECTED CITIES
page
–
Description: Indicates which control units have contact with Control

DIAG CAN/POWER 2(X) unit, cab (D790-1) via the redundant CAN bus. Note that certain con-
PRESENT REDCAN STATUS trol units are optional and may not be installed on the machine.
CONNECTED CITIES
D797-1 D797-2 XX Circuit diagram: 11.6-1, 11.6-2B, 11.6-2C
005267
D795 D791-1 XX Contact:
D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D797-2, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.3 Frame con-
trol unit (D797-2), 11.5.3.5 Attachment control unit, 11.5.3.12 KID con-
trol unit, 11.6.2 Redundant CAN bus.
Signal value:
1 Communication with the node is OK.
0 No communication and/or there is some node error.

PRESENT OPTION KDU
page
–
Description: Indicates which optional control units should be present

DIAG CAN/POWER 3(X) on the machine and if they have working communication with the cab
PRESENT OPTION KDU KCU control unit (D790-1).
KDU D797-2 XY Circuit diagram: Circuit 11.6-1

007183
KDU D791-1 XY Contact: -

Signal value:
00 The control unit is not installed on the machine.
10 The control unit is installed on the machine but there is no

communication with the cab control unit (D790-1).
11 The control unit is installed on the machine and there is com-

munication with the cab control unit (D790-1).

PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE
page
–
Description: Indicates status for engine in the drivetrain’s CAN bus.

DIAG CAN/POWER 4(X) Circuit diagram: Engine circuit group 1.0, CAN bus circuit group 11.6
PRESENT DRIVE-TRAIN
CAN BUS STATUS Contact:
ENGINE X
Volvo TAD760VE: CAN J1939 from D790-1/K13:1 and K13:2 to
005269
TRANSMISSION X
D794/1 and 2
Volvo TAD950VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TWDTAD1250VE: CAN J1939 from D790-1/K13:1 and
K13:2 to D794/1 and 2

Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to

D794/46 and 37
Cummins QSB6.7: 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:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine 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 elec-
tronic box and the frame electronic box. If there is communication
(to either engine or transmission), then this rules out a fault in the
cable harness between the cab electronic box and the frame
electronic box.
PRESENT DRIVE-TRAIN CAN BUS STATUS,

page
–
TRANSMISSION
Description: Indicates status for transmission in drivetrain’s CAN bus.
Circuit diagram: Transmission circuit group 2.0, CAN bus circuit
group 11.6
Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
and M2
Function: 11.6.3 CAN bus drive-train
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine 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 elec-
tronic box and the frame electronic box. If there is communication
(to either engine or transmission), then this rules out a fault in the
cable harness between the cab electronic box and the frame
electronic box.


IGNITION, KEY IN
page
–
Description: Indicates if ignition is on (key in ignition switch).

DIAG CAN/POWER 5(X)
IGNITION
KEY IN X Connection: signal from S150/15 to digital in D790-1/K11:1
RELAY K315-1 XY
Function: 11.5.1.3 Ignition voltage
007126
RELAY K315-2 XY
Signal value:
1 Input signal active.
0 No signal.
IGNITION, RELAY K315-1

page
–
Description: Control current to Relay, ignition voltage (K315-1),

15-voltage.
Connection: output signal from D790-1/K10:10 to K315-1
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
00 No output signal, open circuit in circuit.
01 No output signal, circuit OK or short-circuiting. Short-

circuiting can only be detected when the output signal is
active.
10 Output signal active, short circuit.
11 Output signal active, circuit OK or open circuit. Open circuit

can only be detected when the output signal is active.
IGNITION, RELAY K315-2

page
–
Description: Control current to Relay, ignition voltage (K315-2)

(15-voltage).
Connection: output signal from D790-1/K10:16 to K315-2
Signal value:

active.



EMERGENCY STOP, SW
page
–
Description: Indicates if switch, emergency stop switch, is activated.

DIAG CAN/POWER 6(X)
Circuit diagram: sheet 11.5-6
EMERGENCY STOP, SW X
RELAY K3009-1 XY Connection: signal from S250/2 to digital in D790-1/K8:4
FEEDBACK X
Function: 11.5.1.4 Emergency stop switch voltage (15E)
007127
RELAY K3009-2 XY
Signal value:
0 No signal.
EMERGENCY STOP, RELAY K3009-1

page
–
Description: Status for control current to relay K3009-1, for emergency

stop switch voltage, 15E voltage.
Connection: signal from D790-1/K10:11 to K3009-1/86
Signal value:

active.

EMERGENCY STOP, FEEDBACK

page
–
Description: Feedback signal from control breaker voltage (K3009-1),

indicates that relay is working normally.
Connection: signal from K3009-1/87 via F58-3/8 to digital in D790-1/
K11:13
Signal value:
0 No signal.
EMERGENCY STOP, RELAY K3009-2

page
–
Description: Status for control current to Relay control breaker voltage

(K3009-2), 15E voltage.
Connection: signal from D790-1/K10:12 to K3009-2/86


Signal value:

active.


790-1 CAB, POWER
page
–
Description: Ignition voltage (15) to Control unit, cab (D790-1).

DIAG CAN/POWER 7(X)
790-1 CAB
POWER XX.XXV Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1 to
5V REF X.XXV D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4
005271
Function: 11.5.1 Voltage feed

Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
790-1 CAB, 5V REF

page
–
Description: Reference voltage 5 V to controls in cab.

Circuit diagram: Circuits 9.4-1, 9.4-2 and 9.3-3 (contact 1, 2),
Circuit 1.0-1 (contact 3), Circuit 7.0-1 (contact 4), Circuit 5.2-1
(contact 5)
Contact:
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10
2. signal from digital out D790-1/K5:11 to S118/1, S139/1 and
S117/1
3. signal from digital out D790-1/K5:13 till B690-1/1 and B690-2/1
4. signal from digital out D790-1/K7:2 to R8071/1, R8072/1,
R8073/1, R8074/1, R8075-1/1 and R8075-2/1
5. signal from digital out D790-1/K9:7 to R825-1/1 and R825-2/1
Function: 9.4 Heating, ventilation and air conditioning (contact 1 and
2); 1 Engine and 2 Transmission (contact 3); 7 Load handling
(contact 4); 5 Steering (contact 5)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).


790-1 CAB, 24V SENSOR SUPPLY
page
–
Description: 24 V voltage feed to components in cab.

DIAG CAN/POWER 8(X)
Circuit diagram:
790-1 CAB
24V SENSOR SUPPLY XY 1. Circuit 9.5-1
24V SUPPLY,RPM>500 XY
2. Circuits 2.0-1, 9.1-1, 9.3-1, 9.6-1, 9.6-2, 9.6-3, 9.6-4 and 9.5-1
005275
3. -
4. -
5. Circuits 4.0-1, 7.5-1, 7.9-1, 8.2-1, 9.1-1, 9.3-3, 9.10-1 and 11.5-6
6. Circuit 5-2-1
7. -
8. Circuit 9.7-1
9. Circuit 9.5-1
10. Circuit 9.5-1

Contact:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S100/5, S110/5, S105-1/5,
S105-2/5, S105-3/5, S143/5, S199-1/5, S199-3/5, S199-4/5,
S220-1/1
3. signal from digital out D790-1/K6:13 not connected
5. signal from digital out D790-1/K8:16 to S107/5, S169/3, S199-2/5,
S250/1, S1002/2, S1003/3, S1004/5, S1005/5, S1010/3,
S1012/3, S1037/5
6. signal from digital out D790-1/K9:1 to S113/5, S149-2/5, S160-2/3
8. signal from digital out D790-1/K11:12 to S230/2
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake sys-
tem; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab;
7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. 5 Steering
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:
01 No output signal. Error detection only possible when output

signal is active.
10 Output signal active, short circuit or open circuit.
11 Output signal active, circuit OK or open circuit.

790-1 CAB, 24V SUPPLY, RPM>500

page
–
Description: Voltage feed at engine speed higher than 500 rpm.

Connection: signal from digital out D790-1/K10:9 to P708/+ and
K358/86
Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter
Signal value:

active.


795 DISPLAY, RED. POWER
page
–
Description: Redundant voltage to Control unit KID (D795).

DIAG CAN/POWER 9(X)
795 DISPLAY
Contact:
RED.POWER LE X RI X
Le: redundant feed to D790/K1:8
005276
Ri: redundant feed to D790/K1:7

Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.


797-1 FRAME, POWER
page
–
Description: Ignition voltage (15) to frame control unit (D797-1).

DIAG CAN/POWER 10(X)
797-1 FRAME
POWER XX.XXV Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to
RED.POWER LE X RI X D797-1/K2:1, D797-1/K2:9 and D797-1/K2:10
005277
POWER 2 X
Signal value: XX.XXV = voltage on connection. The signal value
797-1 FRAME, RED. POWER

page
–
Description: Redundant voltage to frame control unit (D797-1).

Contact:
• Le: redundant feed to D797-1/K2:7
• Ri: redundant feed to D797-1/K2:8
Signal value:
1 Feed active.
0 No feed.
797-1 FRAME, POWER 2

page
–
Description: Battery voltage to frame control unit (D797-1).

Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/1 to
D797-1/K2:11
Signal value:
1 Feed active.
0 No feed.

797-1 FRAME, 5V REF
page
–
Description: Reference voltage 5 v to sensors connected to frame con-

DIAG CAN/POWER 11(X) trol unit (D797-1) (voltage feed to pressure sensors).
797-1 FRAME
5V REF X.XXV Connection: digital out from 797-1/K1:8 to B768-1/1 and B768-2/1
005278
Function: 7.2.8 Hydraulic pressure sensor, lift cylinder and 7.7.8

Hydraulic pressure sensor, tilt cylinder
Signal value: X.XXV = 5.00 V. Important that signal value is stable
(not varying).


793 TRANSMISSION, POWER
page
–
Description: Battery voltage (30) to Control unit, transmission (D793).

Circuit diagram: Circuit 2.0-2A1
793 TRANSMISSION
POWER XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/A1
IGNITION POWER XX.XXV
Function: 11.5.1.1 Battery voltage (30)
005279
SENSOR SUPPLY XX.XXV
793 TRANSMISSION, IGNITION POWER

page
–
Description: Ignition voltage (15) to Control unit, transmission (D793).

Connection: 15-voltage from K315/87 via F54/4 and F58-2/6 to
D793/S2
793 TRANSMISSION, SENSOR SUPPLY

page
–
Description: voltage feed to sensors on transmission, reference volt-

age of 5 V.
Circuit diagram: Circuits 2.0-2A2, 2.0-2A3
Connection: 5V analogue Ref from D793/M1 to S221/1
Function: 2.8 Control system, transmission
Signal value: XX.XXV = voltage on connection. The signal value
should be 8 V, stable (not vary).

797-2 FRAME (OPT), POWER
page
–

797-2 FRAME (OPT) Description: Ignition voltage (15) to frame control unit, option
POWER XX.XXV (D797-2).
RED.POWER LE X RI X
005280
EME STOP POWER X

Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/3 to
D797-2/K2:1, D797-2/K2:9 and D797-2/K2:10

797-2 FRAME (OPT), RED. POWER

page
–
Description: Redundant voltage to frame control unit, option (D797-2).

Circuit diagram: Circuit 11.6-2A
Contact:
• Le: redundant feed to D797-2/K2:7
• Ri: redundant feed to D797-2/K2:8
Signal value:
1 Feed active.
0 No feed.
797-2 FRAME (OPT), EME STOP POWER

page
–
Description: Emergency stop switch voltage to frame control unit, op-

tion (D797-2).
Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and
F58-3/5 to D797-2/K2:11
Signal value:
1 Feed active.
0 No feed.


797-2 FRAME (OPT), 24V SENSOR SUPPLY
page
–
DIAG CAN/POWER 14(17)

797-2 FRAME (OPT) Description: Voltage feed 24 V to sensors connected to the frame con-
24V SENSOR SUPPLY XY trol unit, option (D797-2).
5V REF X.XXV
005281
Connection: signal from digital out D797-2/K1:7 to S720-F/2 and
S720-R/2.
Function: 9.3.9 Sensor, reversible driver’s seat
Signal value:

active.

797-2 FRAME (OPT), 5V REF

page
–
Not used.


791-1 ATTACHMENT, EME POWER
page
–
Description: Voltage feed to attachment control unit (D791-1).

791-1 ATTACHMENT(OPT)
EME POWER XX.XXV Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
RED.POWER LE X RI X D791-1/K2:1, K2:9, K2:10, K2:11
005282
EME POWER 2 X
Signal value:
XX.XXV = voltage on the connection. The signal value should be
22-30 V (battery voltage).
791-1 ATTACHMENT, RED. POWER

page
–
Description: Redundant voltage feed to Control unit, attachment

(D791-1).
Circuit diagram: Circuit 11.5-1, 11.5-6, 11.6-1, 11.6-2B, 11.6-2C
Contact:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Signal value:
1 Feed active.
0 No feed.
791-1 FRAME, EME POWER 2

page
–
Description: Emergency stop switch voltage (15E) to attachment con-

trol unit (D791-1).
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
D791-1/K2:11
Signal value:
1 Feed active.
0 No feed.


791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY
page
–
Description: Voltage feed to sensors connected to the attachment con-

DIAG CAN/POWER 16(X) trol unit (D791-1).
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY Circuit diagram: Circuit 7.5-2, 7.9-2
5V REF X.XXV DCF360-450CSG
005283
Connection: digital out from 791-1/K1:10 to B769-1, B777-1, B7202L,
B7202R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.8 Spreading position sensor, 7.9.1.6 Alignment position
sensor, 7.9.1.7 Twistlocks sensor
DCF 70, DCF 80-100 with twistlock attachment
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position
sensor, 7.9.1.8 Twistlocks sensor
DCF 80-100 with lifting hook
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203LU-2, B7203RU-2, B7203LL, B7203RL, B7203LU,
B7203RU, B7204L, B7204R, B7205LL and B7205RL
Function: 7.5.6 Spreading position sensor, 7.9.2.8 Alignment and de-
tection sensor, 7.9.2.9 Lock tongue sensor
Signal value:

active.

791-1 ATTACHMENT (OPT), 5V REF

page
–
Not used.


REDCAN STATUS CHECK
page
–
Description: Control function from the redundant CAN bus. The cab
DIAG CAN/POWER 17(X) control unit (D790-1) performs a segment check to determine whether
REDCAN STATUS CHECK all control units have contact and are connected in the right order. The
PRESS ENTER control system indicates the fault by numbering the cables between
the control units (segments) from 1 onwards. Segment 1 is always be-
005284
SEGMENT ERROR X
tween the cab control unit (D790-1) and the next control unit in se-
quence. The last segment is always between the KID control unit
(D795) and the cab control unit (D790-1). The segments in between
vary depending on machine configuration.
Circuit diagram: Circuit CAN bus group 11.6
D790-1 D791 D797-2 D797-1 Contact: -
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R
1 2 3 Function: 11.6.2 Redundant CAN bus

5 4 Signal value:
CAN R CAN L
008878
D795
0 No errors.
DCF360-450CSG >0 X > 0, the number indicates incorrect segment. Use circuit di-
Segment numbering with maximum number of control agram to find the incorrect segment.
units. Control units marked with dashes are optional.
D790-1 D797-2 D797-1

CAN L CAN R CAN L CAN R CAN L CAN R
1 2
4 3
CAN R CAN L
008879
D795
DCF 280-520
Segment numbering with maximum number of control
units. Control units marked with dashes are optional.
8.4.2 LIGHTS
LIGHTS, description
page
–
This group covers lighting.

DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
005285
OLS EXTRA

8 Control system – 8.4.2.1 LIGHTS, menu 1 31
8.4.2.1 LIGHTS, menu 1

MAIN LIGHT, SWITCH
page
–
Description: Signal from headlights switch.

DIAG LIGHTS 1(X)
MAIN LIGHT
SWITCH X Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.
005286
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, SIDE LIGHTS
page
–
Description: Voltage feed to side running lights.

DIAG LIGHTS 2(X)
Circuit diagram: Circuit 9.6-5 and 9.6-6
PRESENT OUTPUT SIGNAL
Connection: digital out from D797-1/K1:2 to H416-1, H416-2, H417-1
SIDE LIGHTS XY and H417-2
005287
REAR LIGHTS XY
Function: 9.6.2 Running lights
Signal value:

active.

PRESENT OUTPUT SIGNAL, REAR LIGHTS

page
–
Description: Voltage feed to tail lights.

Connection: digital out from D797-1/K1:33 to H412L and H412R
Function: 9.6.3 Tail lights
Signal value:

active.


32 8 Control system – 8.4.2.3 LIGHTS, menu 3

HEAD LIGHTS, SWITCH
page
–
Description: Lighting headlights front, switch.

DIAG LIGHTS 3(X)
HEAD LIGHTS
SWITCH X Connection: from S162:56A to digital in D790-2/K3:9
HEAD LE/RI XY
Function: 9.6.1 Headlights
005288
DIMMED LE/RI XY
Signal value:
0 No signal.
HEADLIGHTS, HEAD LE/RI

page
–
Description: Voltage feed to headlights, high beam.

Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1
Signal value:

active.

HEADLIGHTS, DIMMED LE/RI

page
–
Description: Voltage feed to headlights, low beam.

Connection: digital out from D797-1/K1:28 to E400L and E400R
Signal value:

active.



PRESENT INPUT SIGNAL, HAZARD SWITCH
page
–
Description: Signal from switch, flashing hazard lights (Hazard).

DIAG LIGHTS 4(X)
PRESENT INPUT SIGNAL
HAZARD SWITCH X Connection: signal from S109/1 to digital in D790-1/K5:6
FLASH.SW. LE X RI X
Function: 9.7 Signalling system
005289
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, FLASH.SW.

page
–
Description: Signal from switch, direction indicators.

Contact:
• LE: signal from S161/6 to digital in D790-2/K8:8
• RI: signal from S161/1 to digital in D790-2/K8:9
Function: 9.6 Lighting system
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT F/R
page
–
Description: Voltage feed to direction indicator, left-hand side.

DIAG LIGHTS 5(X)
HAZARD/FLASHER Connection: digital out from D797-1/K1:30 to H422 and H426
LEFT F/R XY
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
005290
RIGHT F/R XY
(Hazard)
Signal value:

active.


PRESENT OUTPUT SIGNAL HAZARD/FLASHER,

page
–
RIGHT F/R
Description: Voltage feed to direction indicator, right-hand side.
Connection: digital out from D797-1/K1:31 to H423 and H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:

active.


ROTATION BEACON, SWITCH
page
–
Description: Signal from switch, rotating beacon.

DIAG LIGHTS 6(X)
ROTATION BEACON
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
Function: 9.6.8 Revolving beacon
005291
Signal value:
0 No signal.
ROTATION BEACON, OUTPUT

page
–
Description: Voltage feed to rotating beacon.

Connection: digital out from D790-1/K2:5 to H428
Function: 9.6.8 Revolving beacon
Signal value:

signal is active.
11 Output signal active, circuit OK.


PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
page
–
Description: Signal from make-contact (closing switch) brake lights.

DIAG LIGHTS 7(X)
BRAKE LGT SWITCH X Connection: from S216/2 to digital in D797-1/K1:20
REVERSE LGT SIGNAL X
Function: 4.3.8 Make-contact (closing switch) brake lights
005292
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL

page
–
Description: Signal from Control unit, transmission (D793) when re-

verse gear is activated.
Circuit diagram: Circuit Lighting group 9.6
Contact: -
Function: 9.6.5 Back-up lights
Signal value:
1 Input signal active. Output signal "reverse gear active" from

Control unit, transmission (D793).
0 No signal.

PRESENT OUTPUT SIGNAL, BRAKE LGT
page
–
Description: Voltage feed to brake lights.

DIAG LIGHTS 8(X)
BRAKE LGT LE XY RI XY Contact:
REV. LGT LE XY RI XY
• LE: digital out from D797-1/K1:7 to H411L
005293
REVERSE ALARM XY
• RI: digital out from D797-1/K1:9 to H411R
Function: 9.6.4 Brake lights
Signal value:

active.


PRESENT OUTPUT SIGNAL, REV LGT

page
–
Description: Voltage feed to reversing lights.

Contact:
• LE: digital out from D790-1/K2:6 to E405L
• RI: digital out from D790-1/K2:7 to E405R
Function: 9.6.5 Back-up lights
Signal value:

active.

PRESENT OUTPUT SIGNAL, REVERSE ALARM

page
–
Description: Voltage feed to back-up alarm.

Connection: digital out from D797-1/K1:10 to H965
Function: 9.7.5 Back-up alarm
Signal value:

active.


CAB LIGHT, MANUAL SWITCH
page
–
Description: Signal from switch, lighting cab.

DIAG LIGHTS 9(X)
CAB LIGHT
MANUAL SWITCH X Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
005294
OUTPUT XXX
Signal value:
0 No signal.

CAB LIGHT, DOOR SWITCH

page
–
Description: Signal from break-contact (opening switch) door.

Connection: signal from S266-LE or S266-RI (connected in parallel) to
digital in D790-1/K11:3
Function: 9.10.2 Doors
Signal value:

0 No signal.
CAB LIGHT, OUTPUT

page
–
Description: Voltage feed to interior lighting cab.

Connection: digital out from D790-1/K11:6 to E434-1
Function: 9.6.11 Interior lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).

WORKING LIGHT MAST, SWITCH
page
–
Description: Signal from switch for working light, mast.

DIAG LIGHTS 10(X)
WORKING LIGHT MAST
SWITCH X Connection: signal from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE/RI XY
005295
Signal value:

0 No signal.
WORKING LIGHT MAST, OUTPUT

page
–
Description: Voltage feed to working light, mast.

Function: 9.6.9 Working light, mast
Signal value:

active.


WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42
page
–
Description: Voltage feed to auxiliary working light.

DIAG LIGHTS 11(X)
WORKING LIGHT EXTRA
OUTPUT Connection: digital out from D797-1/K1:42 to E404L-4 and E404R-4
D797-1 C1 P42 XY
Function: 9.1.4 Switch for working light, front wing, 9.1.5 Switch for
005296
D797-2 C1 P42 XY
working light, attachment, 9.1.6 Switch for working light, mast
Signal value:

active.

WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

page
–
Description: Voltage feed to auxiliary working light.

Function: 9.6.9 Working light, mast, 9.6.10 Working light, cab,
9.6.12 Working light, attachment, 9.6.14 Working light, front wing
Signal value:

active.


WORKING LIGHT CAB, SWITCH
page
–
Description: Signal from switch, work lights cab roof.

DIAG LIGHTS 12(X)
Circuit diagram: 9.6-1
WORKING LIGHT CAB
005297
OUTPUT 20' XY 40' XY

Signal value:
0 No signal.

WORKING LIGHT CAB, OUTPUT

page
–
Description: Voltage feed to work lights cab roof.

Contact:
• 20’: digital out from D790-1/K7:8 to E406L-2 and E406R-2
• 40’: digital out from D790-1/K10:8 to E406L-1 and E406R-1
Function: 9.6.10 Work light cab
Signal value:

active.
10 Output signal active, short-circuiting.

WORKING LIGHT ATTACH, SWITCH
page
–
Description: Signal from switch, work lights attachment.

DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH
OUTPUT LE XY RI XY
008895
Signal value:

0 No signal.
WORKING LIGHT ATTACH, OUTPUT

page
–
Description: Voltage feed to working light, attachment.

Contact:
• LE: digital out from D791-1/K1:1 to E404L-3
• RI: digital out from D791-1/K1:15 to E404R-3
Function: 9.6.12 Work light attachment
Signal value:

active.


SWITCH LIGHTS, OUTPUT
page
–
Description: Voltage feed to background lighting in switches, panels

DIAG LIGHTS 14(X) and keys.
SWITCH LIGHTS Circuit diagram: Circuits 4.0-1, 5.2-1, 7.5-1, 7.9-1, 9.1-1, 9.3-1, 9.3-3,
9.4-1, 9.6-2, 9.6-3, 9.6-4, 9.6-1
OUTPUT XXX
005300
Contact:
output signal from D790-1/K6:1 to S117, S118, S139
output signal from D790-1/K6:2 to S105-2
output signal from D790-1/K6:4 to S110
output signal from D790-1/K8:15 to S169, S1010
Function: 9.6.11 Interior lighting
Signal value:
50 Means 4-5 V.
170 Means 15-16 V.

STEP LIGHT, SWITCH
page
–
Description: Signal from entry lighting switch.

DIAG LIGHTS 15(X)
STEP LIGHT
OUTPUT XXX
Function: 9.6.13 Entry lighting
008897
Signal value:
0 No signal.

8 Control system – 8.4.3 CAB 41
STEP LIGHT, OUTPUT

page
–
Description: Voltage feed to entry lighting.

Connection: digital out from D790-1/K11:6 to E433
Function: 9.6.13 Entry lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).
8.4.3 CAB
CAB, description
page
–
This group covers functions in the cab.

DIAGNOSIS
CLIMATE HYD ENGINE
005301
OLS EXTRA
8.4.3.1 CAB, menu 1

WASHER, SWITCH
page
–
Description: Signal from gearshift lever and multi-function lever switch

DIAG CAB 1(X) washer.
WASHER
SWITCH X Circuit diagram: Circuit 9.5-1
OUTPUT FRONT XY Connection: signal from S162/53C to digital in D790-2/K3:4
005541
OUTPUT REAR ROOF XY

Function: 9.5 Wiper/washer system
Signal value:
0 No signal.
WASHER FRONT, OUTPUT

page
–
Description: Voltage feed to windscreen washer motor

Connection: digital out from D790-1/K10:13 to M651-1
Function: 9.5.4 Washer motor and reservoir
Signal value:

signal is active.

42 8 Control system – 8.4.3.2 CAB, menu 2
WASHER REAR ROOF, OUTPUT

page
–
Description: Grounding of motor washer roof and rear window. The

motor is supplied with voltage parallel with Motor windshield washing,
activation is controlled by controlling grounding of the motor. The mo-
tor is grounded at windshield washing if the wiper motor roof or rear
window is activated.
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:

active.

8.4.3.2 CAB, menu 2

FRONT WIPER, SWITCH (1-3)
page
–
Description: Signal from multi-function lever, switch wiper function.

DIAG CAB 2(X)
FRONT WIPER
SWITCH (1-3) X Contact:
OUTPUT XY
X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6
005542
FEEDBACK X
X = 2 Interval less slow: signal from S162/J2, digital in
D790-2/K3:7
X = 3 Interval continuous: signal from S162/53, digital in
D790-2/K3:8
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.
FRONT WIPER, OUTPUT

page
–
Description: Voltage feed to wiper front.

Connection: digital out from D790-1/K2:1 to M650-1/53
Function: 9.5.5 Wiper motor front
Signal value:

8 Control system – 8.4.3.3 CAB, menu 3 43

signal is active.
FRONT WIPER, FEEDBACK

page
–
Description: Signal from motor wiper front, indicates when the wiper
sweep is completed.
Connection: signal from M650-1/31B to digital in D790-1/K4:13
Function: 9.5.5 Wiper motor front
Signal value:
1 Input signal active (wiper sweep).
0 No signal (home position).
8.4.3.3 CAB, menu 3

REAR WIPER, SWITCH
page
–
Description: Status of rear window wiper switch on Control unit KIT

DIAG CAB 3(X) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY Contact: -
005543
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.
REAR WIPER, OUTPUT

page
–
Description: Voltage feed to windshield wiper rear.

Function: 9.5.7 Wiper motor rear
Signal value:

signal is active.

REAR WIPER, FEEDBACK

page
–
Description: Signal from motor windshield wiper rear, indicates when

the wiper sweep is completed.
Connection: signal from M650-2/31b to digital in D790-1/K12:2
Function: 9.5.7 Wiper motor rear
Signal value:
8.4.3.4 CAB, menu 4

ROOF WIPER, SWITCH
page
–
Description: Signal from switch, wiper roof.

DIAG CAB 4(X)
Circuit diagram: -
ROOF WIPER
SWITCH X Contact: -
OUTPUT XY
005544
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.
ROOF WIPER, OUTPUT

page
–
Description: Voltage feed to wiper roof.

Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53
Function: 9.5.6 Wiper motor roof
Signal value:

active.


ROOF WIPER, FEEDBACK

page
–
Description: Signal from motor wiper roof, indicates when the wiper
sweep is completed.
Connection: signal from M650-3/31B to digital in D790-1/K12:4
Function: 9.5.6 Wiper motor roof
Signal value:
8.4.3.5 CAB, menu 5

HORN, SWITCH
page
–
Description: Signal from switch, horn.

DIAG CAB 5(X)
HORN
SWITCH X Connection: signal from S162/H to digital in D790-2/K3:2
SWITCH 2 X
005545
OUTPUT XY
Signal value:
0 No signal.
HORN, SWITCH 2
page
–
Description: Signal from horn switch on hydraulic control panel.

Connection: signal from S149-3 to digital in D790-1/K9:10
Signal value:
0 No signal.

HORN, OUTPUT
page
–
Description: Voltage feed to horn.

Circuit diagram: Circuits 9.7-1 and 9.7-3
Connection: digital out D790-1/K11:11 to H850 ( for compressor

horn, signal to relay K3016/86)
Function: 9.7.1 Horn
Signal value:

signal is active.
8.4.3.6 CAB, menu 6

BUZZER
page
–
Description: Voltage feed to buzzer for alarm indication panel, feed.

DIAG CAB 6(X)
BUZZER XY
SWITCH SEAT X Connection: digital out from D790-2/K8:4 to H853/1
ALARM X
Function: 9.3 Seats, 1 Engine, 8.2.1 Overload protection
005546
OP X
Signal value:

active.

SWITCH SEAT
page
–
Description: Signal from Sensor, operator-in-seat.

Connection: signal from S230/1 to D790-1/K11:14
Function: 9.3.14 Sensor operator in seat
1 Input signal active. Operator in seat.
0 No signal. No operator in seat.

ALARM
page
–
Description: Status for alarm indication panel, warning from control

system.
Circuit diagram: -
Contact: -
Function: 8.1.2 Information display
1 Conditions for activation of buzzer from seat switch and park-

ing brake are fulfilled.
0 Conditions for activation of buzzer are not fulfilled.
OP
page
–
Description: Status for overload protection warning from control

system.
Contact: -
Function: 8.2.1 Overload protection
Signal value:
1 Conditions for activation of buzzer fulfilled, that is, overload

system is indicating.
0 Conditions for activation of buzzer are not fulfilled.
8.4.3.7 CAB, menu 7

FUEL, SENSOR VALUE
page
–
Description: Signal from sensor fuel level.

DIAG CAB 7(X)
FUEL
SENSOR VALUE XXXohm Connection: analogue rheostat signal from B757 to D797-1/K2:15
PROC XXX
Function: 1.2.2 Sensor fuel level
009182
Signal value: XXXOHM = Current resistance value from sensor fuel

level in ohm.
FUEL, PROC
page
–
Description: Control system’s interpretation of signal from fuel tank

sensor.
Circuit diagram: -
Contact: -
Function: 1.2.2 Sensor fuel level
Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.

8.4.3.8 CAB, menu 8

SEAT HEATER, SWITCH
page
–
Description: Signal from seat heater switch.

DIAG CAB 8(X)
SEAT HEATER
OUTPUT XY
Function: 9.3 Seat
005548
Signal value:
0 No signal.
SEAT HEATER, OUTPUT

page
–
Description: Voltage feed to seat heating relay.

Connection: digital out from D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil
Signal value:

active.

8.4.4 CLIMATE
CLIMATE, description
page
–
This group covers the cab’s air conditioning.

DIAGNOSIS
CLIMATE HYD ENGINE
005302
OLS EXTRA

8 Control system – 8.4.4.1 CLIMATE, menu 1 49
8.4.4.1 CLIMATE, menu 1

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Set value for desired temperature.

DIAG CLIMATE 1(X)
REQUIRED TEMP XXX Connection: signal from S117/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
Function: 9.4 Heating, ventilation and air conditioning
005549
WATER VALVE FEEDB. XXX
Signal value: XXX = 160-280 = 16-28 C Preset temperature shown in
tenths of degrees and adjusted in increments of half degrees
(200 = 20 C). Test by increasing or decreasing temperature with the
temperature switch on the panel.
PRESENT INPUT SIGNAL, PRESENT TEMP

page
–
Description: Signal from sensor cab temperature.

Connection: signal from B775-1/2 to input D790-1/K4:8
Function: 9.4.17 Sensor cab temperature
Signal value: XXX = Cab’s interior temperature in tenths of degrees
(200 = 20 C).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

page
–
Description: Water valve’s position (opening in percent).

Connection: signal from Y673/9 to analogue in D790-1/K10:4
Function: 9.4.5 Water valve
Signal value: XXX = 0-100 = 0-100% = Water valve’s opening in %.
0 = Closed. 100 = Fully open.

TEMP COIL
page
–
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(X) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit 9.4-1
TEMP AMBIENT XXX Connection: signal from B775-2 to input D790-1/K4:10
005550
TEMP DE-ICE XXX

Function: 9.4.16 Sensor, temperature outlet fan
Signal value: XXX = Temperature of the air blown into the cab in tenths
of degrees (200 = 20 C).

50 8 Control system – 8.4.4.3 CLIMATE, menu 3
TEMP COOLANT
page
–
Description: Coolant temperature (temperature of the engine’s cool-

ant). Signal is retrieved from the engine via CAN bus drivetrain.
Circuit diagram: Circuits 9.4-1, 9.4-2
Connection: from engine via CAN bus, see PRESENT INPUT SIG-
NAL, COOLANT TEMP page 66.
Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees
(200 = 20 C).
TEMP AMBIENT
page
–
Description: Outdoor temperature. Heat radiation from engine and sun

may affect the value since the sensor is installed on the rear of the cab
roof.
Connection: signal from B774/2 to input D790-1/K4:9
Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees
(200 = 20 C).
TEMP DE-ICE
page
–
Description: Temperature in refrigerant circuit.

Connection: signal from B775-3/2 to input D790-1/K4:11
Function: 9.4.12 Sensor temperature refrigerant
Signal value: XXX = Refrigerant temperature in tenths of degrees
(200 = 20 C).

PRESENT INPUT SIGNAL, PRESSURE SWITCH
page
–
Description: Signal from refrigerant pressure monitor.

DIAG CLIMATE 3(X)
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-1/K1:40
Function: 9.4.10 Pressure switch
005551
Signal value:
1 Input signal active. Press Ok.
0 No signal, too high or too low pressure.


PRESENT INPUT SIGNAL, WATER VALVE
page
–
Description: Signal from water valve, the voltage is a measure of the

DIAG CLIMATE 4(X) position.
WATER VALVE XX.XXV Circuit diagram: Circuit 9.4-2
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4
005552
Signal value: XX.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, DRAUGHT VALVE

page
–
Description: Signal from the engine to the air distributor. Voltage is a

measure of the valve’s position.
Connection: signal from Y672/9 to analogue in D790-1/K4:7
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Signal from switch temperature. Voltage when switch is

DIAG CLIMATE 5(X) pressed in voltage level indicates increase or decrease of the
PRESENT INPUT SIGNAL temperature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit 9.4-1
005553
REQ. FAN SPEED XX.XXV Connection: signal from S117/3 to analogue in D790-1/K5:8
Signal value: XX.XXV  2.4 / 0 / 5.0 V = Increase / - / decrease.
PRESENT INPUT SIGNAL, REQ. DRAUGHT

page
–
Description: Signal from switch air distribution, voltage when switch is

pressed in. The voltage level indicates change of air control against
windshield (up) or floor (down). The valve’s position changes in steps
between windshield - floor.
Connection: signal from S139/3 to analogue in D790-1/K5:9
Signal value: XX.XXV  2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, FAN SPEED

page
–
Description: Signal from switch fan speed, switch controls increase or

decrease of fan speed. Speed is endless adjustable. The voltage level
indicates if the speed should be increased or decreased.
Connection: signal from S118/3 to analogue in D790-1/K5:7
Signal value: XX.XXV  2.4 / 0 / 5.0 V = Increase / - / decrease.


PRESENT OUTPUT SIGNAL, FAN SPEED
page
–
Description: Current control of fan motor, speed is controlled with

DIAG CLIMATE 6(X) PWM-control of grounding (of fan motor).
FAN SPEED XXX Circuit diagram: Circuit 9.4-2
RECIRCULATION XY Connection: analogue out from D790-1/K2:2 to M657/31
013616
COMPRESSOR XY
Function: 9.4.3 cab fan.
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
PRESENT OUTPUT SIGNAL, RECIRCULATION

page
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Description: Voltage feed to motor for fresh air and recirculation

damper.
Connection: digital out from D790-1/K2:3 to M612
Function: 9.4.2 Fresh air and recirculation damper
Signal value:

signal is active.
PRESENT OUTPUT SIGNAL, COMPRESSOR

page
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Description: voltage feed of AC compressor’s electromagnetic clutch.

Controls cut-in and cut-out of the compressor. Two outputs are con-
nected in parallel to handle the current.
Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645
Function: 9.4.7 Compressor
Signal value:

active.



OUTPUT WATER VALVE, CLOCKWISE
page
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Description: voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(X) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing are control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temperature, cab temperature and coolant
temperature, so it may be difficult to determine if the valve is working
as it should.
24V
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

005555
0V circuiting can only be detected when the output signal is

H-bridge active.

OUTPUT WATER VALVE, ANTI-CLOCKWISE

page
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Description: voltage feed to water valve, for closing. The valve is con-
nected to an H-bridge. The signal can only be diagnosed when the
valve’s position changes. The valve’s opening and closing are control-
led by the climate control unit’s software depending on desired tem-
perature, outside temperature, cab temperature and coolant
temperature, so it may be difficult to determine if the valve is working
as it should.
D790-1/K4:2 via R4 to Y673/6
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

active.



OUTPUT DRAUGHT VALVE, CLOCKWISE
page
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Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(X) wise. Is connected to an H-bridge. Signal can only be diagnosed when
OUTPUT DRAUGHT VALVE the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit 9.4-2
D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
M 01 No output signal, circuit OK or short-circuiting. Short-

active.

005556
0V 11 Output signal active, circuit OK or open circuit. Open circuit

H-bridge can only be detected when the output signal is active.
OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE

page
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Description: Voltage feed to motor for the air distributor, rotation coun-
ter-clockwise. The motor is connected to an H-bridge. Signal can only
be diagnosed when the air distributor’s position changes.
D790-1/K4:4 via R6 to Y672/6
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

active.

8.4.5 HYD
HYD, description
page
–
This group covers the hydraulic functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005303
OLS EXTRA

8 Control system – 8.4.5.1 HYD, menu 1 55
8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
page
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Description: Signal from sensor hydraulic oil temperature.

DIAG HYDRAULIC 1(X)
HYDRAULIC OIL
TEMP XXX Connection: signal from B776/1 to temperature in D797-1/K2:13
FAN XY
Function: 10.6.4 Sensor hydraulic oil temperature
010070
SET OUTPUT + - X
Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
HYDRAULIC OIL, FAN

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Description: Voltage feed cooling fan hydraulic oil.

Connection: digital out from D797-1/K1:14 to M668/1
Function: 10.6.3 Cooling fan
Signal value:
HYDRAULIC OIL, SET OUTPUT +/-

page
–
Description: Functionality test of hydraulic oil cooling fan.

Connection: digital out from D797-1/K1:14 to M668/1 is activated or
deactivated with +/-
Signal value:

signal is active.
8.4.5.2 HYD, menu 2

BRAKE COOLANT OIL, TEMP
page
–
DIAG HYDRAULIC 2(X)

BRAKE COOLANT OIL
TEMP XXX
FAN XY FEEDBACK X
010071
SET OUTPUT + - X
Menu for DCF360-450CSG

Description: Signal from sensor brake oil temperature.
DIAG HYDRAULIC 2(X)
BRAKE COOLANT OIL
TEMP XXX Connection: signal from B772/1 to temperature in D797-1/K2:6
FAN XY
Function: DCF360-450CSG 4.8.10 Brake oil temperature sensor,
010072
SET OUTPUT + - X
DCF-80-100 4.8.10 Hydraulic oil temperature sensor
Menu for DCF 280-520 and DCF 80-100 Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).

56 8 Control system – 8.4.5.2 HYD, menu 2
BRAKE COOLANT OIL, FAN

page
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Description: voltage feed to cooling fan for brake system oil.

Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1
Signal value:
BRAKE COOLANT OIL, FEEDBACK

page
–
Description: signal from cooling fan for brake system oil.

Connection: signal from M674/1 to D797-1/K1:23
Signal value:
BRAKE COOLANT OIL, SET OUTPUT +/-

page
–
Description: voltage feed to cooling fan for brake system oil.

Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1 is
activated or deactivated with +/-
Signal value:

active.


8.4.5.3 HYD, menu 3

HYDRAULIC PRESSURE, LIFT CYLINDER
page
–
Description: Pressure on lift cylinders’ piston side (C+). For voltage

DIAG HYDRAULIC 3(X) value, see PRESENT INPUT SIGNAL, LIFT CYLINDER page 144.
HYDRAULIC PRESSURE
LIFT CYLINDER XXX Connection: signal from B768-1/3 to analogue in D797-1/K1:21
TILT CYLINDER XXX
Function: 7.2.8 Sensor hydraulic pressure lift cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa.
C- (255 = incorrect signal.)
C+
007239
HYDRAULIC PRESSURE, TILT CYLINDER

page
–
Description: Pressure on the tilt cylinders’ rod side (C-). For voltage
value, see PRESENT INPUT SIGNAL, TILT CYLINDER page 144.
Connection: signal from B768-2/3, analogue in D797-1/K1:22
Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa.
(255 = incorrect signal.)
8.4.5.4 HYD, menu 4

PRESSURE SWITCHES, BRAKE PRESSURE
page
–
Description: Signal from brake pressure NC switch.

DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: signal from S204/2 to analogue in D797-1/K1:13
BRAKE LIGHT PRESS. X
Function: 4.3.7 Normally open (NO) switch, brake pressure
007240
DECLUTCH PRESSURE X
Signal value:
0 No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESSURE

page
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Description: Signal from make-contact (closing switch) brake lights.

Connection: signal from S216/2 to digital in D797-1/K1:20
Function: 4.3.8 Make-contact (closing switch) brake lights
Signal value:
0 No signal.

PRESSURE SWITCHES, DECLUTCH PRESSURE

page
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Description: Signal from normally closed (NC) switch, disengagement.

Connection: signal from S220-2/2 to analogue in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:
0 No signal.
8.4.5.5 HYD, menu 5

P-BRAKE, SWITCH
page
–
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit 4.0-1
007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from

S107/7 to digital in D790-1/K8:5
Function: 4.5 Parking brake system
Signal value:
1/0 Open, parking brake released.
0/1 On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH

page
–
Description: Signal from break-contact (opening switch) parking

brake.
Connection: signal from S200 to analogue in D797-1/K1:41
Function: 4.5.5 Normally open (NO) switch, parking brake
Signal value:
0 No signal.

P-BRAKE, VALVE
page
–
Description: Voltage feed to parking brake solenoid valve.

Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1
Function: 4.5.3 Solenoid valve parking brake
Signal value:

active.

8.4.5.6 HYD, menu 6

CUT OFF HYDRAULIC PUMPS, PUMP 2
page
–
Description: Voltage feed to solenoid valve for disconnection of the hy-

DIAG HYDRAULIC 6(X) draulic pump
CUT OFF HYDRAULIC
PUMPS Circuit diagram: Circuit 10.4-1
PUMP 2 XY Connection: digital out from D797-1/K1:39 to solenoid valve Y6062
007242
PUMP ATTACHMENT XY
Function: 10.4.3 Vane pump with fixed displacement
Signal value:

active.


CUT OFF HYDRAULIC PUMPS, PUMP ATTACHMENT

page
–
Description: Voltage feed to solenoid valve for disconnection of the hy-

draulic pump for the attachment.
Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:

active.

8.4.5.7 HYD, menu 7

PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, VALVE
page
–
Only applies to DCF 80-100

DIAG HYDRAULIC 7(X)
Description: voltage feed to solenoid valve for quick-lift pump.
EXTRA HYD PUMP Circuit diagram: 10.4-1
VALVE XY
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062
010073
SET OUTPUT + - X
Signal value:
1 Output signal active.
0 No output signal.
PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, SET

page
–
OUTPUT +/-
Description: Activate or deactivate the quick-lift pump.
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062 is
activated or deactivated with +/-
Signal value:
0 No output signal.

8.4.5.8 HYD, menu 8

PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM.
page
–
VALVE
Only applies to DCF 70, DCF 80-100
DIAG HYDRAULIC 8(X)
Description: Voltage feed to solenoid valve for main pump relief (pres-
PRESSURE TO ATTACHM. surised attachment).
VALVE XY Circuit diagram: 10.4-1
010074
SET OUTPUT + - X
Signal value:
0 No output signal.
PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM,

page
–
SET OUTPUT +/-

Description: Begin sending or cut off hydraulic pressure to the
attachment.
is activated or deactivated with +/-
Signal value:
0 No output signal.
8.4.6 ENGINE
ENGINE, description
page
–
This group covers engine functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005306
OLS EXTRA
8.4.6.1 ENGINE, menu 1

PRESENT INPUT SIGNAL, ACCELERATOR
page
–
Description: Signal from accelerator pedal.

DIAG ENGINE 1(X)
ACCELERATOR X.XXV Connection: signal from B690-1/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX
Function: 1 Engine
008898
REQUIRED SPD RPM XXXX

Signal value: X.XXV = 0.50 - 4.50 V

62 8 Control system – 8.4.6.2 ENGINE, menu 2
PRESENT INPUT SIGNAL, REQUIRED SPD PROC

page
–
Description: Required engine speed (in percent) which is sent from

Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus
drive-train.
Circuit diagram: -
Contact: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0 - 100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM

page
–
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Contact: -
Signal value: XXXX = 0-2010 rpm

RESENT INPUT SIGNAL, ENGINE SPEED EDC
page
–
Description: Engine speed from Control unit, engine (D794) to Control

DIAG ENGINE 2(X) unit, cab (D790-1) via CAN bus drive-train. Actual value for engine
PRESENT INPUT SIGNAL speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
005308
Contact: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = active speed in rpm.
PRESENT INPUT SIGNAL, ENGINE SPEED TCU

page
–
Description: Engine speed from Control unit, transmission (D793) to

Control unit, cab (D790-1) via CAN bus drive-train. Actual value for en-
gine speed engine.
Circuit diagram: -
Contact: -
Function: 2.2.5 Sensor engine speed and oil temperature transmission
Signal value: XXXX = active speed in rpm.

PRESENT INPUT SIGNAL, PRESENT TORQUE
page
–
Description: Current torque from engine control unit (D794). Percent-

DIAG ENGINE 3(X) age torque use of engine’s capacity.
PRESENT TORQUE XXX Circuit diagram: -
REQUIRED TORQUE XXX Contact: -
005309
PRES TORQUE @ RPM XXX

Signal value: XXXX = 0 - 100%

8 Control system – 8.4.6.4 ENGINE, menu 4 63
PRESENT INPUT SIGNAL, REQUIRED TORQUE

page
–
Description: Requested torque from cab control unit (D790-1) to en-

gine control unit (D794).
Circuit diagram: -
Contact: -
Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, PRES TORQUE @ RPM

page
–
Description: available torque at current engine speed.

Circuit diagram: -
Contact: -
Signal value: XXX = 0-100%

PRESENT INPUT SIGNAL, PREHEAT SWITCH
page
–
DIAG ENGINE 4(X)

PRESENT INPUT SIGNAL Description: Signal from ignition, preheating position. Only used on
PREHEAT SWITCH X machines with Volvo engines.
CRANK ENGINE SWITCH X
005310
D+ X
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

page
–
Description: Signal from ignition, start position.

Function: 1.1.1 Ignition switch, 1.11 Start and stop
Signal value:
0 No signal.

PRESENT INPUT SIGNAL, D+

page
–
Description: Signal from alternator, indicates if alternator supplies

current.
Circuit diagram: Circuits 11.5-1, 1.0-2A, 1.0-1
Connection: signal from G660/D+ to digital in D797-1/K2:16
Function: 11.4.1 Alternator
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, PREHEAT
page
–
Description: Status for preheating of induction air.

DIAG ENGINE 5(X)
Circuit diagram: -
PREHEAT X Contact:
CRANK ENGINE CAN X
Volvo: software signals on CAN-bus drivetrain
007639
CRANK ENGINE WIRE XY

Cummins: controlled by engine’s control system
Function: 1.10.1 Preheating
Signal value:
0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE CAN

page
–
Description: Voltage feed, starter motor. For Volvo TAD760VE,

TAD950VE, TAD952VE and TAD1250VE.
Circuit diagram: -
Connection: software signals on CAN-bus drivetrain
Function: 1.11 Start and stop
Signal value:
0 No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE

page
–
Description: Voltage feed to starter motor relay. For Cummins QSM11.

Circuit diagram: 1.0-1, 1.0-2B1
Connection: digital out D797-1/K1:32 to K360/86.
Function: 1.11 Start and stop
Signal value:

active.


PRESENT INPUT SIGNAL, OIL PRESSURE
page
–
Description: Engine oil pressure. CAN-bus message from Control unit,

DIAG ENGINE 6(X) engine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XX.X Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XX.X Contact:
008899
OIL LEVEL XXX

Volvo TAD760VE: signal from "2 oil pressure sensor" to engine
control unit (D794) "Connector B" sleeve 11
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "28 oil
temperature and oil pressure sensor" to engine control unit (D794)
"Connector B" sleeve 11
Cummins QSM11: signal from "Oil pressure/temperature sensor"
to Control unit, engine (D794) "Sensor connector" socket 44
Function: 1.8.3 Sensor oil pressure engine
Signal value= XX.X = pressure in bar.
PRESENT INPUT SIGNAL, BOOST PRESSURE

page
–
Description: Boost pressure. CAN-bus message from Control unit, en-

gine (D794) to Control unit, cab (D790-1).
Circuit diagram: see supplier documentation, engine
Contact:
Volvo TAD760VE: signal from "33 charge air pressure sensor" to
engine control unit (D794) "Connector A" sleeve 22
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "23
charge air pressure/temperature sensor" to engine control unit
(D794) "Connector A" sleeve 22
Cummins QSM11: signal from "Intake manifold (boost) pressure
sensor" to Control unit, engine (D794) "Sensor connector"
socket 39
Function: 1.6.5 Sensor boost pressure

Signal value= XX.X = pressure in bar.
PRESENT INPUT SIGNAL, OIL LEVEL

page
–
Only Volvo TAD950VE, TAD952VE and TAD1250VE engines

Description: Oil level engine. CAN-bus message from Control unit, en-
gine (D794) to Control unit, cab (D790-1).
Connection: Volvo TAD950VE, TAD952VE, TAD1250VE: signal from
"15 Oil level sensor" to engine control unit (D794) "connector A"
sleeve 3
Function: -
Signal value: XXX = 0-100 = 0-100% = Oil level in percent.

PRESENT INPUT SIGNAL, OIL TEMP
page
–
Description: Temperature engine oil. CAN-bus message from Control

DIAG ENGINE 7(X) unit, engine (D794) to Control unit, cab (D790-1).
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Contact:
005313
INTAKE MAIN.TEMP XXX

Volvo TAD760VE: signal from "1 oil temperature/level sensor" to
engine control unit (D794) "connector A" sleeve 31
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "28 oil
temperature/pressure sensor" to engine control unit (D794) "Con-
nector A" sleeve 31
Cummins QSB6.7 and QSM11: signal from "oil pressure/temper-
ature sensor" sleeve 4 to engine control unit (D794) "sensor con-
nector" sleeve 42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 corresponds to 20 C.
PRESENT INPUT SIGNAL, COOLANT TEMP

page
–
Description: Temperature coolant. CAN-bus message from Control

unit, engine (D794) to Control unit, cab (D790-1).
Contact:
Volvo TAD760VE: signal from "4 coolant temperature sensor" to
engine control unit (D794) "Connector B" sleeve 27
Coolant temperature sensor" to engine control unit (D794) "con-
nector B" sleeve 27
Cummins QSM11: signal from "Coolant temperature sensor" to
Control unit, engine (D794) "Sensor connector" socket 02
Function: 1.7.9 Sensor coolant temperature

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

page
–
Description: Temperature charge-air. CAN-bus message from Control

unit, engine (D794) to Control unit, cab (D790-1).
Contact:
Volvo TAD760VE: signal from "34 charge air pressure/tempera-
ture sensor" to engine control unit (D794) "connector A" sleeve 47
Charge air pressure/temperature sensor" to engine control unit
(D794) "Connector B" sleeve 47
Cummins QSM11: signal from "Intake manifold /(Boost) tempera-
ture sensor" to Control unit, engine (D794) "Sensor connector"
sleeve 38
Function: 1.6.6 Sensor charge-air temperature

PRESENT EDC ERROR, NO. OF ACT ERROR
page
–
Description: Number of error codes from engine control unit EDC

DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Contact: -
005314
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
PRESENT EDC ERROR, SPN

page
–
Description: SPN number for the first error code from Control unit, en-
gine (D794). SPN indicates the malfunction area, i.e., what component
or signal is defective. Error codes are shown using SPN/FMI in the er-
ror code menus.
Circuit diagram: -
Contact: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
PRESENT EDC ERROR, FMI

page
–
Description: FMI number for the first error code from the engine control
unit (D794). FMI indicates error type, e.g., short circuit or low value. Er-
ror codes are shown with SPN/FMI in error code menus.
Circuit diagram: -
Contact: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.


FUEL CONSUMPTION, MOMENTARY l/h
page
–
Description: Current fuel consumption in litres/hour.

DIAG ENGINE 9(X)
Circuit diagram: -
FUEL CONSUMPTION
MOMENTARY l/h XXX Contact: -
Function: 1.2 Fuel system
005315
Signal value: XXX = fuel consumption in l/h.

Not used.
page
–
DIAG ENGINE 10(X)

011268
8.4.6.11 ENGINE CCT, menu 11

ACTIVE ALARM
page
–
Description: shows active alarms from the CCT system control unit
DIAG ENGINE CCT 11(X) (D797-P).
ACTIVE ALARM X
ACTIVE WARNING X Circuit diagram: -
Contact: -
011269
Function: 1.3 Additional exhaust cleaning system

Signal value: -
ACTIVE WARNING
page
–
Description: shows active warnings from the CCT system control unit
(D797-P).
Circuit diagram: -
Contact: -
Signal value: -

FUEL PUMP
page
–
Description: signal to/from fuel pump (M385).

DIAG ENGINE CCT 12(X)
Circuit diagram: Circuit 3
FUEL PUMP X
AIR PUMP X Connection: signal from M385-1/2 to analogue in D790-1/K6:11
FLUSH VALVE XXXX
011270
FUEL INJECTOR XXXX

Signal value:
0 Home position.
1 Active.

8 Control system – 8.4.6.13 ENGINE CCT, menu 13 69
AIR PUMP
page
–
Description: signal to/from air compressor (M358).

Connection: signal from M358-A/B on
Signal value:
0 Home position.
1 Active.
FLUSH VALVE
page
–
Description: current status for the flush valve’s output signal.

Circuit diagram: -
Contact: -
Signal value:
0 Home position.
>0 Active.
FUEL INJECTOR
page
–
Description: current status for injector’s output signal.

Circuit diagram: -
Contact: -
Signal value:
0 Home position.
>0 Active.

DURATION TIMER
page
–
Description: time remaining to complete the regeneration phases.

DIAG ENGINE CCT 13(X)
Circuit diagram: -
DURATION TIMER XXXX
INTERVAL TIMER XXXX Contact: -
SOOT PRESSURE XXX
011271
ASH PRESSURE XXX

Signal value: XXX = Seconds (s)

70 8 Control system – 8.4.6.14 ENGINE CCT, menu 14
INTERVAL TIMER
page
–
Description: time in minutes to the next regeneration.

Circuit diagram: -
Contact: -
Signal value: XXXX = Minutes (min)
SOOT PRESSURE
page
–
Description: part of the exhaust overpressure in relation to the soot

quantity in the particulate filter.
Circuit diagram: -
Contact: -
Signal value: XXX = %
ASH PRESSURE
page
–
Description: part of the exhaust overpressure in relation to the ash

quantity in the particulate filter.
Circuit diagram: -
Contact: -
Signal value: XXX = %

EXHAUST PRES.
page
–
Description: signal from the exhaust back pressure sensor (B7236),

DIAG ENGINE CCT 14(X) exhaust back pressure at the inlet (sensor display = shows 0 mbar in
EXHAUST PRES. XXX normal atmosphere). Used to monitor soot quantity in the particulate
DOC INLET TEMP XXX filter.
DOC OUTLET TEMP XXX
011272
AIR PRESSURE XXXX Circuit diagram: Circuit 3

Connection: signal from B7236-1 to digital in D797-1/27 or Fuel injec-
tion 2 and from B7236-2/3 to digital in D797-1/42 and 23
Signal value: XXX = mbar (G)
DOC INLET TEMP

page
–
Description: temperature in °C sent from exhaust gas temperature

sensor before the catalytic converter (B7235BC) via the CAN bus to
the Gateway CCT control unit (D797-P). Used to check injection dur-
ing regeneration.
Connection: signal from B7235BC-1/2 to digital in D797-P/10 and 38.
Signal value: XXX = °C

8 Control system – 8.4.6.15 ENGINE CCT, menu 15 71
DOC OUTLET TEMP

page
–
Description: temperature in °C sent from exhaust gas temperature

sensor after the catalytic converter (B7235AC) via the CAN bus to the
Gateway CCT control unit (D797-P). Used to check injection during
regeneration.
Connection: signal from B7235AC-1/2 to digital in D797-P/11 and 24.
Signal value: XXXX = °C
AIR PRESSURE
page
–
Description: back pressure measured in the injection block. (Absolute

actuation shows = 1013 mbar at atmospheric pressure). Used to mon-
itor the air/fuel flow in the injection nozzle.
Circuit diagram: -
Contact: -
Signal value: XXXX = mbar (A)

FUEL PRESS.
page
–
Description: pressure generated by the fuel pump (mbar). (Absolute

DIAG ENGINE CCT 15(X) actuation = shows 1013 mbar at atmospheric pressure). Used to mon-
FUEL PRESS. XXXX itor the fuel pump’s function and flow through the injection nozzle.
CURRENT STATE XXXX
SYSTEM INFO XXXX Circuit diagram: Circuit 3
011273
SYSTEM INSTALL XXXX Connection: signal from the fuel pressure sensor in the injection block
of the CCT system control unit (D797-P).
Signal value: XXXX = mbar (A)
CURRENT STATE
page
–
Description: actual condition

Circuit diagram: -
Contact: -
Signal value:
11,12,13: Not used
21: Injection init
22: Injection manifold
23: Injection active
31: Flush unit
32: Flush manifold
33: Flush active

72 8 Control system – 8.4.6.15 ENGINE CCT, menu 15
SYSTEM INFO
page
–
Description: further information for "Current state". Indicates success-

ful or failed regenerations etc.
Circuit diagram: -
Contact: -
Signal value:
0 No info 11 Abort: INJ error

1 Complete: Time duration 12 Abort: Air pressure error
2 Complete: Temp integral 13 Abort: Fuel pressure error
3 Abort: Activation switch 14 Waiting: Disable switch
4 Abort: Disabled switch 15 Waiting: DOC inlet temp
5 Abort: DOC inlet temp under 16 Waiting: HC smoke temp
time
6 Abort: DOC outlet temp un- 17 Waiting: H2O smoke temp
der time
7 Abort: DOC inlet under temp 18 Waiting: Start switch
8 Abort: DOC outlet over temp 19 Waiting: System errors
9 Abort: Speed under time 20 Waiting: Activation switch
10 Abort: EGR error 21 Waiting: Installation
SYSTEM INSTALL
page
–
Description: indicates whether the system is functional or if further in-

stallation is required.
The system is fully functional when the text "System installed" is
shown, if the text is not shown then press ENTER to start re-installa-
tion. Follow the instructions in the display, if the text FAILURE is
shown then the installation must be restarted.
Circuit diagram: -
Contact: -
Signal value:
No. Text Action

0 System installed The installation is finished or deactivated.
1 System not Installation required, but not started or
installed finished.
2 Installation failed Installation started but not finished.

8 Control system – 8.4.7 TRANSM 73
8.4.7 TRANSM
TRANSM, description
page
–
This group covers transmission functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005324
OLS EXTRA
8.4.7.1 TRANSM, menu 1

PRESENT INPUT SIGNAL, BRAKE PEDAL
page
–
Description: Not used.
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

page
–
Description: Signal from declutch pedal.

DIAG TRANSM. 1(X)
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
Function: 2 Transmission
005325
DECLUTCH PRESS SW. X

Signal value:
1 Input signal active. Declutch pedal pressed down.
0 No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

page
–
Description: Signal from normally closed (NC) switch, disengagement

(pressure switch).
Connection: signal from S220-2/2 to digital in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:
0 No signal.

74 8 Control system – 8.4.7.2 TRANSM, menu 2

SWITCHES, FORWARD
page
–
Description: Signal from gearshift lever and multi-function lever

DIAG TRANSM. 2(X) (forward).
SWITCHES
FORWARD X Circuit diagram: Circuit 2.0-1
REVERSE X Connection: signal from S162/F to digital in D790-2/K3:11
005326
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction forward selected.
0 No signal.
SWITCHES, REVERSE
page
–
Description: Signal from gearshift lever and multi-function lever

(reverse).
Connection: signal from S162/R to digital in D790-2/K3:12
Signal value:
1 Input signal active. Travel direction reverse selected.
0 No signal.
SWITCHES, SHIFT MODE

page
–
Description: Signal from shifting program switch. Status on CAN bus

from KIT control unit (D790-2). The switches are integrated in the KIT
Circuit diagram: -
Contact: -
Signal value:
1 Shifting program 1 selected.
2 Shifting program 2 selected.
4 Automatic shifting selected.

8 Control system – 8.4.7.3 TRANSM, menu 3 75

PRESENT VALUE, FORWARD
page
–
Description: Status for forward direction of travel from transmission

DIAG TRANSM. 3(X) control unit (D793). Indicates if forward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
REVERSE X Circuit diagram: -
005327
GEAR X Contact: -
Signal value:
1 Output signal for travel direction forward active.
0 No output signal.
PRESENT VALUE, REVERSE

page
–
Description: Status for rearward direction of travel from transmission

control unit (D793). Indicates if rearward drive is activated in the
transmission.
Circuit diagram: -
Contact: -
Signal value:
1 Output signal for travel direction reverse active.
0 No output signal.
PRESENT VALUE, GEAR

page
–
Description: Current gear, status from transmission control unit

(D793). Shows which gear is activated in the transmission.
Circuit diagram: -
Contact: -
Signal value: X = current gear.

OPERATING STATE, AUT/MAN MODE
page
–
Description: Shows which shifting program is selected automatic or

DIAG TRANSM. 4(X) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Contact: -
005328
OPERATING MODE X
Signal value:
1 Automatic.
0 Manual.

OPERATING STATE, WARNING

page
–
Description: Warning for serious malfunction in transmission from

Control unit, transmission (D793).
Circuit diagram: -
Contact: -
Signal value:
1 Active error.
0 No errors.
OPERATING STATE, OPERATING MODE

page
–
Description: Operating mode status for transmission control unit

(D793); also shown in control unit display.
Circuit diagram: -
Contact: -
Signal value:
0 Not used.
1 Manual or automatic shifting, standard mode shown during

operation.
2 Not used.
3 Not used.
4 Limp home, reduced capacity due to malfunction in

transmission.
5 Shut down, serious transmission malfunction control unit

shuts down, likely that malfunction cannot be shown as
CAN-bus.
6 Calibration of transmission in progress.

OPERATING STATE, SHIFT IN PROGRESS
page
–
Description: Status for transmission function during operation, shifting

DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Contact: -
005329
OLD FAULT X
Signal value:
1 Shifting in progress.
0 No activity.

OPERATING STATE, FAULT

page
–
Description: Status for transmission’s function during operation, active

error codes present.
Circuit diagram: -
Contact: -
Signal value:
1 Active error code.
0 No error codes.
OPERATING STATE, OLD FAULT

page
–
Description: Status for transmission’s function during operation, there

are inactive error codes that have not been acknowledged.
Circuit diagram: -
Contact: -
Signal value:
1 There are inactive error codes that have not been

acknowledged.
0 No unacknowledged error codes.

DRUM SPEED
page
–
Description: Signal from sensor rpm drum (position 1).

DIAG TRANSM. 6(X)
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B752 till D793/B3 and D793/C3
ENGINE SPEED XXXXHz
Function: 2.3.7 Sensor rpm drum
TURBINE SPEED XXXXHz
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
1 2 3
of teeth on drum gear.
5
005330
4
1. Sensor rpm drum (B752)
2. Temperature switch, torque converter (S221)
3. Sensor, engine speed and transmission tempera-
ture (B758/766)
4. Sensor rpm turbine transmission (B751)
5. Sensor rpm output shaft (B758)

OUTPUT SPEED
page
–
Description: Signal from sensor rpm output shaft (propeller shaft)

(position 5).
Connection: signal from B758 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
of teeth on output shaft’s gear.
ENGINE SPEED
page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
Connection: signal from B758/766 to D793/H3
Function: 2.2.5 Sensor engine speed and oil temperature transmission
of teeth on input shaft’s gear.
TURBINE SPEED
page
–
Description: signal from sensor rpm turbine transmission (position 4).

Connection: signal from B751 to D793/ R2
Function: 2.3.6 Sensor rpm turbine
of teeth on turbine’s gear.

OUTPUT STATUS, RSP DRIVE
page
–
Description: Status high and low side for control of solenoid valve RSP
DIAG TRANSM. 7(X) Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit 2.0-2A3
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
005331
1/3 VFS SELECTION X

11 Activated high and low side.
10 High side activated, low side no signal.
01 High side no signal, low side activated.
00 No signal.

OUTPUT STATUS, 2/4 VFS SELECTION

page
–
Description: Status of feed to solenoid valve VFS 2ND/4TH.

Connection: digital out from D793/ D1 and D793/ E1 to Y6069
Signal value:
1 Activated.
0 No signal.
OUTPUT STATUS, 1/3 VFS SELECTION

page
–
Description: Status of feed to solenoid valve VFS 1 ST/3 RD.

Connection: signal from D793/ H1 and D793/ J1 to Y6067
Signal value:
1 Activated.
0 No signal.

FWD SUPPLY
page
–
Description: Status for control current to clutch pack forward.

DIAG TRANSM. 8(X)
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/B1 to Y630
2/4 SUPPLY X
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
005332
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
REV SUPPLY
page
–
Description: Status for control current to clutch pack reverse.

Connection: signal from D793/F1 to Y631
transmission
Signal value:
1 Activated.
0 No signal.

2/4 SUPPLY
page
–
Description: Status for control current to clutch pack 2/4.

Connection: signal from D793/E2 to Y6074
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY
page
–
Description: Status for control current to clutch pack 1/3.

transmission
Signal value:
1 Activated.
0 No signal.

FWD FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack

DIAG TRANSM. 9(X) forward.
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Circuit diagram: Circuit 2.0-2A3
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 to Y630
005333
1/3 FEEDBACK XXXXmA

transmission
Signal value: XXXX = Measured value in mA.
REV FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack

reverse
transmission

2/4 FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack 2/4.

Connection: signal from D793/D1 to Y6069
transmission
1/3 FEEDBACK
page
–
Description: Present control current to solenoid valve clutch

assembly 1/3.
Connection: signal from D793/H1 to Y6067
transmission

PRESENT SENSOR INPUT, PRESS FEEDB.
page
–
Description: Signal from sensor oil pressure in transmission. The

DIAG TRANSM. 10(X) transmission uses a pressure-sensitive make-contact and two resis-
PRESENT SENSOR INPUT tors in the cable harness to generate different voltage levels.
PRESS FEEDB XXXXohm
TRANSM.TEMP XXXXXmV Circuit diagram: Circuit 2.0-2A2
008900
CONV OUT TEMP XXXXXmV Connection: signal from "pressure feedback sensor" to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:
0-1000 mV Short-circuiting to ground.
1500-2500 mV Oil pressure is correct.
2500-4000 mV Oil pressure is low.
4500-8000 mV Open circuit.
Over 8000 mV Short circuit to voltage.
PRESENT SENSOR INPUT, TRANS.TEMP

page
–
Description: Signal from sensor transmission oil temperature.

Connection: signal from B758/766 to D793/H3
Function: 2.7.2 Sensor engine rpm and oil temperature transmission
Signal value: XXXX mV = signal voltage in mV (0-5000 mV).

PRESENT SENSOR INPUT, CONV. OUT TEMP

page
–
Description: signal from oil temperature sensor out from the transmis-
sion to the radiator. The transmission uses a temperature-sensitive
make-contact (closing switch) and two resistors in the cable harness
to generate different voltage levels.
Connection: signal from S221 to D793/J3
Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
0 mV Transmission oil has operating temperature.
2500 mV Transmission oil temperature is low.

AXLE RATIO
page
–
Description: Drive axle gear ratio.

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
AXLE RATIO XXXXX Contact: -
RADIUS XXXX
005335
Signal value: XXXXX = drive axle’s total gear ratio x 1024.
RADIUS
page
–
Description: Drive wheels’ radius.

Circuit diagram: -
Contact: -
Signal value: XXXX = Drive wheels’ radius in mm.

SPEED LIMIT, CAB
page
–
Description: Speed limitation from D790-1, e.g. emergency stop

DIAG TRANSM. 12(X) switch activated, reversible driver’s seat out of position or constant
SPEED LIMIT speed limitation.
SPD GEAR LOG
CAB XX X XX Circuit diagram: -
005336
FRAME XX X XX Contact: -
Function: 8.2.3 Speed limitation
Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed
limitation.

SPEED LIMIT, FRAME

page
–
Description: Speed limitation from D797-1 or D797-2, e.g. cab tilted,

load not in transport position during transport.
Circuit diagram: -
Contact: -
Function: 8.2.3 Speed limitation
Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed
limitation.

ACT ERROR AREA
page
–
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(X) ror code. In case of several error codes, the most serious error code
ACT ERROR AREA XXX is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
005337
TIME AGO XXXXX Contact: -

Signal value: XXX = First part of error code; see section D Error codes.
TYPE
page
–
Description: Indicates type of active error.

Circuit diagram: -
Contact: -
Signal value: XXX = Second part of error code.
NUMBER OF OCCU.
page
–
Description: Number of times active errors have occurred.

Circuit diagram: -
Contact: -
Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
page
–
Description: When latest active error occurred.

Circuit diagram: -
Contact: -
Signal value: XXXXX = Operating time in hours since latest error.


CONVERTER STATUS (Nm), TORQUE IMPELLER
page
–
Description: Torque transmitted by from engine to impeller in torque

DIAG TRANSM. 14(X) converter. The torque absorbed by the transmission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Contact: -
007622
Signal value: XXXX = Torque in Nm.
CONVERTER STATUS (Nm), TORQUE TURBINE

page
–
Description: current torque transmitted by torque converter to the

transmission.
Circuit diagram: -
Contact: -
Signal value: XXXX = Torque in Nm.
8.4.8 ELSERV
ELSERV, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
Confirm selections with function key for Enter.
005400
OLS EXTRA

PRESENT INPUT SIGNALS, P1
page
–
Description: Signal from control lever P1.

DIAG ELSERVO 1(X)
PRESENT INPUT SIGNALS
P1 XX.XXV Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3
P2 XX.XXV
Function: 7.1.1 Control levers
005401
P3 XX.XXV
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

page
–

Connection: signal from R8072/3 (S815/4) to analogue in D790-1/K7:4

8 Control system – 8.4.8.2 ELSERV, menu 2 85

page
–

Connection: signal from R8073/3 (S815/11) to analogue in
D790-1/K7:5

page
–

DIAG ELSERVO 2(X)
P4 XX.XXV Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
P7 XX.XXV
005402
P5 XX.XXV

page
–

Connection: signal from R8075-2/3 to analogue in D790-1/K9:9

page
–


86 8 Control system – 8.4.8.3 ELSERV, menu 3

OUTPUT LIFT, REFERENCE
page
–
Description: Status for control current to control valve (solenoid valve,

DIAG ELSERVO 3(X) lift mast).
OUTPUT LIFT
REFERENCE XY Circuit diagram: Circuit 7.2-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:4 to Y6005/1 (Y6005-1/1 on
005403
FEEDBACK XXXmA machines with freelift).
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG, DCF 70
and DCF 80-100)
7.2.6 Load handling control valve (DCF280-520)
Signal value:
00 No output signal, PWM off.
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
OUTPUT LIFT, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve,

(solenoid valve, lift mast).
Connection: output signal, reference value out from D797-1/K1:16 to
Y6005/2 (Y6005-1/2 on machines with freelift).
and DCF 80-100)
Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT LIFT, FEEDBACK

page
–
Description: Present control current to control valve (solenoid valve, lift

mast).
Connection: output signal, actual value out from D797-1/K1:16 to
and DCF 80-100)
Signal value: XXX = Measured current value in mA.

OUTPUT LOWER, REFERENCE
page
–

DIAG ELSERVO 4(X) lower mast).
OUTPUT LOWER
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:4 to Y6004/1 (Y6004-1/1 on
005404
FEEDBACK XXXmA machines with freelift).

and DCF 80-100)
Signal value:
NOTE
OUTPUT LOWER, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve (sole-

noid valve, lower mast)
and DCF 80-100)

OUTPUT LOWER, FEEDBACK

page
–
Description: Present control current to control valve (solenoid valve,

lower mast).
and DCF 80-100)

OUTPUT TILT IN, REFERENCE
page
–

DIAG ELSERVO 5(X) tilt in).
OUTPUT TILT IN
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6011/1
005405
FEEDBACK XXXmA
and DCF 80-100)
Signal value:
NOTE
OUTPUT TILT IN, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve (sole-

noid valve, tilt in).
Connection: output signal reference value out from D797-1/K1:18 to
Y6011/2
and DCF 80-100)

OUTPUT TILT IN, FEEDBACK

page
–
Description: Present for control current to control valve (solenoid

valve, tilt in).
Y6011/2
and DCF 80-100)

OUTPUT TILT OUT, REFERENCE
page
–

DIAG ELSERVO 6(X) tilt out).
OUTPUT TILT OUT
005406
FEEDBACK XXXmA
and DCF 80-100)
Signal value:
NOTE
OUTPUT TILT OUT, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve, (so-

lenoid valve, tilt out).
Connection: output signal, reference value out from D797-1/K1:19, to
solenoid valve Y6010/1
and DCF 80-100)

OUTPUT TILT OUT, FEEDBACK

page
–
Description: Present control current to control valve (solenoid valve, tilt

out).
Connection: output signal, actual value out from D797-1/K1:19 to so-
lenoid valve Y6010/2
and DCF 80-100)

OUTPUT SIDE SHIFT LE, REFERENCE
page
–
Description: Status for control current to control valve, load handling

DIAG ELSERVO 7(X) (solenoid valve, side shift left).
OUTPUT SIDESHIFT LE
005407
FEEDBACK XXXmA
Function: 7.4.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
OUTPUT SIDE SHIFT LE, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve for

load handling (solenoid valve, side shift left).
Y6020/2
OUTPUT SIDE SHIFT LE, FEEDBACK

page
–
Description: Present control current to control valve, load handling

(solenoid valve, side shift left).
Y6020/2


OUTPUT SIDE SHIFT RI, REFERENCE
page
–

DIAG ELSERVO 8(X) (solenoid valve, side shift right).
OUTPUT SIDESHIFT RI
005408
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SIDE SHIFT RI, REQUIRED VALUE

page
–

load handling (solenoid valve, side shift right).
Y6021/2
OUTPUT SIDE SHIFT RI, FEEDBACK

page
–

(solenoid valve, side shift right).
Y6021/2


OUTPUT SPREADING IN, REFERENCE
page
–

DIAG ELSERVO 9(X) (solenoid valve, spreading left).
OUTPUT SPREADING IN
005409
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SPREADING IN, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve, load

handling (solenoid valve, spreading in).
Y6019/2
OUTPUT SPREADING IN, FEEDBACK

page
–

(solenoid valve, spreading in).
Y6019/2


OUTPUT SPREADING OUT, REFERENCE
page
–

DIAG ELSERVO 10(X) (solenoid valve, spreading out).
OUTPUT SPREADING OUT
005410
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SPREADING OUT, REQUIRED VALUE

page
–

handling (solenoid valve, spreading out).
Y6018/2
OUTPUT SPREADING OUT, FEEDBACK

page
–
Description: Present control current to control valve, load handling (so-

lenoid valve, spreading out).
Y6018/2


OUTPUT LIFT 2, REFERENCE
page
–

DIAG ELSERVO 11(X) (solenoid valve, lift carriage).
OUTPUT LIFT 2
005411
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT LIFT 2, REQUIRED VALUE

page
–

handling (solenoid valve, lift carriage).
Y6022/2
OUTPUT LIFT 2, FEEDBACK

page
–

(solenoid valve, lift carriage).
Y6022/2


OUTPUT LOWER 2, REFERENCE
page
–

DIAG ELSERVO 12(X) (solenoid valve, lower carriage).
OUTPUT LOWER 2
005412
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT LOWER 2, REQUIRED VALUE

page
–

handling (solenoid valve, lower carriage).
Y6023/2
OUTPUT LOWER 2, FEEDBACK

page
–

(solenoid valve, lower carriage).
Y6023/2

PRESENT INPUT SIGNALS, SPREADER
page
–
Description: Signal from switch for spreading the attachment.

DIAG ELSERVO 13(X) Circuit diagram: Circuit 7.0-2
SPREADER IN X OUT X Contact:
PISTOL X
IN: Signal from S815/14 to digital in D790-1/K7:14 (spreading in)
007128
UNLOCK TW X
OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading
out)

Function: 7.1.1 Control lever

Signal value:
0 No signal.
PRESENT INPUT SIGNALS, PISTOL

page
–
Description: Signals from control lever for pistol trigger.

Connection: from S815/19 to digital in D790-1/K7:16
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK TW

page
–
Description: Signal from control lever to unlock twistlock.

Signal value:
0 No signal.

PRESENT INPUT SIGNALS, OPTION LOCKING
page
–
Description: Signal from control lever for option locking.

DIAG ELSERVO 14(X)
OPTION LOCKING X Connection: signal from S815/18 to digital in D790-1/K8:2
LEVELLING LOCKING X
007129
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LEVELLING LOCKING

page
–
Description: Signal from control lever fir levelling locking.

Signal value:
0 No signal.

REGENERATION STATUS, INPUT DAMPING
page
–
Description: Signal from position sensor, end position, regeneration.

DIAG ELSERVO 15(X)
REGENERATION STATUS
INPUT DAMPING X Connection: Signal from B7211-2 to digital in D797-2/K1:24.
OUTPUT LEFT XY
Function: 7.2.10 Mast position sensor (DCF360-450CSG)
005415
OUTPUT RIGHT XY
Signal value:
0 No signal.
REGENERATION STATUS, OUTPUT LEFT

page
–
Description: Power supply to solenoid valve, regeneration, left.

Connection: Signal from D797-1/K1:12 to Y6052/1
Function: 7.2.6 Valve block, lift cylinder (DCF360-450CSG)
Signal value:

active.


98 8 Control system – 8.4.9 ATTACH, DCF360-450CSG
REGENERATION STATUS, OUTPUT RIGHT

page
–
Description: Power supply to solenoid valve, regeneration, right.

Connection: Signal from D797-1/K1:11 to Y6051/1
Function: 7.2.6 Valve block, lift cylinder (DCF360-450CSG)
Signal value:

active.

8.4.9 ATTACH, DCF360-450CSG

ATTACH, description
page
–
This group covers attachment functions.

DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA

page
–

DIAG ATTACHMENT 1(X)
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in
P4 XX.XXV D790-1/K7:5
005416
P7 XX.XXV

page
–


8 Control system – 8.4.9.2 ATTACH, menu 2 99

page
–


page
–

P5 XX.XXV Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
005417

page
–
Description: Signals from switch for spreading the attachment.

DIAG ATTACHMENT 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, AUTO 20/40

page
–
Description: Signal from switch automatic spreading 20/40.

Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:
0 No signal.

100 8 Control system – 8.4.9.4 ATTACH, menu 4
PRESENT INPUT SIGNALS, 30/35 STOP

page
–
Description: Signal from switch for stop at 30’/35’.

Signal value:
0 No signal.

page
–

DIAG ATTACHMENT 4(X) Circuit diagram: Circuit 7.0-2
PISTOL X Function: 7.1.1 Control lever
007130
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOCK CONT
page
–
Description: Signal from switch, lock twistlock.

LOCK CONT X Connection: signal from S1003/7 and S1007/2 to digital in
UNLOCK CONT X D790-1/K8:12
013608
LOCK LEVELLING X
Function: 7.9.1 Twistlocks
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, UNLOCK CONT

page
–
Description: Signal from control lever to unlock twistlock.

Connection: signal from S1002/1 (S815/20) to digital in D790-1/K7:15
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, LOCK LEVELLING

page
–
Description: Signal from switch for levelling lock.

Function: 7.8 Levelling, 7.1.1 Control levers
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOW SPEED 20/40
page
–
Description: Signal from spreading position sensor for end position

DIAG ATTACHMENT 6(X) damping 20’/40’.
LOW SPEED 20/40 X Connection: from inductive sensor B769-1/C to digital in D791-1/K1:12
008902
30/35 STOP X
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.

page
–
Description: Signal from spreading position sensor for stop at 30’/35’.

Connection: from inductive sensor B777-1/C to digital in D791-1/K1:20
Signal value:
0 No signal.


PRESENT INPUT SIGNALS, ALIGNMENT LE RI, FRONT
page
–
Description: Signals from sensors, alignment, right front and left front.
ALIGNMENT LE RI Contact:
FRONT X X
LE: signal from B7202L/C to digital in D791-1/K1:13
005422
REAR X X
RI: signal from B7202R/C to digital in D791-1/K1:40
Function: 7.9.1.7 Alignment sensor
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, ALIGNMENT LE RI, REAR

page
–
Description: Signals from sensors, alignment, right rear and left rear.
Contact:
LE: signal from B7203L/B to digital in D791-1/K1:27
RI: Signal from B7203R/B to digital in D791-1/K1:26
Signal value:
0 No signal.

PRESENT INPUT SIGNAL LE RI, LOCKED CONT
page
–
Description: Signals from sensors locked twistlock right and left.

LE RI Contact:
LOCKED CONT X X
013609
UNLOCKED CONT X X
Function: 7.9.1.8 Sensor twistlock
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

page
–
Description: Signals from sensors open twistlock right and left.

Contact:
Function: 7.9.1.8 Sensor twistlock
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, LOCK TW
page
–
Description: Voltage feed to attachment control valve, locked

DIAG ATTACHMENT 9(X) twistlock.
LOCK TW XY Circuit diagram: Circuit 7.9-1
UNLOCK TW XY Connection: digital out from D791-1/K1:7 to /1
005424
Function: 7.9.1.2 Attachment control valve

Signal value:

active.

PRESENT OUTPUT SIGNAL, UNLOCK TW

page
–
Description: Voltage feed to control valve attachment, open twistlock.

Contact: digital output from D791-1/K1:9 to Y6039/1
Function: 7.9.1.2 Attachment control valve
Signal value:

active.



PRESENT OUTPUT SIGNAL, IND. LOCKED CONT
page
–
Description: Voltage feed, indicator light for locked twistlock - located

DIAG ATTACHMENT 10(X) on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit 7.9-1
IND. UNLOCKED CONT XY Connection: digital out from D791-1/K1:29 to H563/1
013610
IND. ALIGNMENT XY
Signal value:

active.

PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT

page
–
Description: Voltage feed, indicator light for open twistlock - located on

carriage.
Connection: digital out from D791-1/K1:25 to H562/1
Signal value:

active.


PRESENT OUTPUT SIGNAL, ALIGNMENT

page
–
Description: Voltage feed, alignment indicator light - located on

carriage.
Signal value:

active.


page
–
Description: Status for control current to attachment control valve for

DIAG ATTACHMENT 11(X) side shift left.
OUTPUT SIDESHIFT LE
005426
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:
NOTE

page
–
Description: Reference value for control current to attachment control

valve for output signal, side shift left.
Y6020/2


page
–
Description: Present control current to attachment control valve for

side shift left.
Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2

page
–

DIAG ATTACHMENT 12(X) side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXXmA Connection: digital out from D791/K1:33 to Y6021/1
005427
FEEDBACK XXXmA
Signal value:
NOTE

page
–

valve for output signal, side shift right.
Y6021/2

page
–

side shift right.
Y6019/2


OUTPUT SPREADER OUT, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 13(X) spreader out 20/40.
OUTPUT SPREADER OUT
005428
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SPREADER OUT, REQUIRED VALUE

page
–

valve for output signal, spreading out 20/40.
Y6018/2
OUTPUT SPREADER OUT, FEEDBACK

page
–
Description: Present control current to control valve attachment for

spreader out 20/40.
Y6018/2


OUTPUT SPREADER IN, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 14(X) spreader in 40/20.
OUTPUT SPREADER IN
005429
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT SPREADER IN, REQUIRED VALUE

page
–

valve for output signal, spreading in 40/20.
Y6019/2
OUTPUT SPREADER IN, FEEDBACK

page
–
Description: Present control current to control valve attachment for

spreader in 40/20.
Y6019/2


PRESENT OUTPUT SIGNAL, UNLOCK LEVELLING
page
–
Description: Voltage feed to levelling solenoid valve.

UNLOCK LEVELLING XY Connection: digital out from D791-1/K1:42 to Y637-1/1 and Y637-2/1
Function: 7.8.4 Valve block, levelling cylinders
005430
Signal value:

active.


OUTPUT LEVELLING, CLOCKWISE
page
–
Description: Voltage feed to attachment control valve, clockwise

DIAG ATTACHMENT 16(X) levelling.
OUTPUT LEVELLING
CLOCKWISE XY Circuit diagram: Circuit 7.8-1
COUNTERCLOCKWISE XY Connection: digital out from D791-1/K1:30 to Y6036/1
005431

Signal value:

active.


OUTPUT LEVELLING, COUNTERCLOCKWISE

page
–
Description: Voltage feed to attachment control valve, anticlockwise

levelling.
Connection: digital out from D791-1/K1:31 to Y6035/1
Signal value:

active.


OUTPUT PROJECT LE OUT, REFERENCE
page
–

DIAG ATTACHMENT 17(X) extension, left side, out.
OUTPUT PROJECT LE OUT
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:3 to Y6046-2/1
005432
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT LE OUT, REQUIRED VALUE

page
–

valve for output signal, extension, left side out
Y6046-2/2

OUTPUT PROJECT LE OUT, FEEDBACK

page
–
Description: Present control current to attachment control valve for ex-

tension, left side out.
Y6046-2/2

OUTPUT PROJECT LE IN, REFERENCE
page
–

DIAG ATTACHMENT 18(X) extension, left side in.
OUTPUT PROJECT LE IN
005433
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT LE IN, REQUIRED VALUE

page
–

valve for output signal, extension, left side in.
Y6046-1/2
OUTPUT PROJECT LE IN, FEEDBACK

page
–

tension, left side in.
Y6046-1/2


OUTPUT PROJECT RI OUT, REFERENCE
page
–

DIAG ATTACHMENT 19(X) extension, right side out.
OUTPUT PROJECT RI OUT
005434
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT RI OUT, REQUIRED VALUE

page
–

valve for output signal, extension, right side out
Y6046-4/2
OUTPUT PROJECT RI OUT, FEEDBACK

page
–

tension, right side out.
Y6046-4/2


OUTPUT PROJECT RI IN, REFERENCE
page
–

DIAG ATTACHMENT 20(X) extension, right side in.
OUTPUT PROJECT RI IN
005435
FEEDBACK XXXmA
Signal value:
NOTE
OUTPUT PROJECT RI IN, REQUIRED VALUE

page
–

valve for output signal, extension, right side in.
Y6046-3/2
OUTPUT PROJECT RI IN, FEEDBACK

page
–

tension, right side in.
Y6046-3/2


PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer, automatic spreading 20’-40’.
Circuit diagram: Circuit 7.5.3
BUZZER AUTO 20-40 XY
009181
Signal value:

signal is active.
8.4.9 ATTACH, DCF 80-100 with lifting hook

attachment
ATTACH, description
page
–

DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA

page
–

P4 XX.XXV D790-1/K7:5
005416
P7 XX.XXV

page
–



page
–


page
–

005417

page
–

AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790/K7:14
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790/K7:13
(spreading out)
Signal value:
0 No signal.

page
–

Signal value:
0 No signal.


page
–

Signal value:
0 No signal.

page
–

007130
Signal value:
0 No signal.

page
–
Description: Signal from switch, lock lock tongue.

LOCK CONT X Connection: signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
Function: 7.9.2 Lifting hook
010079
Signal value:
0 No signal.

page
–
Description: Signal from control lever to open lock tongue.

Connection: signal from S1002 to digital in D790-1/K7:15
Signal value:
0 No signal.


page
–

DIAG ATTACHMENT 6(X) damping 20’/40’ right or left.
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Signal value:
0 No signal.

page
–
Description: signal from position sensor for end position 30’ right or
left.
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, UPPER
page
–
Description: Signals from sensors alignment right upper and left

DIAG ATTACHMENT 7(X) upper.
ALIGNMENT LE RI Circuit diagram: Circuit 11B
UPPER X X Contact:
010081
LOWER X X
LE: signal from B7203RU-2 to digital in D791/K1:36
RI: Signal from B7203LU-2 to digital in D791/K1:11
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, LOWER

page
–
Description: Signals from sensors alignment right lower and left lower.
Circuit diagram: Circuit 11B
Contact:
LE: signal from B7203LL to digital in D791/K1:27
RI: Signal from B7203RL to digital in D791/K1:26
Signal value:
0 No signal.

page
–
Description: Signals from sensors locked lock tongue right and left.
LE RI Contact:
LOCKED CONT X X
010082
UNLOCKED CONT X X
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.

page
–
Description: Signals from sensors open lock tongue right and left.
Contact:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL, LOCK CONT
page
–
Description: Voltage feed to attachment control valve, locked lock

DIAG ATTACHMENT 9(X) tongues.
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040
010083
Signal value:

active.

PRESENT OUTPUT SIGNAL, UNLOCK CONT

page
–
Description: Voltage feed to attachment control valve, open lock

tongues.
Connection: digital out from D791/K1:9 to Y6039
Signal value:

active.



page
–
Description: Voltage feed, indicator light for locked lock tongues - lo-
DIAG ATTACHMENT 10(X) cated on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084
IND. ALIGNMENT XY
Signal value:

active.


page
–
Description: Voltage feed, indicator light for unlocked lock tongues - lo-
cated on carriage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:25 to H562
Signal value:

active.



page
–

carriage.
Signal value:

active.


page
–

OUTPUT SIDESHIFT LE
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:32 to Y6020/1
010088
FEEDBACK XXX
Signal value:
NOTE

page
–

Y6020/2


page
–

side shift left.
Y6020/2

page
–

OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089
FEEDBACK XXX
Signal value:
NOTE

page
–

Y6021/2

page
–

side shift right.
Y6019/2


OUTPUT LEVELLING CW, REFERENCE
page
–
Description: Status control current to control valve attachment for lev-

DIAG ATTACHMENT 13(X) elling right.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:31 to Y6035
010085
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CW, REQUIRED VALUE

page
–

valve for output signal, levelling right.
Connection: output signal reference value out from D791/K1:19 to
Y6035
OUTPUT LEVELLING CW, FEEDBACK

page
–
Description: Current control current to control valve attachment for lev-

elling right.
Connection: output signal, actual value out from D791/K1:19 to Y6035


OUTPUT LEVELLING CCW, REFERENCE
page
–

DIAG ATTACHMENT 14(X) elling left.
OUTPUT LEVELLING CW
010086
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CCW, REQUIRED VALUE

page
–

valve for output signal, levelling left.
Connection: output signal, reference value out from D791/K1:19 to
Y6036
OUTPUT LEVELLING CCW, FEEDBACK

page
–

elling left.


Not used.
page
–

NOT USED
010077
Not used.
page
–

NOT USED
010078

OUTPUT SPREAD LE OUT, REFERENCE
page
–

DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
REQUIRED VALUE XXX Connection: digital out from D791/K1:3 to Y6018L
010087
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, left side out
Y6018L

OUTPUT SPREAD LE OUT, FEEDBACK

page
–

spreading, left side out
Connection: output signal, actual value out from D791/K1:16 to
Y6018L

OUTPUT SPREADER LE IN, REFERENCE
page
–

DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
010090
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE

page
–

valve for output signal, spreading, left side in
Y6019L
OUTPUT SPREADER LE IN, FEEDBACK

page
–

spreading, left side in.
Y6019L


OUTPUT SPREAD RI OUT, REFERENCE
page
–

DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
REFERENCE XY
REQUIRED VALUE XXX Connection: digital out from D791/K1:5 to Y6018R
010091
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, right side out
Y6018R
OUTPUT SPREAD RI OUT, FEEDBACK

page
–

spreading, right side out.
Y6018R


OUTPUT SPREADER RI IN, REFERENCE
page
–

DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
010092
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE

page
–

valve for output signal, spreading, right side in.
Y6019R
OUTPUT SPREADER RI IN, FEEDBACK

page
–

spreading, right side in.
Y6019R


page
–

009181
Signal value:

signal is active.

PRESENT INPUT SIGNALS, DETECT UPPER CONT.
page
–
Description: Signals from detection sensor for upper container right

DIAG ATTACHMENT 22(X) (B7203 RU) and detection sensor for upper container left (B7203LU).
DETECT UPPER CONT. Circuit diagram: Circuit 11B
LE RI LE: signal from B7203LU to digital in D791-1/K1:13
010075
X X
RI: Signal from B7203RU to digital in D791-1/K1:21
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, IND. UPPER ALIGNMENT
page
–
Description: Signals from alignment sensor right upper (B7203RU-2)

DIAG ATTACHMENT 23(X) and left upper (B7203LU-2).
IND. UPPER Circuit diagram: Circuit 11B
ALIGNMENT XY Contact:
010076
LE: signal from B7203LU-2 to digital in D791-1/K1:11

RI: Signal from B7203RU-2 to digital in D791-1/K1:36
Signal value:
0 No signal.

130 8 Control system – 8.4.9 ATTACH, DCF 70 and DCF 80-100 with twistlock attachment
8.4.9 ATTACH, DCF 70 and DCF 80-100

with twistlock attachment
ATTACH, description
page
–

DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA

page
–

P4 XX.XXV D790-1/K7:5
005416
P7 XX.XXV

page
–


page
–


page
–

005417


page
–

AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Signal value:
0 No signal.

page
–

Signal value:
0 No signal.

page
–

Signal value:
0 No signal.


page
–

007130
Signal value:
0 No signal.

page
–
Description: Signal from switch for locking twistlocks.

LOCK CONT X Connection: signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
010079
Signal value:
0 No signal.

page
–
Description: Signal from control lever to open twistlocks.

Connection: signal from S1002 to digital in D790-1/K7:15
Signal value:
0 No signal.


page
–

DIAG ATTACHMENT 6(X) damping 20’/40’ right or left.
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Signal value:
0 No signal.

page
–
Description: signal from position sensor for end position 30’/35’ right
or left.
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI
page
–
Description: Signals from right and left alignment sensors.

ALIGNMENT LE RI Contact:
X X
LE: signal from B7203R to digital in D791/K1:26
010093
RI: signal from B7203L to digital in D791/K1:27

Signal value:
0 No signal.


page
–
Description: Signals from sensors locked twistlock right and left.

LE RI Contact:
LOCKED CONT X X
010082
UNLOCKED CONT X X
Function: 7.9.1.8 Twistlocks sensor
Signal value:
0 No signal.

page
–
Description: Signals from sensors open twistlock right and left.

Contact:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41
Function: 7.9.1.8 Twistlocks sensor
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, LOCK CONT
page
–
Description: Voltage feed to attachment control valve, locked

DIAG ATTACHMENT 9(X) twistlocks.
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040
010083

Signal value:

active.


PRESENT OUTPUT SIGNAL, UNLOCK CONT

page
–
Description: Voltage feed to attachment control valve, open twistlocks.

Connection: digital out from D791/K1:9 to Y6039
Signal value:

active.


page
–
Description: Voltage feed, indicator light for locked twistlocks - located

DIAG ATTACHMENT 10(X) on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084
IND. ALIGNMENT XY
Signal value:

active.


page
–
Description: Voltage feed, indicator light for unlocked twistlocks - lo-

cated on carriage.


Signal value:

active.


page
–

carriage.
Signal value:

active.


page
–

OUTPUT SIDESHIFT LE
010088
FEEDBACK XXX
Signal value:
NOTE


page
–

Y6020/2

page
–

side shift left.
Y6020/2

page
–

OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089
FEEDBACK XXX
Signal value:
NOTE

page
–

Y6021/2


page
–

side shift right.
Y6019/2

OUTPUT LEVELLING CW, REFERENCE
page
–

DIAG ATTACHMENT 13(X) elling right.
OUTPUT LEVELLING CW
010085
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CW, REQUIRED VALUE

page
–

valve for output signal, levelling right.
Connection: output signal reference value out from D791/K1:19 to
Y6035
OUTPUT LEVELLING CW, FEEDBACK

page
–

elling right.


OUTPUT LEVELLING CCW, REFERENCE
page
–

DIAG ATTACHMENT 14(X) elling left.
OUTPUT LEVELLING CW
010086
FEEDBACK XXX
Signal value:
NOTE
OUTPUT LEVELLING CCW, REQUIRED VALUE

page
–

valve for output signal, levelling left.
Y6036
OUTPUT LEVELLING CCW, FEEDBACK

page
–

elling left.


Not used.
page
–

NOT USED
010077
Not used.
page
–

NOT USED
010078

OUTPUT SPREAD LE OUT, REFERENCE
page
–

DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
010087
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, left side out
Y6018L

OUTPUT SPREAD LE OUT, FEEDBACK

page
–

spreading, left side out
Y6018L

OUTPUT SPREADER LE IN, REFERENCE
page
–

DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
010090
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE

page
–

valve for output signal, spreading, left side in
Y6019L
OUTPUT SPREADER LE IN, FEEDBACK

page
–

spreading, left side in.
Y6019L


OUTPUT SPREAD RI OUT, REFERENCE
page
–

DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
REFERENCE XY
010091
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE

page
–

valve for output signal, spreading, right side out
Y6018R
OUTPUT SPREAD RI OUT, FEEDBACK

page
–

spreading, right side out.
Y6018R

OUTPUT SPREADER RI IN, REFERENCE
page
–

DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
REFERENCE XY
REQUIRED VALUE XXX
010092
FEEDBACK XXX


Connection: digital out from D791/K1:4 to Y6019R
Signal value:
NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE

page
–

valve for output signal, spreading, right side in.
Y6019R
OUTPUT SPREADER RI IN, FEEDBACK

page
–

spreading, right side in.
Y6019R

page
–

009181

Signal value:

signal is active.

144 8 Control system – 8.4.10 OLS
8.4.10 OLS
OLS, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers overload protection functions.
CLIMATE HYD ENGINE
005436
OLS EXTRA
8.4.10.1 OLS, menu 1

PRESENT INPUT SIGNAL, LIFT CYLINDER
page
–
Description: Signal from hydraulic pressure sensor, lift cylinder. See

DIAG OLS 1(X) also HYDRAULIC PRESSURE, LIFT CYLINDER page 57 for pres-
PRESENT INPUT SIGNAL sure information.
LIFT CYLINDER X.XXV Circuit diagram: Circuit 8.2-2

005437
TILT CYLINDER X.XXV Connection: signal from B768-1/3 to analogue in D797-1/K1:21

Function: 7.2.8 Sensor hydraulic pressure lift cylinder
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
PRESENT INPUT SIGNAL, TILT CYLINDER

page
–
Description: Signal from hydraulic pressure sensor, lift cylinder

(C+ piston side). See also HYDRAULIC PRESSURE, TILT CYLIN-
DER page 57 for pressure information.
Connection: signal from B768-2/3, analogue in D797-1/K1:22
Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
8.4.10.2 OLS, menu 2

PRESENT INPUT SIGNAL, BYPASS
page
–
Description: Signal from switch, bypass.

DIAG OLS 2(X)
BY-PASS X
Function: 8.1.3 Bypass switch
005438
Signal value:
1 Input signal active. The signal is only active for max.

60 seconds.
0 No signal.

8 Control system – 8.4.10.3 OLS, menu 3 145
8.4.10.3 OLS, menu 3

VD VALUE
page
–
Description: Permitted load at load centre in question as per Vehicle

DIAG OLS 3(X) Data.
VD VALUE XXXXXkg
PRESENT LOAD XXXXXkg Circuit diagram: -
Contact: -
008903
MAST POS SENSOR X
Signal value: XXXXX = Weight, kg
PRESENT LOAD
page
–
Description: Calculated load.

Circuit diagram: -
Contact: -
Signal value: XXXXX = Weight, kg
MAST POS SENSOR

page
–
Applies to DCF360-450CSG with 14000 mm lift height.

Description: Signal from sensor for limiting lift over 13000 mm for loads
over 30 metric tons.
Connection: signal from B7211-3/C to digital in D797-1/K1:37
Signal value:
0 No signal.
8.4.10.4 OLS, menu 4

PRESENT INPUT SIGNAL, TILT ANGLE LIM.
page
–
Not used.
PRESENT INPUT SIGNAL, HEIGHT LIM.

page
–
Applies to DCF360-450CSG with 14000 mm lift height and machines

DIAG OLS 4(X) equipped with lift height indicator/lift height limitation.
TILT ANGLE LIM X Description: signal from sensor for limiting lift or warning for lift over
HEIGHT LIM X XXXXX mm.
010621

Function: lift height limitation
Signal value:
0 No signal.

146 8 Control system – 8.4.11 EXTRA
8.4.11 EXTRA
EXTRA, description
page
–
This menu consists of optional functions:

DIAGNOSIS
CAN/POWER LIGHTS CAB • Turnable operator’s station, VBFS
CLIMATE HYD ENGINE • Lever steering or mini-wheel, EL-STEERING
• External attachment, EXT-ATTACH
005440
OLS EXTRA
• Freelift, FREELIFT
• Cab tipping, MOVE-CAB
• Auxiliary equipment, OPT
• Inputs and outputs, control units, I/O
• Remote machine interface, RMI
Confirm selections in the main menu with function key for Enter.
8.4.11.1 VBFS
VBFS, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers turnable operator’s station functions.
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
008904
VBFS, menu 1
page
–
PRESENT INPUT SIGNAL REVERSIBLE SEAT, SWITCH

CW
DIAG VBFS 1(X)

PRESENT INPUT SIGNAL Description: Signal from switch, reversible driver’s seat, clockwise
REVERSIBLE SEAT rotation.
SWITCH CW X
005561
SWITCH CCW X
Function: 9.3.9 Reversible driver’s seat
Signal value:
0 No signal.

8 Control system – 8.4.11.1 VBFS 147
PRESENT INPUT SIGNAL REVERSIBLE SEAT,

SWITCH CCW
Description: Signal from switch, reversible driver’s seat, anticlockwise

rotation.
Signal value:
0 No signal.
VBFS, menu 2
page
–
PRESENT OUTPUT SIGNAL REVERSIBLE SEAT,

SEAT CW
DIAG VBFS 2(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to seat reversal control unit
REVERSIBLE SEAT (clockwise rotation).
SEAT CW XY
007131
SEAT CCW XY
Connection: digital out from D797-2/K1:29 to A798/6
Signal value:

active.


148 8 Control system – 8.4.11.1 VBFS
PRESENT OUTPUT SIGNAL REVERSIBLE SEAT,

SEAT CCW
Description: Voltage feed to seat reversal control unit

(anticlockwise rotation).
Signal value:

active.

VBFS, menu 3
page
–
PRESENT INPUT SIGNAL SEAT SENSORS,

SEAT POS FRONT
DIAG VBFS 3(X)

PRESENT INPUT SIGNAL Description: Signal from sensor, reversible driver’s seat, forward.
SEAT SENSORS Circuit diagram: Circuit 9.3-3
SEAT POS FRONT X
005563
SEAT POS REAR X Connection: signal from S720-F/2 to digital in D790-1/K1:13

Signal value:
0 No signal.
PRESENT INPUT SIGNAL SEAT SENSORS,

SEAT POS REAR
Description: Signal from sensor, reversible driver’s seat, rearward.

Connection: signal from S720-R/2 to digital in D790-1/K1:20
Signal value:
0 No signal.

VBFS, menu 4
page
–
PRESENT INPUT SIGNAL, ACCELERATOR 2
DIAG VBFS 4(X)

PRESENT INPUT SIGNAL Description: Signal from switch for auxiliary accelerator pedal
ACCELERATOR 2 X.XXV (reverse).
REQUIRED SPD PROC XXX
007623
REQUIRED SPD RPM XXXX
Connection: signal from B690-2/2 to analogue in D790-1/K6:12
Function: 1 Engine
Signal value: X.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC
Description: Required engine speed (in percent) which is sent from

Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus
drive-train.
Circuit diagram: -
Contact: -
Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Contact: -
Signal value: XXXX = 0-2010 rpm

VBFS, menu 5
page
–
PRESENT OUTPUT SIGNAL STEERING VALVE,

VALVE CAB FRONT
DIAG VBFS 5(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to directional control valve, reversible driv-
STEERING VALVE er’s seat (forward).
VALVE CAB FRONT XY
005565
VALVE CAB REAR XY
Connection: digital out from D797-2/K1:9 to Y636-1/1
Function: 9.3.12 Directional control valve, reversible driver’s seat
Signal value:

active.

PRESENT OUTPUT SIGNAL STEERING VALVE,

VALVE CAB REAR
Description: Voltage feed to directional control valve, reversible driv-

er’s seat (rearward).
Connection: digital out from D797-2/K1:10 to Y636-2/1
Function: 9.3.12 Directional control valve, reversible driver’s seat
Signal value:

active.


VBFS, menu 6
page
–
HEAD LIGHTS, REAR, SWITCH
DIAG VBFS 6(X)

HEAD LIGHTS REAR Description: Signal from headlights switch.
SWITCH X Circuit diagram: Circuit 9.6-4
HEAD LE/RI XY
005566
DIMMED LE/RI XY Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.
Signal value:
0 No signal.
HEADLIGHTS REAR, HEAD L/R
Description: Voltage feed to high beam rear

Connection: digital out from D797-2/K1:1 to E402L-2/1 and E402R-2/1
Signal value:

active.


HEADLIGHTS REAR, DIMMED L/R
Description: Voltage feed to low beam rear.

Connection: digital out from D797-2/K1:15 to E401L/1 and E401R/1
Signal value:

active.

VBFS, menu 7
page
–
PRESENT OUTPUT SIGNAL, TAILLIGHT FRONT
DIAG VBFS 7(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to front tail lights.
TAILLIGHT FRONT Circuit diagram: Circuit 9.3-5
005567
FRONT LE/RI XY Connection: digital out from D797-2/K1:25 to H413L/1 and H413R/1
Function: 9.6.3 Tail lights
Signal value:

active.


VBFS, menu 8
page
–
PRESENT OUTPUT SIGNAL, BRAKE LIGHT FRONT
DIAG VBFS 8(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to front brake lights.
BRAKE LIGHT FRONT Circuit diagram: Circuit 9.3-4
005568
FRONT LE XY RI XY Contact:
LE: digital out from D797-2/K1:37 to H410L/1
RI: digital out from D797-2/K1:36 to H410R/1
Function: 9.6.4 Brake lights
Signal value:

active.

VBFS, menu 9
page
–
PRESENT OUTPUT SIGNAL, REVERSIBLE SEAT,

RELEASE BRAKE
DIAG VBFS 9(X)

PRESENT OUTPUT SIGNAL Description: Voltage feed to brake solenoid valve, seat reversal. The
REVERSIBLE SEAT brake keeps the seat locked in position. The break is only released
RELEASE BRAKE XY when the stool is rotated.
008918
DAMP SPEED XY

active.


154 8 Control system – 8.4.11.2 EL-STEERING
PRESENT OUTPUT SIGNAL, REVERSIBLE SEAT,

DAMP SPEED
Description: Voltage feed to seat reversal control unit (speed

damping).

active.

8.4.11.2 EL-STEERING
EL-STEERING, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group handles functions for joystick steering/mini-wheel steering.
EXT-ATTACH FREELIFT
008911
EL-STEERING, menu 1
page
–
PRESENT INPUT SIGNAL, SIGNAL 1 P6

Description: Signal from mini-wheel (signal 1) or joystick.
DIAG STEERING 1(X)
SIGNAL 1 P6 X.XXV Connection: signal from R825/H1 to digital in D790-1/K9:8
SIGNAL 2 P7 X.XXV
Function: 5.2 Power-assisted steering system
005443
LOGIC X.XXV
Signal value, control lever: XX.XXV = 0.50 - 4.50 V
Signal value, mini-wheel: XX.XXV = 0 - 5 V
PRESENT INPUT SIGNAL, SIGNAL 2 P7

Description: Signal from mini-wheel (signal 2). (Only applies to
mini-wheel.)
Connection: signal from R825/H2 to digital in D790-1/K9:9
Signal value: XX.XXV = 0 - 5 V

8 Control system – 8.4.11.2 EL-STEERING 155
PRESENT INPUT SIGNAL, LOGIC

Description: Signal from mini-wheel (signals 1 and 2). Indicates logical
value for mini-wheel. A high value indicates steering to the left. A low
value indicates steering to the right.
Connection: signal from R825/H1 to digital in D790-1/K9:8 and R825/
H2 to digital in D790-1/K9:9.
Signal value: XX.XXV = 0 - 5 V
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/joystick.
DIAG STEERING 2(X)
SWITCHES
ON/OFF X Connection: signal from S113/1 to digital in D790-1/K9:5
FORWARD X
005569
REVERSE X
Signal value:
0 No signal.
SWITCHES, FORWARD
Description: Signal from mini-wheel or joystick (travel direction
selector forward).
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or joystick (travel direction
selector reverse).
Signal value:
0 No signal.

156 8 Control system – 8.4.11.2 EL-STEERING
EL-STEERING, menu 3
page
–
PRESENT INPUT SIGNAL, HORN

Description: Signal from mini-wheel or steering lever (audible signal).
DIAG STEERING 3(X)
HORN X Connection: signal from S149-2/1 to digital in D790-1/K9:10
STEER.WHEEL CUT OFF X
007624
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, STEER. WHEEL CUT OFF

Description: Signal from sensor steering angle.
Connection: Signal from B770/2 to digital in D790-2/K8:2
Function: 5.2.12 Sensor steering angle
Signal value:
0 No signal.
EL-STEERING, menu 4
page
–
OUTPUT STEERING LEFT, REFERENCE

Description: Status for control current to control valve for mini-wheel/
DIAG STEERING 4(X) lever steering, solenoid valve steering left.
OUTPUT STEERING LEFT
REQUIRED VALUE XXX Connection: output signal, reference value out from D797-2/K1:3 to
005570
FEEDBACK XXX Y636-4/1

Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value:
NOTE

8 Control system – 8.4.11.2 EL-STEERING 157
OUTPUT STEERING LEFT, REQUIRED VALUE

mini-wheel/lever steering, solenoid valve steering left.
Y636-4/2
OUTPUT STEERING LEFT, FEEDBACK

Description: Present control current to control valve for mini-wheel/le-
ver steering, solenoid valve steering left.
Y636-4/2
EL-STEERING, menu 5
page
–
OUTPUT STEERING RIGHT, REFERENCE

Description: status for control current to control valve for mini-wheel/
DIAG STEERING 5(X) lever steering, solenoid valve steering right.
OUTPUT STEERING RIGHT
REQUIRED VALUE XXX Connection: output signal, reference value out from D797-2/K1:2 to
005571
FEEDBACK XXX Y636-3/1

Signal value:
NOTE
OUTPUT STEERING RIGHT, REQUIRED VALUE

Description: reference valve for control current to control valve for
mini-wheel/lever steering, solenoid valve steering right.
Y636-3/2

158 8 Control system – 8.4.11.3 EXT-ATTACH
OUTPUT STEERING RIGHT, FEEDBACK

Description: present control current to control valve for mini-wheel/le-
ver steering, solenoid valve steering right.
Y636-3/2
8.4.11.3 EXT-ATTACH
EXT-ATTACH, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers the external attachment functions.
EXT-ATTACH FREELIFT
007625
EXT-ATTACH, menu 1
page
–
PRESENT INPUT SIGNAL, EXT-ATTACH ACTIVE

Description: Signal which indicates if external attachment is
DIAG EXT-ATTACH 1(X) connected.
EXT-ATTACH ACTIVE X Contact: -
007626
Function: 7.10.5 Separate top lift attachment

Signal value:
0 No signal.
EXT-ATTACH, menu 2
page
–
PRESENT INPUT SIGNALS, LOCK TW

Description: Signal from switch for locking twistlock.
DIAG EXT-ATTACH 2(X) Circuit diagram: Circuit 7.9-1
LOCK TW X Connection: signal from S1003/2 to digital in D790-1/K8:12
UNLOCK TW X Function: 7.10.5 Separate top lift attachment.
007627
Signal value:
0 No signal.

8 Control system – 8.4.11.3 EXT-ATTACH 159
PRESENT INPUT SIGNALS, UNLOCK TW

Description: Signal from switch/control lever for opening the twistlock.
Function: 7.1.1 Control lever, 7.10.5 Separate top lift attachment
Signal value:
0 No signal.
EXT-ATTACH, menu 3
page
–
PRESENT INPUT SIGNALS, SPREADING OUT

DIAG EXT-ATTACH 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
SPREADING OUT X Connection: signal from S1012/7 (S815/16) to digital in D790-1/K7:13
SPREADING IN X Function: 7.5 Spreading, 7.1.1 Control lever
007628
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, SPREADING IN

Function: 7.5 Spreading, 7.1.1 Control lever
Signal value:
0 No signal.
EXT-ATTACH, menu 4
page
–
PRESENT INPUT SIGNALS, ALIGNMENT

Description: Signal from alignment sensor.
DIAG EXT-ATTACH 4(X)
ALIGNMENT X Connection: Signal from B7202L/R and B7203L/R to digital in D790-1/
LOCKED TW X K10:3
007629
UNLOCKED TW X
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOCKED TW

Description: Signal from sensor for locked twistlocks.
Connection: Signal from B7205L/R to digital in D790-1/K8:8
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCKED TW

Description: Signal from sensor for open twistlock.
Connection: Signal from B7204L/R to digital in D790-1/K8:9
Signal value:
0 No signal.
EXT-ATTACH, menu 5
page
–
Not used.
EXT-ATTACH, menu 6
page
–
PRESENT OUTPUT SIGNAL 4TH FUNCTION, TW ACTIVE

Description: Voltage feed to relay for activating twistlock.
DIAG EXT-ATTACH 6(X) Circuit diagram: Circuit 7.0-5
4:E FUNCTION Connection: digital out from D790-1/K7:10 to K3005/86
TW ACTIVE XY Function: 7.10.5 Separate top lift attachment
007631
SPREADING ACTIVE XY
Signal value:

active.


8 Control system – 8.4.11.3 EXT-ATTACH 161
PRESENT OUTPUT SIGNAL 4TH FUNCTION,

SPREADING ACTIVE
Description: Voltage feed to relay for activating spreading.
Connection: digital out from D790-1/K7:11 to K3006/86
Signal value:

active.

EXT-ATTACH, menu 7
page
–
OUTPUT SPREADING IN, REFERENCE

Description: Status for control current to load handling control valve
DIAG EXT-ATTACH 7(X) (solenoid valve, spreading in).
OUTPUT SPREADING IN
REFERENCE Circuit diagram: Circuit 7.5-1
XY
007632
FEEDBACK XXX
Function 7.5.5 Solenoid valve, load handling
Signal value:
NOTE
OUTPUT SPREADING IN, REQUIRED VALUE

Description: Reference value for control current to load handling con-
trol valve (solenoid valve, spreading in).
Y6019/2

OUTPUT SPREADING IN, FEEDBACK

Description: Present control current to load handling control valve
(solenoid valve, spreading in).
Y6019/2
EXT-ATTACH, menu 8
page
–
OUTPUT SPREADING OUT, REFERENCE

Description: Status for control current to load handling control valve
DIAG EXT-ATTACH 8(X) (solenoid valve, spreading out).
OUTPUT SPREADING OUT
REFERENCE Circuit diagram: Circuit 7.5-1
XY
007633
FEEDBACK XXX
Signal value:
NOTE
OUTPUT SPREADING OUT, REQUIRED VALUE

Description: Reference value for control current to load handling con-
trol valve (solenoid valve, spreading out).
Y6018/2.
OUTPUT SPREADING OUT, FEEDBACK

Description: Present control current to load handling control valve
(solenoid valve, spreading out).
Y6018/2

8 Control system – 8.4.11.4 FREELIFT 163
8.4.11.4 FREELIFT
FREELIFT, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers freelift functions.
EXT-ATTACH FREELIFT
008912
FREELIFT, menu 1
page
–
PRESENT INPUT SIGNAL MAST CARRIAGE, MAST POS

DOWN
Description: Signal from sensor, mast down.
DIAG FREELIFT 1(X) Circuit diagram: Circuit 7.2-3
MAST CARRIAGE Connection: Signal from B261 to digital in D797-1/K1:11
MAST POS DOWN X Function: 7.2.10 Mast position sensor
007635
LIFT CARRIAGE TOP X

Signal value:
0 No signal.
PRESENT INPUT SIGNAL MAST CARRIAGE, LIFT

CARRIAGE TOP
Description: Signal from sensor, mast up.
Connection: Signal from B260 to digital in D797-1/K1:12
Function: 7.2.10 Mast position sensor
Signal value:
0 No signal.
8.4.11.5 MOVE-CAB
MOVE-CAB, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers tiltable cap functions.
EXT-ATTACH FREELIFT
008913

164 8 Control system – 8.4.11.5 MOVE-CAB
MOVE-CAB, menu 1
page
–
INPUT SWITCHES, UP
Description: Signal from switch for manual cab tilt, cab up.
DIAG MOVE-CAB 1(X) Circuit diagram: Circuit 9.10-1
INPUT SWITCHES
UP/RIGHT X Connection: signal from S1010/1 to digital in D790-1/K8:6
DOWN/LEFT X Function: 9.10.4 Cab tilt
007133
OPEN DOORS X
Signal value:
0 No signal.
INPUT SWITCHES, DOWN

Description: Signal from switch for manual cab tilt, cab down.
Connection: signal from S1010:/7 to digital in D790-1/K8:7
Function: 9.10.4 Cab tilt
Signal value:
0 No signal.
INPUT SWITCHES, OPEN DOORS

Description: Signal from sensor for opening doors.
Connection: signal from S266-LE/2 to S266-RI/2 to digital in D790-1/
K11:3
Function: 9.10.2 Doors
Signal value:
0 No signal.
MOVE-CAB, menu 2
page
–
PRESENT INPUT SIGNAL, AUTO CAB TILT

Description: Signal from switch for automatic/manual cab tilt.
AUTO CABTILT X Connection: signal from S199-2/1 to digital in D790-1/K8:14
LIFT HEIGHT POS X Function: 9.10.4 Cab tilt
005447
Signal value:
0 No signal.

8 Control system – 8.4.11.5 MOVE-CAB 165
PRESENT INPUT SIGNAL, LIFT HEIGHT POS

Description: Signal from sensor for automatic cab tilt.
Signal value:
0 No signal.
MOVE-CAB, menu 3
page
–
PRESENT INPUT SIGNAL, CAB UPPER POS

Description: Signal from sensor for cab tilt, cab in upper position.
CAB UPPER POS X Connection: signal from B769-1/C to digital in D797-2/K1:13
CAB LOWER POS X Function: 9.10.4 Cab tilt
005448
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CAB LOWER POS

Description: Signal from sensor for cab tilt, cab in lower position.
Signal value:
0 No signal.

MOVE-CAB, menu 4
page
–
PRESENT OUTPUT SIGNAL, VALVE CAB UP

Description: Voltage feed to cab tilt control valve, cab up.
DIAG MOVE-CAB 4(X)
VALVE CAB UP XY Connection: digital out from D797-2/K1:29 to Y6047/1
VALVE CAB DOWN XY
005449
Signal value:

active.

PRESENT OUTPUT SIGNAL, VALVE CAB DOWN

Description: Voltage feed to cab tilt control valve, cab down.
Signal value:

active.


8 Control system – 8.4.11.5 MOVE-CAB 167
MOVE-CAB, menu 5
page
–
PRESENT OUTPUT SIGNAL, ACTIVATE SLID-CAB

Description: Voltage feed to control valve to activate sliding cab.
ACTIVATE SLID-CAB XY Connection: digital out from D797-2/K1:25 to Y6080/1
Function: 9.10.4 Hydraulic sliding cab
007134
Signal value:

active.

MOVE-CAB, menu 6
page
–
OUTPUT RIGHT, REFERENCE

DIAG MOVE-CAB 6(X) (solenoid valve, side shift right).
OUTPUT RIGHT
007135
FEEDBACK XXX
Signal value:
NOTE
OUTPUT RIGHT, REQUIRED VALUE

load handling (solenoid valve, side shift right).
Y6021/2

OUTPUT RIGHT, FEEDBACK

Description: Present control current to control valve, load handling (so-
lenoid valve, side shift right).
Y6019/2
MOVE-CAB, menu 7
page
–
OUTPUT LEFT, REFERENCE

DIAG MOVE-CAB 7(X) (solenoid valve, side shift left).
OUTPUT LEFT
FEEDBACK XXX
013611

Signal value:
NOTE
OUTPUT LEFT, REQUIRED VALUE

load handling (solenoid valve, side shift left).
Y6020/2
OUTPUT LEFT, FEEDBACK

(solenoid valve, side shift left).
Y6020/2

8 Control system – 8.4.11.6 OPT 169
8.4.11.6 OPT
OPT, description
page
–
This group covers a number of options.

DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selections with function key for Enter.
EXT-ATTACH FREELIFT
008914
OPT, menu 1
page
–
OPTION SWITCH, S199-1

Description: Signal from switch S199-1.
DIAG OPTION 1(X) Circuit diagram: Circuit 9.1-1
OPTION SWITCH
S199-1 X S199-4 X Connection: signal from S199-1/1 to digital in D790-1/K6:9
S199-2 X Function: -
005488
S199-3 X
Signal value:
0 No signal.

Function: -
Signal value:
0 No signal.

Function: -
Signal value:
0 No signal.

170 8 Control system – 8.4.11.6 OPT

Function: -
Signal value:
0 No signal.
OPT, menu 2
page
–
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,

FRAME
Description: Voltage feed to central lubrication of frame.
DIAG OPTION 2(X)
CENTRAL LUBRICATION Connection: digital out from D797-1/K1:42 to M693-1/1
FRAME XY
Function: 9.14.1 Pump unit
005489
ATTACHMENT XY
Signal value:

active.

PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,

ATTACHMENT
Description: Voltage feed to central lubrication of attachment.
Function: 9.14.1 Pump unit
Signal value:

signal is active.

8 Control system – 8.4.11.6 OPT 171
OPT, menu 3
page
–
PRESENT OUTPUT SIGNAL, D797-1/K1:42

Description: Voltage feed from D797-1/K1:42.
DIAG OPTION 3(X)
Circuit diagram: -
D797-1 C1 P42 XY Connection: digital out D797-1/K1:42
Function: -
005490
Signal value:

active.

OPT, menu 4
page
–

DIAG OPTION 4(X)
Circuit diagram: -
D797-2 C1 P28 XY Connection: digital out from D797-2/K1:28
D797-2 C1 P42 XY
Function: -
005491
Signal value:

active.


172 8 Control system – 8.4.11.6 OPT

Circuit diagram: -
Connection: digital out from D797-2/K1:42
Function: -
Signal value:

active.

OPT, menu 5
page
–

DIAG OPTION 5(X)
Circuit diagram: -
D791-1 C1 P14 XY Connection: digital out from D791-1/K1:14
D791-1 C1 P28 XY
Function: -
005492
Signal value:

signal is active.

Circuit diagram: -
Connection: digital out from D791-1/K1:28
Function: -
Signal value:

active.


8 Control system – 8.4.11.7 RMI 173
8.4.11.7 RMI
RMI, description
page
–
This group covers RMI (Remote Machine Interface) functions.

DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selections with function key for Enter.
EXT-ATTACH FREELIFT
007657
RMI, menu 1
page
–
MIU SW VER
Description: Software version in RMI interface.
DIAG RMI 1(X) Circuit diagram: -
MIU SW VER XXXX.XXXX
MIU TIME XX.XX.XX Contact: -
Function: 11.6.5 RMI (Remote Machine Interface)
010094
Signal value: xxxx.xxxx = software number.
MIU TIME
Description: Date setting in RMI interface.
Circuit diagram: -
Contact: -
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
RMI, menu 2
page
–
SIGNAL QUALITY, GSM

Description: Signal strength of GSM-signal through receiver in the RMI
DIAG RMI 2(X) interface.
SIGNAL QUALITY
GSM XXX GPRS XXX Circuit diagram: Circuit 8.2-4
WLAN XXX RADIO XXX Contact: -
007659
SMS XXX: UNS.DATA XXX

Signal value: XXX = 0-100 = Signal strength, 0-100%.
SIGNAL QUALITY, GPRS

Description: Signal strength of GPRS-signal through receiver in the
RMI interface.
Contact: -

174 8 Control system – 8.4.11.7 RMI
SIGNAL QUALITY, WLAN

Description: Signal strength of WLAN-signal through receiver in the
RMI interface.
Contact: -
SIGNAL QUALITY, RADIO

Description: Signal strength of RADIO-signal through receiver in the
RMI interface.
Contact: -
SIGNAL QUALITY, SMS

Description: Signal strength of SMS-signal through receiver in the RMI
interface.
Contact: -
SIGNAL QUALITY, UNS.DATA

Description: Amount of unsent data in line in transmitter part in the RMI
interface.
Contact: -
Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.

8 Control system – 8.4.11.7 RMI 175
RMI, menu 3
page
–
ERROR
Description: Internal error code for the RMI interface
DIAG RMI 3(X) Circuit diagram: Circuit 8.2-4
ERROR XX.XX.XX.XX
ERR.VALID XX.XX.XX.XX Contact: -
ACT ERR XX.XX.XX.XX Function: 11.6.5 RMI (Remote Machine Interface)
007660
Signal value: XX.XX.XX.XX = Error code
ERR.VALID
Contact: -
ACT.ERR
Contact: -

176 8 Control system – 8.5 Setup
8.5 Setup
Setup, general
page
–
Settings are built-in functions to adapt the functions to the unique ma-
chine individual. Settings are performed via menus in the display. Set-
tings 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 done to compensate for mechanical and electrical toler-
ances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain func-
tions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
page
–
1 2
DANGER
INIT ELSERVO 1(X)
START CURRENT The settings influence the functions. Adjustments
LIFT may impair the function. If in doubt, contact Cargotec
4 STORED VALUE XXXmA 3 Service.
008891
PRESENT VALUE XXXmA
Example of initiation menu, start current for lift NOTE

function.
Initiation does not need to be performed in one process but each
1. Menu group step can be performed separately, independently of other steps.
2. Number of menus. Because the number of menus In order that hydraulic functions shall work satisfactorily and safely,
depends on machine configuration, it is specified as certain values must be set to operate the machine, this is known as
(X) in this manual. initiation.
3. Signal value
Initiation consists of several menus grouped according to functions.
4. Current variable
Each individual menu sets a specific variable. The menus are similar
in construction 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. Save 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.

8 Control system – 8.5.1 Initiation 177
START CURRENT
I [mA]
Specifies the start current to the solenoid valve for the selected func-
1 tion. The start current is the lowest current that can be actuated. In
2 practice, this controls how slowly a function can be operated. On func-
tions with analogue control activation (variable), e.g. lift, this is the cur-
3
006299
rent that is triggered when the lever leaves the zero position. On
t [s] certain functions with digital activation (off/on) which are soft-started,
1. Max. current (END CURRENT) this is the current which is triggered immediately the function is
2. Damping (PROC DAMPING) activated.
3. Start current (START CURRENT)
END CURRENT
Specifies the max. current to the solenoid valve for the selected func-
tion. The max. current is the highest current that can be triggered. In
practice, it controls how quickly a function can be operated. On func-
tions with analogue control activation (controllable), e.g. lift, this is the
current 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 damp-
ing. The interval is specified as 0-100% of the active range between
START CURRENT and END CURRENT.
Overview, initiations DCF360-450CSG
Function Menu
INIT DRIVE-TRAIN, menu 9
1 Engine, speed limitation (limitation of engine speed
page 208

1 Engine, automatic engine shut-down on idle
page 208
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13
page 209
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1

page 205
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2

page 205
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3
page 206
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4
page 206
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5

page 207
2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6

page 207

178 8 Control system – 8.5.1 Initiation
Function Menu
2 Transmission, speed limitation (gear lock-out)
page 208

2 Transmission, automatic engine speed reduction for shift forward - reverse
page 209
7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1 page 184

INIT ELSERVO, menu 2 page 184
7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3 page 185

Note: The current value is for unloaded machines. When loaded, the current value INIT ELSERVO, menu 4 page 185
is controlled by the limited lowering speed.
7.3 Extension out INIT ATTACH for DCF360-450CSG

page 191
INIT ATTACH, menu 2 page 192
7.3 Extension in INIT ATTACH, menu 3 page 192

7.4 Side shift INIT ATTACH, menu 5 page 193

7.5 Spreading out INIT ATTACH, menu 9 page 194

7.5 Spreading in INIT ATTACH, menu 12 page 195

7.7 Tilt INIT ELSERVO, menu 5 page 185

7.8 Levelling INIT ATTACH, menu 7 page 193


Overview, initiations DCF 280-520
Function Menu
1 Engine, speed limitation (limitation of engine speed)
page 208

page 208
page 209

page 205

page 205
page 206
page 206

page 207

page 207

page 208

page 209
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 1 page 200
lever response
speed dependent INIT STEERING, menu 3 page 201
INIT STEERING, menu 4 page 202
steering angle right INIT STEERING, menu 8 page 203
steering angle left INIT STEERING, menu 10 page 204



Function Menu
7.2 Lifting/lowering, lift trolley INIT ELSERVO, menu 13 page 188
7.2 Lifting/lowering, lower trolley INIT ELSERVO, menu 15 page 189

7.4 Side shift INIT ELSERVO, menu 9 page 187

7.5 Spreading (positioning) INIT ELSERVO, menu 11 page 187


9.10.4 Hydraulic sliding cab INIT SLID-CAB, menu 1 page 210

INIT SLID-CAB, menu 2 page 211

Overview, initiations DCF 70
Function Menu
page 208

page 208
page 209

page 205

page 205
page 206
page 206

page 207

page 207

page 208

page 209







Overview, initiations DCF 80-100
Function Menu
INIT DRIVE-TRAIN, menu 9 page 208

page 208
page 209
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page 205
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page 205
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page 206
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page 206
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page 207
2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6 page 207

page 208

page 209






7.8 Levelling INIT ATTACH, menu 7 page 193


Initiate hydraulic function, work instruction

page
–
To select a hydraulic function to initiate, proceed as follows:

All hydraulic functions are initiated in the same way.
1 Navigate to the service menu.
2 Press Enter.
000056
3 Enter the code for initiation.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Diag-

nostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
INITIATION firm with Enter.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN Each initiation consists of a sequence of a number of menus. The
SLIDING-CAB first menu for the selected initiation opens in the display. Select
007169
RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INIT ELSERVO 1(X)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
005494
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".

184 8 Control system – 8.5.1.1 ELECTRIC SERVO
8.5.1.1 ELECTRIC SERVO

INIT ELSERVO
page
–
The menu group for this function covers initiation of the electric servo
INITIATION functions for load handling.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN For DCF360-450CSG, DCF 70 and DCF 80-100, settings are made
SLIDING-CAB for lift, lower, tilt in and tilt out. For other load handling functions, see
007169
RETURN INIT ATTACH page 191.
For DCF 280-520, settings are made for lift, lower, tilt in, tilt out, side
shift left, side shift right, spreading in and spreading out.
DANGER
The settings affect the functions for lift, lower, tilt,
and, for DCF370-500, spreading and side shift. Adjust-
ment can impair functionality. If in doubt, contact
Cargotec Service.
NOTE
step can be performed separately, independently of other steps.
INIT ELSERVO, menu 1

page
–
START CURRENT, LIFT

INIT ELSERVO 1(X)
Description: Start current for activation of solenoid valve, lift mast
START CURRENT
LIFT (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005494
PRESENT VALUE XXXmA Adjust 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 stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.

page
–
END CURRENT, LIFT

INIT ELSERVO 2(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
LIFT the solenoid valve for mast lift (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005495
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.

8 Control system – 8.5.1.1 ELECTRIC SERVO 185


page
–
START CURRENT, LOWER

INIT ELSERVO 3(X)
Description: Start current for the activation of the solenoid valve for
START CURRENT
LOWER mast lowering (Y6004).
005496
with the R-key.
Component: Solenoid valve, lower mast(Y6004)

page
–
END CURRENT, LOWER

INIT ELSERVO 4(X)
END CURRENT
LOWER the solenoid valve for mast lowering (Y6004).
005497
R-key.
Component: Solenoid valve, stand (Y6004)

page
–
START CURRENT, TILT IN

INIT ELSERVO 5(X)
Description: Start current for the activation of the solenoid valve for tilt
START CURRENT
TILT IN in (Y6011).
007139
with the R-key.
Component: Solenoid valve, tilt in (Y6011)


page
–
END CURRENT, TILT IN

INIT ELSERVO 6(X)
END CURRENT
TILT IN the solenoid valve for tilt in (Y6011).
007140
R-key.
Component: Solenoid valve, tilt in (Y6011)

page
–
START CURRENT, TILT OUT

INIT ELSERVO 7(X)
Description: Start current for the activation of the solenoid valve for tilt
START CURRENT
TILT OUT out (Y6010).
007141
with the R-key.
Component: Solenoid valve, tilt out (Y6010)

page
–
END CURRENT, TILT OUT

INIT ELSERVO 8(X)
END CURRENT
TILT OUT the solenoid valve for tilt out (Y6010).
007142
R-key.
Component: Solenoid valve, tilt out (Y6010)


page
–
START CURRENT, SIDE SHIFT LE/RI

INIT ELSERVO 9(X)
Description: Start current of activation of solenoid valve for side shift
START CURRENT
SIDESHIFT LE/RI left (Y6020) and solenoid valve for side shift right (Y6021).
007143
with the R-key.
Function: 7.4.5 Load handling control valve (DCF 280-520)
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)

page
–
END CURRENT, SIDE SHIFT LE/RI

INIT ELSERVO 10(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SIDESHIFT LE/RI lenoid valve for side shift left (Y6020) and solenoid valve for side shift
STORED VALUE XXXmA right (Y6021).
007144
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
R-key.
Function: 7.4.5 Load handling control valve (DCF 280-520)
valve for side shift right (Y6021)

page
–
START CURRENT, SPREADING IN/OUT

INIT ELSERVO 11(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADING IN/OUT in (Y6019) and solenoid valve for spreading out (Y6018).
007145
with the R-key.
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)


page
–
END CURRENT, SPREADING IN/OUT

INIT ELSERVO 12(X)
END CURRENT
SPREADING IN/OUT lenoid valve for spreading in (Y6019) and solenoid valve for spreading
STORED VALUE XXXmA out (Y6018).
007146
R-key.
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)

page
–
START CURRENT, LIFT 2

INIT ELSERVO 13(X)
Description: Start current for activation of solenoid valve, lift carriage
START CURRENT
LIFT 2 (Y6022).
007147
with the R-key.
Component: Solenoid valve, lift carriage (Y6022)

page
–
END CURRENT, LIFT 2

INIT ELSERVO 14(X)
END CURRENT
LIFT 2 the solenoid valve for carriage lift (Y6022).
007148
R-key.
Component: Solenoid valve, lift carriage (Y6022)


page
–
START CURRENT, LOWER 2

INIT ELSERVO 15(X)
Description: Start current for activation of solenoid valve, lower car-
START CURRENT
LOWER 2 riage (Y6023).
007149
with the R-key.
Component: Solenoid valve, lower carriage (Y6023)

page
–
END CURRENT, LOWER 2

INIT ELSERVO 16(X)
END CURRENT
LOWER 2 the solenoid valve for carriage lowering (Y6023).
007150
R-key.
Component: Solenoid valve, lower carriage (Y6023)

page
–
DAMP (PROC), LIFT

INIT ELSERVO 17(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
LIFT for mast lift (Y6005) when the mast reaches max height.
STORED VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
PRESENT VALUE XX value with the plus and minus keys. Save the set value with the Enter
I [mA] key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
STORED VALUE: indicates stored value in percent.
2 Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
3
007151

t [s]
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
3. Start current (START CURRENT) rent. 0% means full damping i.e. start current.


page
–
START CURRENT, 6TH OUT

INIT ELSERVO 18(X)
Description: start current for the activation of the 6th function out.
START CURRENT
6:E OUT PRESENT VALUE: Indicates the current value for the start current.
STORED VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
013612
PRESENT VALUE XXXmA the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
Function: -
Component: -

page
–
END CURRENT, 6TH OUT

INIT ELSERVO 19(X)
Description: control current on full lever actuation for the activation of
END CURRENT
6:E OUT the 6th function out.
013613
R-key.
Function: -
Component: -

page
–
START CURRENT, 6TH IN

INIT ELSERVO 20(X)
Description: start current for the activation of the 6th function in.
START CURRENT
6:E IN PRESENT VALUE: Indicates the current value for the start current.
STORED VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
013614
PRESENT VALUE XXXmA the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
Function: -
Component: -

page
–
END CURRENT, 6TH IN

INIT ELSERVO 21(X)
Description: control current on full lever actuation for the activation of
END CURRENT
6:E IN the 6th function in.
013615
R-key.

8 Control system – 8.5.1.2 ATTACHMENT 191

Function: -
Component: -
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
This function handles initiation of the attachment functions:

INITIATION
ELSERVO ATTACHMENT • extension, side shift, spreading, rotation and controllable levelling
STEERING DRIVE-TRAIN for DCF360-450CSG, see INIT ATTACH for DCF360-450CSG
SLIDING-CAB 007170 page 191
RETURN • side shift and spreading for DCF 70, see INIT ATTACH for DCF
70 and DCF 80-100 page 196
• side shift, spreading and controllable levelling for DCF 80-100,
see INIT ATTACH for DCF 70 and DCF 80-100 page 196
DANGER
The settings affect the functions extension, side shift,
spreading, rotation and controllable levelling for
DCF360-450CSG, the functions side shift and spread-
ing for DCF 70, and the functions side shift, spreading
and controllable levelling for DCF 80-100. Adjust-
ments could impair functionality. In the event of un-
certainty, contact Cargotec Service.
NOTE
INIT ATTACH for DCF360-450CSG

page
–
INIT ATTACH, menu 1

START CURRENT, PROJECTION OUT
INIT ATTACH 1(X)
Description: Start current for activation of solenoid valve for extension
START CURRENT
PROJECTION OUT left side out (Y6046-2) and solenoid valve for extension right side out
STORED VALUE XXXmA (Y6046-4).
005509
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
Component: Solenoid valve, extend left side out (Y6046-2), Solenoid
valve, extend right side out (Y6046-4).
Signal value: XXXmA = 0 - 999 mA

192 8 Control system – 8.5.1.2 ATTACHMENT
INIT ATTACH, menu 2

END CURRENT, PROJECTION OUT
INIT ATTACH 2(X)
END CURRENT
PROJECTION OUT left side out (Y6046-2) and solenoid valve for extension right side out
005510
R-key.
INIT ATTACH, menu 3

START CURRENT, PROJECTION IN
INIT ATTACH 3(X)
START CURRENT
PROJECTION IN left side in (Y6046-1) and solenoid valve for extension right side in
005511
Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
INIT ATTACH, menu 4

END CURRENT, PROJECTION IN
INIT ATTACH 4(X)
Description: Control current at full lever angle for activation of solenoid
END CURRENT
PROJECTION IN valve for extension left side in (Y6046-1) and solenoid valve for exten-
STORED VALUE XXXmA sion right side in (Y6046-3).
005512
R-key.

INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
START CURRENT
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
005513
with the R-key.
valve for side shift right (Y6021).
INIT ATTACH, menu 6

END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
END CURRENT
SIDESHIFT lenoid valve for side shift left (Y6020) and solenoid valve for side shift
005514
R-key.
INIT ATTACH, menu 7

Not used.
INIT ATTACH, menu 8

Not used.

INIT ATTACH, menu 9

START CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 9(X)
START CURRENT
SPREADER OUT, 20'-40' out 20’-40’ (Y6018).
I [mA] the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
2 Function: 7.5.2 Control valve attachment
3 005517
Component: Solenoid valve for spreading out 20’-40’ (Y6018)
t [s]
2. Damping (PROC DAMPING)
INIT ATTACH, menu 10

END CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 10(X)
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out 20’-40’ (Y6018).
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
3
005518

t [s]

DAMP (PROC), SPREADER OUT, 20’-40’
INIT ATTACH 11(X)
DAMP PROC
SPREADER OUT, 20’-40’ for spreading in 20’-40’ (Y6018) when outward spreader
STORED VALUE XX approaches 40’.
PRESENT VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] 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
1 R-key.
2 STORED VALUE: indicates stored value in percent.
011295
t [s] Component: Solenoid valve for spreading out 20’-40’ (Y6018)

1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
2. Damping (PROC DAMPING) rent. 0% means full damping i.e. start current.


START CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 12(X)
START CURRENT
SPREADER IN, 40'-20' in 40’-20’ (Y6019).
with the R-key.
1
3
005520
Component: Solenoid valve for spreading in 40’-20’ (Y6019)
t [s]

END CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 13(X)
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in 40’-20’ (Y6019).
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
3
005521
Component: Solenoid valve for spreading in 40’-20’ (Y6019)

t [s]

DAMP (PROC), SPREADER IN, 40’-20’
INIT ATTACH 14(X)
DAMP PROC
SPREADER IN, 40’-20’ for spreading in 40’-20’ (Y6019) when inward spreader
STORED VALUE XX approaches 20’
1 R-key.
011296
t [s] Component: Solenoid valve for spreading in 40’-20’ (Y6019)

1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
2. Damping (PROC DAMPING) rent. 0% means full damping i.e. start current.

INIT ATTACH for DCF 70 and DCF 80-100

page
–
INIT ATTACH, menu 1

Not used.
INIT ATTACH, menu 2

Not used.
INIT ATTACH, menu 3

Not used.
INIT ATTACH, menu 4

Not used.
INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
START CURRENT
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
005513
with the R-key.
INIT ATTACH, menu 6

END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
END CURRENT
SIDESHIFT lenoid valve for side shift left (Y6020) and solenoid valve for side shift
005514
R-key.

INIT ATTACH, menu 7

START CURRENT, LEVELLING
INIT ATTACH 7(X)
Description: Start current of activation of solenoid valve for levelling
START CURRENT
LEVELLING left (Y6036) and solenoid valve for levelling right (Y6035).
010067
with the R-key.
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
INIT ATTACH, menu 8

END CURRENT, LEVELLING
INIT ATTACH 7(X)
END CURRENT
LEVELLING lenoid valve for levelling left (Y6036) and solenoid valve for levelling
010068
R-key.
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
INIT ATTACH, menu 9

START CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 9(X)
START CURRENT
SPREADER OUT, 20'-40' out left (Y6018L) and solenoid valve for spreading out right (Y6018R)
with the R-key.
1
3
005517

t [s]


END CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 10(X)
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out left (Y6018L) and solenoid valve for
STORED VALUE XXXmA spreading out right (Y6018R).
I [mA] the value with the plus and minus keys. Save the set value with the En-
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 005518
t [s] Component: Solenoid valve for spreading out left (Y6018L) and sole-
1. Max. current (END CURRENT) noid valve for spreading out right (Y6018R).
2. Damping (PROC DAMPING) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER OUT, 20’-40’
INIT ATTACH 11(X)
DAMP (PROC)
SPREADER OUT, 20'-40' for spreading out left (Y6018L) and solenoid valve for spreading out
STORED VALUE XX right (Y6018R) when spreading out approaches 40’.
1 R-key.
005519
t [s] Component: Solenoid valve for spreading out left (Y6018L) and sole-
1. Max. current (END CURRENT) noid valve for spreading out right (Y6018R).

START CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 12(X)
START CURRENT
SPREADER IN, 40'-20' in left (Y6019L) and solenoid valve for spreading in right (Y6019R)
with the R-key.
1
3
005520
Component: Solenoid valve for spreading in left (Y6019L) and sole-

t [s] noid valve for spreading in right (Y6019R).
1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA


END CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 13(X)
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in left (Y6019L) and solenoid valve for
STORED VALUE XXXmA spreading in right (Y6019R)
1 R-key.
t [s] 005521 Component: Solenoid valve for spreading in left (Y6019L) and sole-
1. Max. current (END CURRENT) noid valve for spreading in right (Y6019R).
2. Damping (PROC DAMPING) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER IN, 40’-20’
INIT ATTACH 14(X)
DAMP (PROC)
SPREADER IN, 40'-20' for spreading in left (Y6019L) and solenoid valve for spreading in right
STORED VALUE XX (Y6019R) when spreading in approaches 20’.
1 R-key.
005522
t [s] Component: Solenoid valve for spreading in left (Y6019L) and sole-
1. Max. current (END CURRENT) noid valve for spreading in right (Y6019R).

200 8 Control system – 8.5.1.3 STEERING
8.5.1.3 STEERING
INIT STEERING
page
–
This function covers initiation of lever steering or mini-wheel.

INITIATION
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB DANGER
007171
RETURN
The settings influence the functions. Adjustments
may impair the function. If in doubt, contact Cargotec
Service.
NOTE
INIT STEERING, menu 1

page
–
CHARACTER OF THE STEERING LEVER

INIT STEERING 1(X)
Description: Indicates the responsiveness of the steering lever in ac-
CHARACTER OF THE
STEERING LEVER, 0-31 cordance with 32 predefined curves (0-31) 0 means that linear wheel
STORED VALUE XX angle is uniform in relation to lever angle during the whole lever move-
PRESENT VALUE XX ment. 31 means that the wheel angle is small at the beginning of the
lever movement and large at the end.
U [V] 0
PRESENT VALUE: indicates current curve. Change curve with the
plus or minus keys. Save the set curve with the Enter key. Go to the
next menu with the arrow keys. Go back from initiation using the R key.
31
STORED VALUE: indicates saved curve.
Function: 5.2 Power-assisted steering system (product option lever
005572
steering or mini-wheel)
X Component: -
U = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement

8 Control system – 8.5.1.3 STEERING 201

page
–
BREAK POINT BP1

INIT STEERING 2(X)
Description: Speed for cut-off point 1. Cut-off points are used to adapt
BRAKE POINT BP1
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 1.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 1.
% BP2 Function: 5.2 Power-assisted steering system (product option lever
% BP3 steering or mini-wheel)
005573
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP1 in km/h.
V [kph] = machine’s speed in km/h
BP1 = speed setting for break point 1
%BP2 = per cent of control current to solenoid
valve at BP2
valve at BP3

page
–
BREAK POINT BP2

INIT STEERING 3(X)
Description: Speed for cut-off point 2. Cut-off points are used to adapt
BRAKE POINT BP2
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 2.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 2.
% BP3 steering or mini-wheel)
005574
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP2 in km/h.
V [kph] = machine’s speed in km/h
valve at BP2
valve at BP3


page
–
BREAK POINT BP3

INIT STEERING 4(X)
Description: Speed for cut-off point 3. The cut-off points are used to
BRAKE POINT BP3
(kph) adapt the steering angle in accordance with the machine’s speed. This
STORED VALUE XX.X enables both sensitive steering at low speeds and stable steering at
PRESENT VALUE XX.X higher speeds.
I [mA] PRESENT VALUE: indicates present speed setting for cut-off point 1.
100% Change speed with plus or minus keys. Save set speed with the Enter-
key. Go to the next menu with arrow keys. Exit initiation with the R-key.
% BP2 STORED VALUE: indicates saved speed for break point 3.
V [kph] 005575 steering or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XX.X = speed for BP3 in km/h.
valve at BP2
%BP3 = per cent of control current to
solenoid valve at BP3

page
–
PROC REDUCTION, AT PB2

INIT STEERING 5(X)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP2 for steering right (Y636-3) and solenoid valve for steering left (Y636-4)
STORED VALUE XXX at BP2.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
005576
V [kph] steering or mini-wheel)

BP1 BP2 BP3
Component: -
V [kph] = machine’s speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
%BP2 = per cent of control current to solenoid valve at
BP2
%BP3 = per cent of control current to solenoid valve at
BP3

8 Control system – 8.5.1.3 STEERING 203

page
–
PROC REDUCTION, AT PB3

INIT STEERING 6(X)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP3 for steering right (Y636-3) and solenoid valve for steering left (Y636-4)
STORED VALUE XXX at BP3.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
005577
V [kph] steering or mini-wheel)
BP1 BP2 BP3
Component: -
V [kph] = machine’s speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
valve at BP2
valve at BP3

page
–
START CURRENT, STEERING RIGHT

INIT STEERING 7(X)
Description: Start current to the solenoid valve for steering right
START CURRENT
STEERING RIGHT (Y636-3).
005578
with the R key.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636-3)

page
–
END CURRENT, STEERING RIGHT

INIT STEERING 8(X)
Description: Control current to the solenoid valve for steering right
END CURRENT
STEERING RIGHT (Y636-3) at end lever position.
005579
R key.
Component: Solenoid valve for steering right (Y636-3)


page
–
START CURRENT, STEERING LEFT

INIT STEERING 9(X)
Description: Start current to the solenoid valve for steering left
START CURRENT
STEERING LEFT (Y636-4).
005580
with the R-key.
Component: Solenoid valve for steering left (Y636-4)

page
–
END CURRENT, STEERING LEFT

INIT STEERING 10(X)
Description: Control current to the solenoid valve for steering left
END CURRENT
STEERING LEFT (Y636-4) at end lever position.
005581
R-key.
Component: Solenoid valve for steering left (Y636-4)

8 Control system – 8.5.1.4 DRIVE-TRAIN 205
8.5.1.4 DRIVE-TRAIN
INIT DRIVE-TRAIN
page
–
This function covers engine and transmission initiation.

INITIATION
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB DANGER
007172
RETURN
The settings influence the functions. Adjustments
may impair the function.
If uncertain, contact Cargotec Service.
NOTE
NOTE
The machine must be stationary with parking brake applied in or-
der 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.

page
–
START IN 2ND
INIT DRIVE-TRN 1(X)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
1=YES 0=NO in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
005525
PRESENT VALUE XXX 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.
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

page
–
VEHICLE SPEED F-R

INIT DRIVE-TRN 2(X)
Description: Setting of highest permitted speed for shifting between
VEHICLE SPEED F-R
forward and reverse.
005582

206 8 Control system – 8.5.1.4 DRIVE-TRAIN

Component: -
Signal value: XXX = speed in km/h

page
–
ENGINE SPEED F-R

INIT DRIVE-TRN 3(X)
Description: Setting of highest permitted engine speed when shifting
ENGINE SPEED F-R
between forward and reverse.
STORED VALUE XXX 005583
PRESENT VALUE XXX NOTE
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
PRESENT VALUE: Indicates the current setting. Change the value
Component: -
Signal value: XXX = engine speed (rpm)

page
–
ENGINE SPEED N-DIR

INIT DRIVE-TRN 4(X)
Description: Setting of highest permitted engine speed for shifting from
ENGINE SPEED N-DIR
neutral to gear.
STORED VALUE XXX
005584

This setting takes priority over the setting in INIT DRIVE-TRAIN,
menu 3 page 206. If the engine speed is set lower in this menu
that in menu 3, this engine speed will also apply to switching di-
rection of travel. This occurs because the transmission must shift
into neutral when changing direction of travel.
Component: -


page
–
ENGINE SPEED, KICKDOWN 1ST

INIT DRIVE-TRN 5(X)
Description: Setting of the lowest engine rpm when conditions for kick-
ENGINE SPEED
KICK DOWN 1:ST down to 1st gear are to be checked.
STORED VALUE XXX
007152
If the rpm is set too low, kick-down may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not
at all.
Component: -

page
–
VEHICLE SPEED, DECLUTCH

INIT DRIVE-TRN 6(X)
Description: Setting of highest permitted speed for disengaging the
VEHICLE SPEED
DECLUTCH transmission.
005586
Component: -
Signal value: XXX = speed (km/h)

page
–
Not used.

page
–
Not used.

208 8 Control system – 8.5.1.4 DRIVE-TRAIN

page
–
OPTION SPEED LIMIT

INIT DRIVE-T 9(X)
OPTION SPEED LIMIT
(km/h)
Description: Setting of speed limitation.
STORED VALUE XXX
005587
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Component: -
Signal value: XXX = speed (km/h)

page
–
OPTION HIGHEST GEAR AT SPEED LIMIT

INIT DRIVE-T 10(X)
OPTION HIGHEST GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
005588
PRESENT VALUE XXX through blocked gears).

Component: -
Signal value: XXX = gear

page
–
OPTION ENGINE SHUT DOWN

INIT DRIVE-T 11(X)
OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown.
STORED VALUE XXX
005589
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.


page
–
F-R WITHOUT ENGINE SPEED REDUCTION

INIT DRIVE-T 12(X)
Description: activation or deactivation of automatic engine speed re-
F-R WITHOUT ENGINE
SPEED REDUCTION duction when changing travel direction forward - reverse. This makes
STORED VALUE X it possible to change travel direction without releasing the accelerator
005590
PRESENT VALUE X pedal. Engine speed drops to that set in menu 3 (see INIT DRIVE-
TRAIN, menu 3 page 206). If no value is set in menu 3, engine speed
is reduced to idling speed.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

page
–
AUTO ENGINE SPEED AT LIFT

INIT DRIVE-T 13(X)
AUTO ENGINE SPEED AT
LIFT
Description: Activation or deactivation of automatic engine speed in-
STORED VALUE X
005591
PRESENT VALUE X crease during lift.

Component: -
Signal value:
X = 1, activated
X = 0, deactivated

210 8 Control system – 8.5.1.5 SLIDING-CAB
8.5.1.5 SLIDING-CAB
INIT SLIDING-CAB
page
–
This function handles initiation of the hydraulic sliding cab.

INITIATION
ELSERVO ATTACHMENT The sliding cab is smooth started by means of the control current to
STEERING DRIVE-TRAIN the solenoid valves being increased from a low start value to a max.
SLIDING-CAB level. When the cab reaches an end position the speed is dampened
007161
RETURN by means of the control current being reduced.
DANGER
The settings influence the function for hydraulic slid-
ing cab. Adjustments may impair the function. If in
doubt, contact Cargotec Service.
NOTE
INIT SLID-CAB, menu 1

page
–
START CURRENT, RIGHT

INIT SLID-CAB 1(X)
Description: Start current to solenoid valve side shift right (Y6021) at
START CURRENT
RIGHT activation of sliding cab. The control current controls the start speed
STORED VALUE XXXmA for cab sliding to the right.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
3 Function: 9.10.4 Hydraulic sliding cab
007162
t [s] Component: Solenoid valve, side shift right (Y6021)


8 Control system – 8.5.1.5 SLIDING-CAB 211

page
–
END CURRENT, RIGHT

INIT SLID-CAB 2(X)
Description: Control current to solenoid valve for side shift right
END CURRENT
RIGHT (Y6021) after full ramp time at activation of switch for cab sliding. This
STORED VALUE XXXmA current controls maximum speed cab sliding speed to the right.
1 R-key.
t [s] 007163 Component: Solenoid valve, side shift right (Y6021)

page
–
Not used.

page
–
START CURRENT, LEFT

INIT SLID-CAB 4(X)
Description: Start current to solenoid valve side shift left (Y6020) at ac-
START CURRENT
LEFT tivation of sliding cab. The control current controls the start speed for
STORED VALUE XXXmA cab sliding to the left.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
007165
t [s] Component: Solenoid valve, side shift left (Y6020)


212 8 Control system – 8.5.1.5 SLIDING-CAB

page
–
END CURRENT, LEFT

INIT SLID-CAB 5(X)
Description: Control current to solenoid valve for side shift left (Y6020)
END CURRENT
LEFT after full ramp time at activation of switch for cab sliding. This current
STORED VALUE XXXmA controls maximum speed cab sliding speed to the left.
1 R-key.
3 007166 Function: 9.10.4 Hydraulic sliding cab
t [s] Component: Solenoid valve, side shift left (Y6020)

page
–
Not used.

8 Control system – 8.5.2 Calibration 213
8.5.2 Calibration
Calibration, description
page
–
Certain functions require calibration in order to operate correctly. The

control system has integrated calibrations for these functions.
SCALE
This menu handles calibration of sensors to weight indication.
CALIBRATION
Scale, calibration page 215
SCALE STEERING
DRIVE-TRAIN RETURN
000062
STEERING
This menu handles calibration of the steering lever for lever steering,
CALIBRATION see:
SCALE STEERING Lever steering, calibration page 215

DRIVE-TRAIN RETURN
000074
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVE-TRAIN
This function handles calibrations for engine and transmission. The
CALIBRATION menu loop contains two different calibrations which are not connected
to each other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration page 216
000078
Transmission, calibration page 219
NOTE
steps.

214 8 Control system – 8.5.2 Calibration
Calibration menu, explanation

The figure shows an example of a menu, here for calibrating the centre
1 2
position of the lever steering control. The table indicates what a de-
scription contains (which follows in the next section):
5 CALIBR STEERING 1(X)
STEERING LEVER CENTER
POSITION Designation: Example Description
4 STORED VALUE X.XXV
3 Variable (position 5): STEERING Name of the input signal/
008892
PRESENT VALUE X.XXV
LEVER CENTRE POSITION control signal affected.
1. Menu group Description: Setting the centre po- A short description of what is
2. Sequence number. Because the number of menus sition of the lever steering control calibrated and the meaning
depends on machine configuration, it is specified as (R825). of the variables.
(X) in this manual.
STORED VALUE: Gives the stored
3. Signal value
signal value for lever steering con-
4. STORED indicates stored value, PRESENT indi-
trol (R825), centre position.
cates current value of the signal to be calibrated
5. Heading of menu figure PRESENT VALUE: Gives the
present signal value for lever steer-
ing control (R825), centre position.
Function: 5.2 Power-assisted Name of current function.

steering system
Component: Control joystick Indicates the component

steering (R825) whose signal is the basis for
calibration.
Calibration, work instructions

page
–
Calibration consists of a number of menus (the number of menus de-

pends on the function). All menus are similar in construction and there-
fore the descriptions are similar.
To select a function to calibrate, proceed as follows:
1 Navigate to the service menu.

2 Press Enter.
000056
3 Enter the code for calibration.

1 23
4 5 NOTE
000060
The code determines which service menu is activated

(Diagnostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
CALIBRATION firm with Enter.
SCALE STEERING Each calibration consists of a sequence of a number of menus.

DRIVE-TRAIN RETURN The first menu for the selected calibration appears in the display.
000062
Select the next menu with key 1 and 2 (arrow function).

8 Control system – 8.5.2.1 Calibrate SCALE 215
8.5.2.1 Calibrate SCALE

Scale, calibration
page
–
1 Park the machine on level ground with the mast vertical and with-
out load.
CALIBR SCALE, menu 1

2 Go into the calibration menus and select CALIBR SCALE, menu
CALIBR SCALE 1(X) 1, see Calibration, work instructions page 214
PRESENT LOAD XXXXXkg
Description: Setting of dead weight (tare).
STORED TARE XXXXXkg PRESENT LOAD: indicates present load.
PRESENT TARE XXXXXkg 007154
PRESENT TARE: indicates present dead weight (tare).
STORED VALUE: indicates stored dead weight (tare).
3 Move the mast to the position where weighing normally is done.
Lower just a little and wait until the value in present load has
stabilised.
4 Store values with function key for Enter.
CALIBR SCALE, menu 2
CALIBR SCALE 2(X)
Description: Diagnostic menu for scale. The values come from the
PRESENT LOAD XXXXXkg
LIFT PRESSURE XXXbar Vehicle data file and cannot be adjusted.
GEAR RATIO MAST X PRESENT LOAD: indicates present load.
007155
CYL. AREA XXXXXmm2

LIFT PRESSURE: indicates lift pressure.
GEAR RATIO MAST: indicates gear ratio for the mast.
CYL. AREA: indicates cylinder area.
8.5.2.2 Calibrate STEERING

Lever steering, calibration
page
–
NOTE
steps.
1 Start key in operating position.
CALIBR STEERING, menu 1

2 Go into the calibration menus and select CALIBR STEERING,
CALIBR STEERING 1(X) menu 1, see Calibration, work instructions page 214.
STEERING LEVER CENTER
POSITION STEERING LEVER CENTRE POSITION
STORED VALUE X.XXV Description: Setting the centre position for Control joystick
005529
PRESENT VALUE X.XXV steering (R825).

PRESENT VALUE: indicates current signal value from lever
steering control (R825).
STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).

216 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN
Component: Control joystick steering (R825)

3 Move steering lever to required centre position.
4 Store the position with function key for Enter.

5 Select CALIBR STEERING, menu 2.
CALIBR STEERING 2(X)
STEERING LEVER LEFT POSITION
STEERING LEVER LEFT
POSITION Description: Setting of position for max. angle left on lever steer-
STORED VALUE X.XXV 005530 ing control (R825).
PRESENT VALUE X.XXV
PRESENT VALUE: indicates current signal value from lever
steering control (R825).
ing control (R825).
6 Move steering lever to required position for max. angle left.

8 STEERING LEVER RIGHT POSITION
CALIBR STEERING 3(X)
Description: Setting of position for max. angle right on lever steer-
STEERING LEVER RIGHT
POSITION ing control (R825).
STORED VALUE X.XXV PRESENT VALUE: indicates current signal value from lever
005531
PRESENT VALUE X.XXV steering control (R825).

ing control (R825).
9 Move steering lever to required position for max. angle right.
8.5.2.3 Calibrate DRIVETRAIN

Accelerator pedal, calibration
page
–
To calibrate the accelerator pedal for forward driving, use steps 1-7.
To calibrate accelerator pedal 2 (with a reversible driver’s seat), use
steps 1 + 8-13.
1 Start key in operating position, engine switched off.

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 217
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(X) see Calibration, work instructions page 214.
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
STORED VALUE X.XXV Description: setting the accelerator’s pedal zero position.
005532
PRESENT VALUE X.XXV
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
3 Release the accelerator pedal.
DRIVE-TRAIN, menu 2
5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(X) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, PRESS (B690-1).
THE PEDAL TO FLOOR
STORED VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
PRESENT VALUE X.XXV accelerator pedal (R690-1).
00

Function: 1 Engine
6 Press the accelerator pedal down fully and keep it down until the
position is stored.
DRIVE-TRAIN, menu 5
8
CALIBR DRIVE-TRN 5(X)
ACCELERATOR 2, Go into the calibration menus and select DRIVE-TRAIN, menu 5,
RELEASE THE PEDAL see Calibration, work instructions page 214.
STORED VALUE X.XXV
ACCELERATOR 2, RELEASE THE PEDAL
005534
PRESENT VALUE X.XXV

Description: Calibration of accelerator pedal 2, for driving rear-
ward on machines with reversible driver’s seat. Setting of accel-
erator pedal’s zero position.
Function: 1 Engine
9 Release the accelerator pedal.

DRIVE-TRAIN, menu 6
11
ACCELERATOR 2, PRESS ACCELERATOR 2, PRESS THE PEDAL TO FLOOR
THE PEDAL TO FLOOR Description: Calibration of accelerator pedal 2 for driving rear-
STORED VALUE X.XXV
ward on machines with a reversible driver’s seat. Setting of full
005535
PRESENT VALUE X.XXV
throttle position for the accelerator pedal (B690-2).
Function: 1 Engine
12 Press the accelerator pedal down fully and keep it down until the
position is stored.
DRIVE-TRAIN, menu 7
14
CCT EMISSION CONTROL CCT EMISSION CONTROL
STEP XXX COMP. XXX Description: calibration of CCT EMISSION CONTROL.
MIN XXX MAX XXX
011645
DATA XXX STEP: specifies with text the action being performed or due to be
performed.
COMP: shows the active component
MIN: specifies MIN. value for the selected component.
MAX: specifies MAX. value for the selected component.
DATA: indicates actual value. Text is displayed to the right of the
data describing the driver’s action as described below.

15 Access the menu and press ENTER, follow the instructions in the
display:
No. Text Action

8 START ENG Start the engine.
9 HI IDLE Rev up the engine to full revolutions
10 ADJUST? Unable to adjust in this application. (Must
be confirmed with ENTER)
11 WAIT Testing the system, wait
12 FAIL Installation failed, try again
13 WAIT Testing the system, wait
14 REPEAT? (Must be confirmed with ENTER)
15 INSTALL OK The installation was successful
16 WAIT Wait
- - -
18 FAIL
19 FUEL? (Must be confirmed with ENTER)
20 STOP ENG Turn off engine.
In the event of FAIL the latest action must be repeated to

continue.
If INSTALL OK is shown then the installation is complete.
Transmission, calibration
page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
2 Go into the calibration menus and select DRIVE-TRAIN, menu 4,
CALIBR DRIVE-TRN 4(X) see Calibration, work instructions page 214.
GEARBOX WARM UP
MODE X 3 Check that the oil temperature is at least 61 C, (press Enter to
ACTUAL TEMP XXX show Acttemp and Target temp).
005610
TARGET TEMP XXX If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.
A. Apply the service brake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for
20 seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idling speed.
D. Repeat steps B and C until the oil is hot.

The engine speed may be reduced towards the end of heating as

the oil from the transmission is too warm. If this occurs, leave the
gear in neutral position and hold the engine speed at 1200 rpm
for 20 seconds.
When the temperature is correct, MODE changes from 0 to 1.
4 Select DRIVE-TRAIN, menu 3.
CALIBR DRIVE-TRN 3(X) GEARBOX TUNING
START AUTO CALIBR
PHASE X SUB-PH X Description: Calibration of transmission clutches.
CLUTCH X STATUS X
005609
ACTION X XXXXrpm PHASE: Indicates current phase in the calibration.
0. Pre-filling of clutch
1. Calibration of clutch
4. Calibration complete
5. Calibration incorrect
CLUTCH: Indicates which clutch shall be calibrated.

F. Clutch forward
R. Clutch reverse
1. Clutch gear 1
2. Clutch gear 2
3. Clutch gear 3
4. Clutch gear 4
ACTION: Indicates action from mechanics (in the event of a

fault)
0. No action (normal condition if no malfunction).
1. Increase throttle application.
2. Reduce throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (depress the service brake if the
machine starts to move).
6. Heat the transmission, see step 4.
7. No action; the engine is controlled via the transmis-
sion control unit (D793).
8. Keep the accelerator pedal in its current position.
9. Check error codes.
SUB-PH: Internal value for sub-phase 1 or 0.
STATUS: Calibration status.

0. Calibration not in progress.
3. Calibration in progress.
5 Check that the gear selector is in neutral position.

6 Start calibration by pressing Enter.

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

raised to approx. 750 rpm.
The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration, use the
service brake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.
8 When the engine speed decreases to idling and PHASE = 4 then

calibration is complete.
9 Switch off the ignition to store the values.


1
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9 Frame, body, cab and accessories............................................................... 5

9.1.1 Gear selector and multi-function lever ................................................. 11
9.1.22 Switch, direction indicators .................................................................. 12
9.2 Safety and emergency equipment ............................................................ 13
9.2.1 Control breaker .................................................................................... 13
9.2.2 Seat belt ............................................................................................... 13
9.2.3 Fire extinguisher .................................................................................. 13
9.2.4 Seat buzzer .......................................................................................... 13
9.2.5 Roof grating ......................................................................................... 13
9.3 Seat .......................................................................................................... 14
9.3.1 Seat cushion ........................................................................................ 18
9.3.2 Back rest cushion ................................................................................ 18
9.3.3 Heating coil .......................................................................................... 19
9.3.4 Bumper ................................................................................................ 20
9.3.5 Air suspension ..................................................................................... 20
9.3.6 Compressor air-suspension seat ......................................................... 20
9.3.7 Mechanical seat adjustment ................................................................ 21
9.3.8 Passenger seat .................................................................................... 21
9.3.9 Arm rest ............................................................................................... 21
9.3.14 Sensor, operator-in-seat ...................................................................... 22
9.4 Heating, ventilation and air conditioning ................................................... 23
9.4.1 Fresh air filter ....................................................................................... 31
9.4.2 Fresh air and recirculation damper ...................................................... 32
9.4.3 Cab fan ................................................................................................ 35
9.4.4 Heat exchanger heat ........................................................................... 38
9.4.5 Water valve .......................................................................................... 41
9.4.6 Sensor, engine temperature ................................................................ 42
9.4.7 Compressor ......................................................................................... 42
9.4.8 Condenser ........................................................................................... 46
9.4.9 Moisture filter ....................................................................................... 47
9.4.10 Pressure switch ................................................................................... 48
9.4.11 Expansion valve ................................................................................... 49
9.4.12 Sensor, temperature refrigerant ........................................................... 51
9.4.13 Heat exchanger, cooling ...................................................................... 53
9.4.14 Air distributor ........................................................................................ 54
9.4.15 Defroster nozzles ................................................................................. 55
9.4.16 Sensor, temperature outlet fan ............................................................ 56
9.4.17 Sensor cab temperature ...................................................................... 57
9.4.18 Sensor, ambient temperature .............................................................. 58
9.4.19 Pause heater ....................................................................................... 59
9.5 Wiper/washer system ............................................................................... 60
9.5.1 Wiper front ........................................................................................... 60
9.5.2 Wiper roof ............................................................................................ 60

2
9.5.3 Wiper rear ............................................................................................. 60

9.5.4 Washer motor and reservoir ................................................................. 60
9.5.5 Wiper motor front .................................................................................. 61
9.5.6 Wiper motor roof ................................................................................... 62
9.5.7 Wiper motor rear .................................................................................. 63
9.6 Lighting system ......................................................................................... 65
9.6.1 Headlights ............................................................................................ 70
9.6.2 Running lights ....................................................................................... 70
9.6.3 Tail lights .............................................................................................. 70
9.6.4 Brake light ............................................................................................ 70
9.6.5 Back-up lights ....................................................................................... 71
9.6.6 Direction indicators ............................................................................... 71
9.6.7 Flashing hazard lights .......................................................................... 71
9.6.8 Revolving beacon ................................................................................. 72
9.6.9 Working lights, mast ............................................................................. 72
9.6.10 Working lights, cab ............................................................................... 73
9.6.11 Interior lighting ...................................................................................... 73
9.6.12 Working lights, attachment ................................................................... 73
9.6.13 Entry lighting ......................................................................................... 74
9.6.14 Work lights, front wing .......................................................................... 74
9.7 Signalling system ...................................................................................... 75
9.7.1 Horn ...................................................................................................... 78
9.7.2 Flashing hazard lights .......................................................................... 79
9.7.3 Revolving beacon ................................................................................. 79
9.7.4 Warning parking brake ......................................................................... 79
9.7.5 Back-up alarm ...................................................................................... 79
9.8 Entertainment and communication ........................................................... 80
9.9 Glass/windows/mirrors .............................................................................. 81
9.9.1 Windscreen .......................................................................................... 82
9.9.2 Side window ......................................................................................... 84
9.9.3 Roof window ......................................................................................... 88
9.9.4 Rear window ......................................................................................... 88
9.9.5 Rear view mirror ................................................................................... 89
9.9.6 Reversing camera ................................................................................ 89
9.9.7 Monitor, reversing camera .................................................................... 89
9.10 Cab structure and suspension .................................................................. 90
9.10.1 Cab frame ............................................................................................. 90
9.10.2 Doors .................................................................................................... 91
9.10.3 Cab substructure .................................................................................. 91
9.10.4 Tiltable cab ........................................................................................... 92
9.11 Cab interior ............................................................................................. 100
9.11.1 Instrument and control panels ............................................................ 100
9.11.2 Interior fittings, plastic ......................................................................... 101
9.11.3 Interior fittings, textile ......................................................................... 101
9.11.4 Floor covering ..................................................................................... 102
9.11.5 Insulation ............................................................................................ 102
9.11.6 Sun visors ........................................................................................... 102

3
9.11.7 Terminal console ............................................................................... 102

9.11.8 Reading-lamp .................................................................................... 102
9.11.9 Writing desk ....................................................................................... 103
9.12 Frame ..................................................................................................... 104
9.13 Body structure ........................................................................................ 105
9.13.1 Wings ................................................................................................. 105
9.13.2 Hood engine compartment ................................................................ 105
9.13.3 Footsteps and hand rail ..................................................................... 106
9.13.4 Counterweights .................................................................................. 106
9.14 Central lubrication .................................................................................. 107
9.14.1 Pump unit ........................................................................................... 109
9.14.2 Distribution block ............................................................................... 110
9.14.3 Lines .................................................................................................. 110
9.15 Paint/coatings ......................................................................................... 111

4 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories 5
9 Frame, body, cab and

mm mm mm mm mm mm
accessories
Controls and instruments, overview
page
–
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
008108
14
Overview
1 Left instrument panel
2 Gear selector and multi-function lever (S162)
3 Steering wheel panel
4 Steering wheel
5 Switch direction indicators (S161)
6 Panel for hydraulic functions
7 Switch safety switch (S250)
8 Switch for parking brake (S107)
9 Hydraulic control
10 Driver’s seat
11 Accelerator pedal (B690)
12 Brake pedals
13 Declutch pedal (S220-1)
14 Electronic box with fuses and relays
15 Hour meter (P708)
A Joystick or mini-wheel

6 9.1 Controls and instruments
Left-hand instrument panel

16 Switch, fan (S118)
17 Switch, heating (S117)
18 Switch, air distribution (S139)
24..28 29 30 31 19 Switch work lights cab roof (S105-1)
19..23
Auxiliary work lights, front wing
18 20 Switch, work lights on carriage and attachment (S105-2)
004394
17
16 Auxiliary work lights, carriage and attachment
Left instrument panel 21 Switch, work lights on mast (S105-3)
Auxiliary work lights, mast

22 Switch, revolving beacon (S110)
23 Switch, flashing hazard lights (S109)
24 Switch, headlights (S100)
25 Switch seat heater (S143)

(May appear in driver’s seat)
26 Switch for electrically heated rearview mirrors (S199-4)

27 Spare
28 Switch for pause heater (S199-1)

29 Spare
30 Spare
31 Socket 12 VDC

9 Frame, body, cab and accessories – 9.1 Controls and instruments 7
Steering wheel panel

32 Warning lamp, low battery charging
36
35 33 Warning lamp for low brake pressure
34
33 34 Indicator for active error codes
32
35 Warning lamp, by-pass of hydraulic functions
36 Indicator light for activated steering with lever or mini-wheel
37..41 37 Warning lamp, high coolant temperature

49
38 Warning light, low oil pressure engine
42..46 39 Indicator light for preheating
47 48
40 Warning lamp for low coolant level engine
41 Warning light, high gearbox oil temperature
42 Warning lamp, low fuel level
50 51 52 53 43 Warning lamp, high temperature hydraulic oil
44 Indicator light, high beams
45 Indicator light, travel direction indication
46 Indicator light, parking brake
47 Indicator light, locked twistlock/lock tongue (secured load)
48 Indicator light, alignment (attachment / load)
49 Indicator light, unlocked twistlock/lock tongue (load released)
64
54 50 Panel, warning and indicator lights
63
55 51 Control system display
62
56 52 Control system indicator
008132
61 60 59 58 57 53 Ignition
54 Switch for defroster
Steering wheel panel
55 Switch, windscreen wiper roof, interval
56 Switch, windscreen wiper roof, continuous
57 Switch, interior lighting
58 Switch, windscreen wiper rear, interval
59 Switch, windscreen wiper rear, continuous
60 Control system function keys
61 Travel direction indicator, Forward Neutral Reverse
62 Shifting program A, automatic shifting
63 Shifting program 1, locked to 1st gear
64 Shifting program 2, locked to 2nd gear

8 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Panel for hydraulic functions

65 Lift/lower (R8071)
65
66 66 Tilt (R8072)
67
68 67 Side shift (R8073)
69 68 Levelling (R8074)
70 69 Opening of twistlock / Opening and locking of lock tongues
(attachment) (S1002)
71
70 Switch, horn (S149)
72
73 71 Switch for twistlock/lock tongues, automatic/manual locking
74 (S1003)
75
76 72 Switch, spreading 20’-40’ (S1012)
77
73 Switch for spreader stop at 30’ or 35’ (S1004)
74 Spare
008130
8 78 79 78 75 Switch for automatic/manual cab tilt (S199-2)

Panel for hydraulic functions and control levers
electric servo 76 Switch for manual cab tilt (S1010)
77 Switch, automatic spreading 20’-40’ (S1012-2)

78 Switch for bypassing of hydraulic functions (S1005)
69 Key for bypassing hydraulic functions
75
79 Emergency stop switch (S250)
71
73
76
78
77
008131
78 8 79 70
Panel for hydraulic functions and control lever

9 Frame, body, cab and accessories – 9.1 Controls and instruments 9
Operating menus, overview
1 2 3 4
9 8 7 6
10
009174
11 12 13 14
1. Engine and transmission operating menu 8. Service operating menu
2. Engine operating menu 9. Operating menu heating and air conditioning
3. Operating menu for oil temperature 10. Operating menu, code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu, container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
7. Operating menu statistics 14. Operating menu statistics, lift statistics

10 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Event menus overview

Side lift attachment with twistlocks
1 2 3 4
009176
1. Event menu start interlock
2. Event menu, twistlock alignment
3. Event menu twistlocks
4. Event menu open door
5. Event menu automatic spreading
Event menus overview

Side lifting attachment with side lock tongues
1 2 3 4
009781
1. Event menu start interlock
2. Event menu, alignment
3. Event menu open door
4. Event menu automatic spreading

9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever 11
9.1.1 Gear selector and multi-function

lever
Gear selector and multi-function lever, description
page
–
The following functions are handled by the gear and multi-function

2 lever (position 2).
3 1
0 Movement Function
Forward/ Travel direction (for selecting shifting program
Reverse and travel direction, see section 2 Transmission).
Inward, handle Washing of windscreen, roof window and rear
000338
window.
The signal can be checked from the diagnostic
menu, see section 8 Control system,
group 8.4.3.1 CAB, menu 1.
Rotation Windscreen wiper, front.
0 – No wiping front windshield. If wiper rear or
roof are active then these run at slow interval
wiping.
1 – Slow interval wiping windscreen, controls
slow interval wiping for roof window and rear
window.
2 – Fast interval wiping front window, controls
fast interval wiping for roof window and rear
window.
3 – Continuous wiping front windshield. If wiper
rear or roof are active then these run at fast inter-
val wiping.
Upward Light signal

Downward High beam (on/off)
With headlights on:The gear selector and multi-
function lever are used for switching between
high and low beams.
000339
A With headlights off: Gear and multi-function lever

is used to flash with the headlights.
The signal can be checked with the diagnostic
group 8.4.2.3 LIGHTS, menu 3.
Inward, button Horn (position A).

12 9 Frame, body, cab and accessories – 9.1.22 Switch, direction indicators
Gear selector and multi-function lever, replacement

page
–
1 Separate the steering wheel panel.

6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Steering wheel panel, replace-
ment page 100.
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from Control unit KIT (D790-2).
4 Fit a new lever and refit the steering wheel panel.
9.1.22 Switch, direction indicators

Switch, direction indicators, replacement
page
–

2 Remove the steering wheel and separate the steering wheel
panel.
3 Detach the cable harness from the direction indicator.

4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.

9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment 13
9.2 Safety and emergency

equipment
9.2.1 Control breaker
Emergency stop switch, description
page
–
See section 11 Common electrics, group 11.5.1.4 Emergency stop

switch voltage.
9.2.2 Seat belt

Seat belt, description
page
–
The seat belt is a two-point or a three-point belt, depending on the type

of seat installed in the machine. The seat belt is installed on the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
page
–
The fire extinguisher sits at the entry on the left frame beam or inside
the cab. Instructions on use are found on the fire extinguisher.
9.2.4 Seat buzzer

Seat buzzer, description
page
–
See Sensor operator in seat, description page 22.
9.2.5 Roof grating

Roof grating, description
page
–
The roof grating protects the operator from falling objects. This consti-
tutes protection that goes beyond the legal requirements.

14 9 Frame, body, cab and accessories – 9.3 Seat
9.3 Seat
Seat, general
page
–
There are three versions of the operator’s seat:

• Seats, description (product alternative standard seat) page 14
• Seats, description (product alternative Bege 9120) page 15
• Seats, description (product alternative Isringhausen 6800)

page 16
As an option, the machine can be equipped with a fold-down passen-

ger seat to the left of the operator.
Seats, description (product alternative standard

page
–
seat)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• arm rest right
• armrest left
4
• seat heating
• seat belt
• head rest
5
8 6
006825
7
Controls, standard seat
1. Lumber support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest angle adjustment
5. Suspension position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment
8. Fore/aft adjustment

9 Frame, body, cab and accessories – 9.3 Seat 15
Seats, description
page
–
(product alternative Bege 9120)
Bege 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and
springing to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • arm rest right
• armrest left
8 6
006826
7 • seat heating
Controls, Bege 9120 • seat belt
1. Lumber support adjustment
2. Right armrest adjustment • head rest
3. Left armrest adjustment

4. Backrest rake adjustment
5. Springing position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment
8. Front/rear adjustment

16 9 Frame, body, cab and accessories – 9.3 Seat
Seats, description
page
–
(product alternative Isringhausen 6800)
The Isringhausen 6800 seat has the following equipment:
• head rest
• arm rest
• air suspension (with external compressor)
• air-adjusted lumbar support
• seat belt
• seat heating
11
10
34 567
004691
9 8 2
Controls, Isringhausen 6800
1. Fore/aft adjustment
2. Seat cushion adjustment
3. Seat height lowering
4. Seat cushion angle
5. Seat height raising
6. Backrest angle
7. Damping adjustment
8. Seat heating
9. Level damping OFF/ON
10. Lumbar support adjustment
11. Armrest

9 Frame, body, cab and accessories – 9.3 Seat 17
Seat, changing
page
–

2 Slide back the seat to its rear position, remove the front attaching
bolts.
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.

18 9 Frame, body, cab and accessories – 9.3.1 Seat cushion
9.3.1 Seat cushion

Seat cushion, description
page
–
The function of the seat cushion is to provide comfort to the operator.

The seat cushion houses the driver’s seat frame and a breaker for the
buzzer. There may also be a heating coil ( ).
For location, see Seat, general page 14.
Seat cushion, replacement

page
–
(product alternative BE-GE)

2 Loosen the rubber bellows by removing the plastic clips
(position 1).
3 Unhook the upholstery’s rails (position 2) from the seat frame
2 5 (position 3) and remove the upholstery.
4 Remove the padding (position 4).
4
If the seat is equipped with seat heater.
Unplug the connector for the heating coil before the padding is
removed.
NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.
1
006276
1. Plastic clips rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heating coil
9.3.2 Back rest cushion

Back rest cushion, description
page
–
The function of the back cushion is to provide comfort for the operator.
Under the back cushion is the operator’s seat frame. There may also
be a heating coil ( ).

9 Frame, body, cab and accessories – 9.3.3 Heating coil 19
Back rest cushion, replacement

page
–

1 Machine in service position, see section B Safety
2 Detach the rubber bellows on the rear of the seat by removing the
plastic clips and folding down the rubber bellows. See Seat cush-
ion, replacement (product alternative BE-GE) page 18.
3
3 Remove the back rest by first removing the attaching bolts (posi-
tion 1) on the right and left side of the seat and then remove the
4 attaching bolts (position 2) for the seat belt on the right and left
side of the seat.
4 If the seat is equipped with 3-point seat belt.

Remove the belt guide (position 3) by removing the cover and the
attaching bolt (position 4).
5 5 If the seat is equipped with arm rests (position 5).

Remove the arm rest by removing the attaching bolts (position 6).
6 Place the backrest on the seat and install the attaching bolts (po-
sition 1), do not tighten. Then install the attaching bolts for the
6 seatbelt (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.
7 If the seat is equipped with 3-point seat belt or arm rest.

Cut holes in the upholstery for seat belt and arm rest on the new
006278
1 2 back rest before arm rest or seat belt is installed.
1. Attaching bolt backrest 8 Fit in the reverse order.

2. Attaching bolt seatbelt
3. Cover belt guide
4. Attaching bolt belt guide
5. Armrest
6. Attaching bolt armrest.
9.3.3 Heating coil

Heating coil, description
page
–
The heating coil’s function is to warm the back and seat cushions in
the operator’s seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied power upon warm-up of the cab
control unit (D790-1) via the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system,
Heating coil, replacement

page
–

See Seat cushion, replacement (product alternative BE-GE)
page 18.

20 9 Frame, body, cab and accessories – 9.3.4 Bumper
9.3.4 Bumper
Bumper, description
page
–
The bumpers are integrated in the suspension unit in the seat’s frame
and are self-adjusting, that is, they adjust automatically to the opera-
tor’s weight.
Bumper, replacement (product alternative BE-GE)

page
–
2 1 Machine in service position, see section B Safety.

2 Remove the operator’s seat from the frame and lift it out of the
machine. See Seat, changing page 17.
3 Remove the seat cushion, see Seat cushion, replacement
(product alternative BE-GE) page 18.
1 4 Remove the back rest cushion, see Back rest cushion, replace-
ment (product alternative BE-GE) page 19.
5 Remove the shock absorbers attaching bolts (position 2 and 3).
6 Replace the shock absorber (position 1).
006277
3 7 Assemble in reverse order.

1. Shock absorbers
2. Attaching bolt
3. Attaching bolt
9.3.5 Air suspension

Air suspension, description
page
–
The air-suspended operator’s seat consists of a seat with rubber bel-

lows and compressor. Air-suspension is self-adjusting, that is, adjust
automatically to the operator’s body weight. The compressor provides
air for the suspension unit.
9.3.6 Compressor air-suspension seat

Compressor air-suspension seat, description
page
–
Bege 9120:
The compressor is part of the air-suspension driver’s seat and is fitted

inside the seat’s suspension unit.
001621
Isringhausen 6800:
Compressor air-suspension seat
The compressor is an external part for the air-suspended operator’s

seat that is installed on the underside of the cab floor.

9 Frame, body, cab and accessories – 9.3.7 Mechanical seat adjustment 21
9.3.7 Mechanical seat adjustment

Mechanical seat adjustment, description
page
–
Seat adjustment is all mechanical and is adapted by the operator with

different controls in order to obtain a good sitting position.
See:
• Seats, description (product alternative standard seat) page 14
• Seats, description (product alternative Bege 9120) page 15
• Seats, description (product alternative Isringhausen 6800)
page 16
9.3.8 Passenger seat

Passenger seat, description
page
–
The passenger seat is collapsible (vertically), provided with a seat belt

and is located on the left-hand side of the driver’s seat.
001627
Passenger seat with bracket
9.3.9 Arm rest

Armrests, description
page
–
The armrest is fixed to the backrest and is individually adjustable ver-

tically (around the attachment point). Depending on options there is
also an armrest for the left-hand side that can be equipped with:
• Mini-wheel
• Joystick control

22 9 Frame, body, cab and accessories – 9.3.14 Sensor, operator-in-seat
9.3.14 Sensor, operator-in-seat

Sensor operator in seat, description
page
–
The operator-in-seat sensor (S230) detects whether the driver’s seat

springs are depressed, which indicates to the control system that the
1 driver’s seat is occupied. This is used to allow the control system to in-
dicate with the operator-in-seat buzzer (H853) if the operator leaves
the machine without applying the parking brake. The sensor also ena-
bles the control system to prevent a gear from being engaged if the op-
2 erator is not in the driver’s seat or to automatically disengage the gear
after 3 seconds if the operator leaves the seat with a gear engaged.
The operator-in-seat sensor (S230) is supplied power by and sends a
voltage signal to the cab control unit (D790-1). The signal can be
checked with the diagnostic menu, see section 8 Control system,
008220
Seat seen from below

1. Sensor operator in seat (S230)
2. Buzzer (H853)

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 23
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
page
–
description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 27 C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat 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.
6 A B Air conditioning (ECC)
The climate control system (ECC) handles for heating, ventilation,

cooling, and drying. The air is heated in the same way as for the heat-
ing system (EHC).
1 During cooling, ambient air is forced through the evaporator, which
5 G cools the air. The air can then be directed in the same way as for the
000762
heating system.
Principle illustration, climate control system The function of the air conditioning is to:
1. Fluid reservoir/filter dryer with built-in pressure • heat the air when it is cold
monitor
• dehumidify the air when it is damp
2. Heater and evaporator
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser • defrost (defroster function)
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
IMPORTANT
D. Low-pressure gas
E. Ambient air for cab ventilation On machines with ECC or AC, it is vital that the engine
F. Heated or cooled air to the cab cooling system is refilled with coolant with the correct
G. Ambient air for removal of heat concentration of antifreeze. Otherwise there is a risk
that the air conditioning system will freeze during
usage.

24 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

page
–
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690

1 Switch, temperature (S117) sends a Increase: U = 2.0–2.5 V Controls and instruments, overview page 5
voltage signal to Control unit, cab Unaffected: U = 0-0.5 V D1: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.4.5, CLIMATE menu 5
Decrease: U = 4.5-5.0 V
2 Switch, fan (S118) sends a voltage sig- Increase: U = 2.0–2.5 V Controls and instruments, overview page 5
nal to Control unit, cab (D790-1). Unaffected: U = 0-0.5 V D2: Diagnostic menu, see section 8 Control
Decrease: U = 4.5-5.0 V system, group 8.4.4.5, CLIMATE menu 5


3 Switch, air distribution (S139) sends a Scroll up: Controls and instruments, overview page 5
voltage signal to Control unit, cab U = 2.0–2.5 V D3: Diagnostic menu, see section 8 Control
Unaffected: U = 0 V
Scroll down:
U = 4.5-5.0 V
4 Sensor, cab temperature (B775-1) R = 10 k at 25 C Sensor, cab temperature, description

sends a voltage signal proportional to page 57
the temperature to Control unit, cab D4: Diagnostic menu, see section 8 Control
5 The outlet fan temperature sensor R = 10 k at 25 C Sensor, temperature outlet fan, description
(B775-2) sends the cab control unit page 56
(D790-1) a voltage signal proportional to D5: Diagnostic menu, see section 8 Control
temperature. system, group 8.4.4.2, CLIMATE menu 2
6 Sensor, ambient temperature (B774) R = 10 k at 25 C Sensor, ambient temperature, description

sends a voltage signal proportional to page 58
the temperature to Control unit, cab D6: Diagnostic menu, see section 8 Control
7 Control unit, cab (D790-1) regulates Checked by control sys- Section 11 Common electrics,
temperature and air distribution with sig- tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
nals from sensors and controls. ror code.
8 The engine produces heat when run- - -

ning. It is cooled with the cooling sys-
tem. The heat from the cooling system is
used to heat the cab air.
9 Control unit, cab (D790-1) controls Wa- U = 0.5–4.5 V Water valve, description page 41
ter valve (Y673), which routes hot water D9: Diagnostic menu, see section 8 Control
for heat exchanger heat. system, group 8.4.4.7 CLIMATE, menu 7
The water valve’s opening (%) is sent and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling the
water valve’s position.
10 Sensor, engine temperature, sends a Checked by control sys- Section 1 Engine

voltage signal proportional to the engine tem, error shown with er- D10: Diagnostic menu, see section 8 Con-
temperature to Control unit, engine ror code. trol system, group 8.4.4.2, CLIMATE
(D794). menu 2
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 38
cab air. Heat is transferred from the en-
gine’s cooling system to the cab air.
12 Control unit, engine (D794) transmits Checked by control sys- Section 11 Common electrics,
engine temperature in the cooling system, error shown with er- group 11.5.3.10 Engine control unit (D794)
tem on the CAN bus. ror code.


13 Control unit, cab (D790-1) controls Actu- Checked by control sys- Fresh air filter or recirculation damper, de-
ator motor, recirculation (M612) which tem, error shown with er- scription page 32
sets the fresh air or recirculation damper ror code. D13: Diagnostic menu, see section 8 Con-
in the required position. trol system, group 8.4.4.6, CLIMATE
menu 6
14 Control unit, cab (D790-1) controls Fan Checked by control sys- Cab fan, description page 35
motor (M657), which increases the air- tem, error shown with er- D14: Diagnostic menu, see section 8 Con-
flow in the cab. ror code. trol system, group 8.4.4.6, CLIMATE
menu 6
15 Control unit, cab (D790-1) controls U = 0.5–4.5 V Air distributor, description page 54
Damper motor (Y672), which sets the air D15: Diagnostic menu, see section 8 Con-
distributor to the required position. trol system, group 8.4.4.8 CLIMATE, menu
The air distributor’s position is sent back 8 and 8.4.4.4 CLIMATE, menu 4
to the cab control unit (D790-1). This
gives information for controlling the air
distributor’s position.
16 The frame control unit (D797-1) controls Checked by control sys- Section 11 Common electrics, group
AC compressor engagement. tem, error shown with er- 11.5.3.3 Frame control unit (D797-1)
ror code.
17 The frame control unit (D797-1) supplies U = 24 V AC compressor, description page 42

voltage to the compressor’s electromag- D17: Diagnostic menu, see section 8 Con-
netic clutch (645). trol system, group 8.4.4.6, CLIMATE
menu 6
18 The compressor draws gaseous refrig- - AC compressor, description page 42

erant from the evaporator, compresses
it, and forces it on to the condenser.
19 The condenser cools the refrigerant. - Condenser, description page 46

The gaseous refrigerant condenses to
liquid form and is pumped on in the
circuit.
20 The moisture filter absorbs any moisture - Moisture filter, description page 47
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
21 The pressure switch (S246) sends a sig- U = 24 V Pressure switch, description page 48
nal to the frame control unit (D797-1) if D21: Diagnostic menu, see section 8 Con-
the pressure in the system becomes ab- trol system, group 8.4.4.3, CLIMATE
normally high or low. menu 3
22 The expansion valve adjusts the amount - Expansion valve, description page 49
of refrigerant that is let in to the evapora-
tor. If the temperature in the evapora-
tor’s outlet pipe increases, the
evaporator valve increases flow of re-
frigerant so that heat dissipation in the
evaporator increases.


23 Sensor, refrigerant circuit temperature, R = 10 k at 25 C Sensor, temperature of refrigerant, descrip-
sends a voltage signal proportional to tion page 51
the temperature to Control unit, cab D23: Diagnostic menu, see section 8 Con-
(D790-1). trol system, group 8.4.4.2 CLIMATE,
menu 2.
24 Heat exchanger cooling dissipates heat - Heat exchanger, cooling, description

from the cab air. Heat is transferred from page 53
the air to the refrigerant and transforms
the refrigerant to a gaseous state.
25 The defroster switch on Control unit KIT Checked by control sys- Section 11 Common electrics,
(D790-2) activates the defroster pro- tem, error shown with er- group 11.5.3.11 KIT control unit (D790-2)
gram for the air conditioning for six ror code.
minutes.
26 Control unit KID (D795) shows the heat- Checked by control sys- Section 11 Common electrics,
ing and ventilation settings in the tem, error shown with er- group 11.5.3.12 KID control unit (D795)
display. ror code.

page
–
checking
2 Navigate to the service menu and press Enter.
000056
3 Enter code for diagnostics. Code is obtained from Cargotec

Support.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Diag-

nostic test, Initiation, Calibration, or Service indication).
4 Select CLIMATE.
DIAGNOSIS
CAN/POWER LIGHTS CAB Menu 1
CLIMATE HYD ENGINE
004998
OLS EXTRA
5 Checking the desired temperature, inside temperature sensor

DIAG CLIMATE 1(8) and water valve.
REQUIRED TEMP XXX REQUIRED TEMP: 160 (16.0 C) for max. cooling and 280
PRESENT TEMP XXX (28.0 C) for max. heating. The setting is changed with the tem-
000132
WATER VALVE FEEDB. XXX perature switch.

PRESENT TEMP shows the temperature inside the cab. This is

measured by Sensor cab temperature (located down to the right
on the instrument panel, behind the rubber bushing). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the re-
quested temperature is 160, and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.
Menu 2
6 Check of Sensor, temperature outlet fan (B775-2), engine tem-
DIAG CLIMATE 2(8) perature, Sensor, outdoor temperature (B774), and check of
TEMP COIL XXX Sensor, temperature refrigerant (B775-1).
TEMP COOLANT XXX
TEMP AMBIENT XXX TEMP COIL: temperature that the air has in the air distributor is
000133
TEMP DE-ICE XXX measured by Sensor, temperature outlet fan (B775-2).

TEMP COOLANT: engine temperature that is sent on the
CAN bus.
TEMP AMBIENT: outdoor temperature that is measured by
Sensor, outdoor temperature (B774).
TEMP DE-ICE: cooling circuit’s temperature measured by Sen-
sor temperature refrigerant (B775-1). If the compressor is activat-
ed the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.
Menu 3
7 (Only machines with ECC)

DIAG CLIMATE 3(X)
PRESENT INPUT SIGNAL Checks that the refrigerant circuit is filled.
PRESSURE SWITCH X PRESSURE SWITCH: 0 = not filled, 1 = filled.
OPT DOOR SWITCH X
006865
The sensor is located on the receiver drier which is fitted right

rear in the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8)
WATER VALVE: should work between 1.0-1.24 V and
WATER VALVE XX.XXV 2.95-3.2 V. This is checked by turning the temperature control
DRAUGHT VALVE XX.XXV and changing the temperature setting from min. to max.
000135
DRAUGHT VALVE: should work in the range 1.0-4.0 V. The dif-

ference between min. and max. should be approx 1 V. This is
checked by changing the air distribution from floor to front wind-
shield. At the same time, feel with your hand so that air blows
through different vents.
NOTE
Air to the round panel vents is not controlled by the air
conditioning.

Menu 5
9 Checks the switches for temperature, air distribution and fan
DIAG CLIMATE 5(8) speed.
REQUIRED TEMP XX.XXV REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V;
REQ. DRAUGHT XX.XXV lower U = 4.5-5 V.
000136
REQ. FAN SPEED XX.XXV REQ. DRAUGHT: home position U = 0 V; against window
U = 2-2.5 V; against floor U = 4.5-5 V.
REQ. FAN SPEED: home position U = 0 V; raise U = 2-2.5 V;
lower U = 4.5-5 V.
Menu 6
10 Checks Cab fan (M657), Fresh air and recirculation damper
DIAG CLIMATE 6(8)
PRESENT OUTPUT SIGNAL (M612) and Electromagnetic clutch, compressor (M645) .
FAN SPEED XXX FAN SPEED: increase and decrease fan speed, value should in-
RECIRKULATION XY crease from 0 to 255 in steps.
000137
COMPRESSOR XY
RECIRCULATION: press in the bypass switch (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)

COMPRESSOR: lower the temperature setting to max. cooling,
after approx. 45 seconds the compressor will be activated and
the display should show "11".
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) CLOCKWISE: when the temperature is increased and the water
OUTPUT WATER VALVE valve opens shows "CLOCKWISE 11 11" and "ANTI-CLOCK-
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY WISE 00 11".
ANTI-CLOCKWISE: when the temperature is decreased and the
water valve closes shows "CLOCKWISE 00 11" and "ANTI-
24V CLOCKWISE 11 11".
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
M not changing position. The water valve does not open if en-
gine temperature is low, or if outdoor temperature is high.
000138
0V

Menu 8
12 Checks the direction selector for the air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windscreen
OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY and the air distributor changes position shows
ANTI-CLOCKWISE XY XY "CLOCKWISE 00 11" and "ANTI-CLOCKWISE 11 11".
ANTI-CLOCKWISE: when the air is directed against the feet and
the air distributor changes position shows "CLOCKWISE 11 11"
24V and "ANTI-CLOCKWISE 00 11".
NOTE
The "ones" are only shown for a moment when the air dis-
tributor changes position, "zeros" are shown when the air
M distributor does not change position.
000139
0V

9 Frame, body, cab and accessories – 9.4.1 Fresh air filter 31
9.4.1 Fresh air filter

Fresh air filter, description
page
–
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. A finer filter can be used
( ), but this may affect maximum airflow.
1 004999
Fresh air intake, cab

1. Fresh air filter
2. Fresh air and recirculation damper

32 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper
9.4.2 Fresh air and recirculation damper

Fresh air filter or recirculation damper, description
page
–
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.
section 8 Control system, group 8.4.4.6 CLIMATE, menu 6 .
2 004999

1. Fresh air filter
2. Fresh air and recirculation damper

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 33
Motor, fresh air filter or recirculation damper,

page
–
replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
5 Remove the fresh air filter.

34 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.

9 Frame, body, cab and accessories – 9.4.3 Cab fan 35
9.4.3 Cab fan

Cab fan, description
page
–
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
1
003209

1. Cab fan
Cab fan, replacement

page
–


36 9 Frame, body, cab and accessories – 9.4.3 Cab fan
3 Remove the bolts which hold the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.

9 Frame, body, cab and accessories – 9.4.3 Cab fan 37
7 Remove the bolts which secure the plate and cab fan.
8 Detach the connector from the cab fan.

9 Remove the cab fan.
10 Replace the cab fan.

38 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat
9.4.4 Heat exchanger heat

Heat exchanger heat, description
page
–
The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant
temperature

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 39
Heat exchanger, cooling/heating, replacement

page
–
WARNING
Personal injury, environmental damage
Read the safety instructions for refrigerant, see sec-

tion B Safety.

2 Drain the AC system of R134a refrigerant.
IMPORTANT
Working on the air conditioning requires special
authorisation.
3 Detach the AC system hoses and the coolant hoses.

5 Remove the nuts which hold the wiper motor in the protective
plate.

40 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat
9 Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.

9 Frame, body, cab and accessories – 9.4.5 Water valve 41
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
16 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Connection points for cooling hoses. Working on the air conditioning requires special
authorisation.
9.4.5 Water valve

Water valve, description
page
–
The water valve controls the climate control system’s capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is controlled electrically.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system, group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE,
menu 4 and 8.4.4.7 CLIMATE, menu 7.
010021
Water valve position under cab floor (from below)

42 9 Frame, body, cab and accessories – 9.4.6 Sensor, engine temperature
Water valve, replacement

page
–

2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
8 Check the coolant level.
9 Run the heating system at the highest setting (fully open valve)
to vent air from the system.
1. Water valve
2. Steering valve
9.4.6 Sensor, engine temperature

Sensor, engine temperature, description
page
–
Sensor, coolant temperature, is fitted on the engine and detects en-

gine’s coolant temperature. See supplier documentation, engine.
system, group 8.4.4.2 CLIMATE, menu 2
For location, see section 1 Engine.
9.4.7 Compressor
AC compressor, description
page
–

9 Frame, body, cab and accessories – 9.4.7 Compressor 43
1 2 3 NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
The compressor drives the climate control system by working as a
pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
4
tromagnetic clutch, which is controlled by a thermostat.
009116
5 The signal can be checked via the diagnostic menu, section 8 Control
The illustration depicts the compressor for Cummins
QSB 6.7
1. Rigging screw (belt tensioner)
2. Compressor
3. Connections
4. Screw and nut
5. Drive belt
Compressor, replacement
page
–
2
WARNING
Read the safety instructions for refrigerant, see

1
section B Safety.
007865

2 Drain the AC system of R134a refrigerant.
The illustration depicts the compressor for Volvo
TAD760VE.
1. Compressor IMPORTANT
2. Rigging screw (belt tensioner)
authorisation.
3 Detach the coolant hoses from the compressor.

4 Loosen the turnbuckle so that the compressor belt is released.
5 Undo the hose couplings and detach the hoses from the com-
pressor intake and outlet. Plug the connections immediately to
prevent contamination.
6 Remove the bolts which secure the compressor.

44 9 Frame, body, cab and accessories – 9.4.7 Compressor
7 Drain the oil from the old compressor (through the intake and out-
let connections) and the hoses. Measure the oil quantity.
8 Drain the oil from the new compressor.
9 Fill the new compressor with the same quantity of oil as was
drained from the old compressor - minimum 0.1 litre.
NOTE
Fill new oil through the compressor’s suction connection.
10 Fit the new compressor and other equipment in reverse order.
For volume, see the plate for the climate control system.
IMPORTANT
authorisation.
Pulley and electromagnetic clutch, replacement

page
–
There is no need to drain refrigerant from the system before

replacement.
2 Slacken the belt tensioner and remove the drive belt.
3 Remove the screw from the centre of the pulley.
006263

9 Frame, body, cab and accessories – 9.4.7 Compressor 45
4 Remove the locking washer and the outer lock ring.

1
006264
1. Lock ring
2. Locking washer
5 Remove the groove.

1
006265
1. Groove
6 Remove the three screws securing the electromagnetic clutch.

006266
7 Remove the electromagnetic clutch.

1 9 Check the function.
006267
1. Electromagnetic clutch

46 9 Frame, body, cab and accessories – 9.4.8 Condenser
9.4.8 Condenser
Condenser, description
page
–
NOTE
For tightening torque of refrigerant hoses and pressure switch,
The condenser is located on the radiator in the engine compartment.
The function of the condenser is to convert the hot, high-pressure gas
from the compressor to liquid form. Pipes and cooling fins in the con-
denser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from ap-
prox. 50 C to 70 C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condens-
er. When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
010023
Condenser, replacement
page
–
WARNING

section B Safety.
1. Radiator 2 Drain the AC system of R134a refrigerant.

2. Condenser
IMPORTANT
authorisation.
3 Detach the inlet and outlet hoses from the condenser.

4 Remove the bolts which secure the condenser at the top edge and
lift the condenser out in a suitable way.
5 Replace the condenser, fitting it in the reverse order.

9 Frame, body, cab and accessories – 9.4.9 Moisture filter 47
IMPORTANT
authorisation.
9.4.9 Moisture filter

Moisture filter, description
page
–
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
The moisture filter collects the liquid refrigerant, binds moisture, and
filters 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 flow is without bubbles and that the system is
adequately filled with refrigerant.
010024
1. Fluid reservoir, moisture filter

2. Pressure switch
3. Sight glass

48 9 Frame, body, cab and accessories – 9.4.10 Pressure switch
9.4.10 Pressure switch

Pressure switch, description
page
–
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
mally high or low.
010024
1. Fluid reservoir, moisture filter

2. Pressure switch
3. Sight glass

9 Frame, body, cab and accessories – 9.4.11 Expansion valve 49
Pressure switch, replacement

page
–
WARNING
2 3
1 Personal injury, environmental damage
Read the safety instructions for refrigerant, see sec-

tion B Safety.

2 Drain the machine of refrigerant, R134a.
IMPORTANT
authorisation.
010024
3 Detach the connector from the pressure switch.
1. Fluid reservoir moisture filter 4 Unscrew the pressure switch from its mounting.
2. Pressure switch. 5 Replace the pressure switch.
3. Sight glass
IMPORTANT
authorisation.
9.4.11 Expansion valve

Expansion valve, description
page
–
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 pres-
sure. 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 the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.

50 9 Frame, body, cab and accessories – 9.4.11 Expansion valve
Expansion valve, replacement

page
–
WARNING

section B Safety.

2 Drain the AC system of refrigerant.
IMPORTANT
authorisation.
3 Detach the AC system hoses.

4 Detach the coolant hoses.
5 Remove the heat exchanger for cooling/heating to access the ex-
pansion valve, see Heat exchanger, cooling/heating, replace-
ment page 39.
6 Replace the expansion valve.
IMPORTANT
authorisation.

9 Frame, body, cab and accessories – 9.4.12 Sensor, temperature refrigerant 51
9.4.12 Sensor, temperature refrigerant

Sensor, temperature of refrigerant, description
page
–
Sensor, temperature refrigerant, (position 2) detects the refrigerant

temperature in the heat exchanger, cooling. This is used to control the
air conditioning.
1
3
005001
2
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor temperature outlet fan
Sensor, temperature refrigerant, replacement

page
–
WARNING

section B Safety.
NOTE
Requires special authorisation.
2 Drain the AC system of refrigerant.
IMPORTANT
Working on the air conditioning requires special au-
thorisation.
3 Detach the AC system hoses from the heat exchanger.

4 Detach the coolant hoses from the heat exchanger.
5 Detach the heat exchanger to access the refrigerant temperature
sensor, see Heat exchanger, cooling/heating, replacement
page 39.
6 Replace the temperature sensor.

52 9 Frame, body, cab and accessories – 9.4.12 Sensor, temperature refrigerant

For volume, see section F Technical data
IMPORTANT
authorisation.

9 Frame, body, cab and accessories – 9.4.13 Heat exchanger, cooling 53
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
page
–
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant
temperature
Heat exchanger, cooling, replacement

page
–
See Heat exchanger, cooling/heating, replacement page 39.

54 9 Frame, body, cab and accessories – 9.4.14 Air distributor
9.4.14 Air distributor

Air distributor, description
page
–
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
trol system, group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLIMATE,
menu 5 and 8.4.4.8 CLIMATE, menu 8.
002230
Air distributor, replacement

page
–

2 Remove the dashboard panel.
3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the
driver’s seat.
5 Remove the lower cover in front of the pedal assembly.
6 Detach the air hoses from the air distributor and detach the
connector.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor

9 Frame, body, cab and accessories – 9.4.15 Defroster nozzles 55
9.4.15 Defroster nozzles

Defroster nozzles, description
page
–
There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windshield. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).
001839
Defroster nozzles, replacement

page
–

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster noz-
zle in the dashboard.

56 9 Frame, body, cab and accessories – 9.4.16 Sensor, temperature outlet fan
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.
9.4.16 Sensor, temperature outlet fan

Sensor, temperature outlet fan, description
page
–
The outlet fan temperature sensor (position 3) detects the temperature

of the air that blows out in the defroster nozzles. The air conditioning
is controlled by signals from the following sensors:
2. Sensor temperature refrigerant
1 3. Sensor, temperature outlet fan
3 The signal can be checked via the diagnostic menu, section 8 Control
005001
Sensor, temperature outlet fan, replacement

page
–

3 Remove the lower protective cover in front of the steering
wheel shaft.
4 Detach the steering wheel shaft and angle it back against the
driver’s seat.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover

9 Frame, body, cab and accessories – 9.4.17 Sensor cab temperature 57
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.
9.4.17 Sensor cab temperature

Sensor, cab temperature, description
page
–
Sensor, cab temperature, detects the temperature of the air in the cab.
system, group 8.4.4.1 CLIMATE, menu 1
1
3
005001
3. Sensor temperature outlet fan
Sensor, cab temperature, replacement

page
–


58 9 Frame, body, cab and accessories – 9.4.18 Sensor, ambient temperature
3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
007985
9.4.18 Sensor, ambient temperature

Sensor, ambient temperature, description
page
–
Sensor, ambient temperature, detects the temperature of the air out-

side the cab.
Sensor, ambient temperature
Sensor, ambient temperature, replacement

page
–

2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.

9 Frame, body, cab and accessories – 9.4.19 Pause heater 59
9.4.19 Pause heater

Pause heater, description
page
–
1
Pause heating is an option for the heating unit, which uses residual
heat in the engine’s cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is off. The cabin fan forces air into the
cab. The pause heater is turned off automatically when the tempera-
ture in the cab is six degrees below the value set on the climate control
system. The pause heater is activated with the pause heater switch
2 when the ignition is on.
3
004909
1. Switch, pause heater (S0_OPT-1)

2. Control unit cab (D790-1)
3. Circulation pump, pause heater (M667)

60 9 Frame, body, cab and accessories – 9.5 Wiper/washer system
9.5 Wiper/washer system

Wiper/washer system, description
page
–
The wipers automatically switch off 2 minutes after the operator has
left the driver’s seat.
9.5.1 Wiper front

Wiper front, description
page
–
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
9.5.2 Wiper roof

Wiper roof, description
page
–
Wiper roof is of the type sector wiper. Wiping angle is approx.

180 degrees.
9.5.3 Wiper rear

Wiper rear, description
page
–
The rear wiper is of the type sector wiper. The wiping angle is approx.
180 degrees.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
page
–
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This minimises the time from activation of switch
washing and washer fluid spraying on the windshield.
The washer nozzles are mounted on the wiper arms.

9 Frame, body, cab and accessories – 9.5.5 Wiper motor front 61
Washer motor and reservoir, replacement

page
–

2 Remove the protection over the washer fluid reservoir.
3 Drain the washer fluid from the fluid reservoir.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid reservoir in the cab wall.
6 Change the washer fluid reservoir. Change the washer motor, if
needed.
003619
A B
A. Washer fluid reservoir
B. Washer motors
9.5.5 Wiper motor front

Wiper motor front, description
page
–
The wiper motor drives the front windshield wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
Wiper motor front, replacement

page
–

3 Remove the nuts which hold the motor in the protective plate.

62 9 Frame, body, cab and accessories – 9.5.6 Wiper motor roof
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Install in reverse order. Tighten the wiper arms with 16-20 Nm.
9.5.6 Wiper motor roof

Wiper motor roof, description
page
–
The wiper motor drives the roof window’s wiper. The wiper arm is
wiper.
Wiper motor roof, replacement

page
–

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.

9 Frame, body, cab and accessories – 9.5.7 Wiper motor rear 63
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
6 Install in reverse order. Tighten the wiper arm with 16-20 Nm.
9.5.7 Wiper motor rear

Wiper motor rear, description
page
–
The wiper motor drives the rear window wiper. The wiper arm is
wiper.
Wiper motor rear, replacement

page
–

2 Remove the panels behind the driver’s seat.
3 Remove the screws holding the motor’s plastic cover.
4 Detach the connector to the motor.

5 Raise the plastic cover and remove the nut securing the wiper
arm. Detach the washer fluid hose.

64 9 Frame, body, cab and accessories – 9.5.7 Wiper motor rear
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.

9 Frame, body, cab and accessories – 9.6 Lighting system 65
9.6 Lighting system

Lighting system, function description
page
–
Work lights are shut off automatically after 5 minute’s idling in order to
prevent discharge of the batteries. Auxiliary work lights are shut off af-
ter 2 minutes. Lighting is activated automatically again when the oper-
ator sits in the seat, a gear is selected or the accelerator pedal is
pressed.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 5 4
D1 D2 D3 D5 D4 9
10
14 D15 11
6 D9
D6 18
D18 D19 15 15
D7 19 D11
7 16
17 M D16 D10
D17 D790-1 D790-2
21 8, 13 30 12 32
D22 D23 D24 D25 D26 D797-1 D797-2 D791-1
Pa 20
D27
D20 D31 D33 D34
D28
010025
D29
22 23 24 25 26 27 28 29 31 33 34

1 The switch for cab roof work lights (S105-1) Switch in ON position: D1: Diagnostic menu, see
sends a voltage signal to the cab control unit U = 24 V section 8 Control system
(D790-1). group 8.4.2.12 LIGHTS, menu 12
2 Switch, working lights attachment (S105-2) Switch in ON position: D2: Diagnostic menu, see
sends a voltage signal to Control unit, cab U = 24 V section 8 Control system
3 The switch for mast work lights (S105-3) sends Switch in ON position: D3: Diagnostic menu, see
a voltage signal to the cab control unit U = 24 V section 8 Control system
4 Switch, headlights (S100) sends a voltage sig- Switch in ON position: D4: Diagnostic menu, see
nal to Control unit, cab (D790-1). U = 24 V section 8 Control system
group 8.4.2.1 LIGHTS, menu 1

66 9 Frame, body, cab and accessories – 9.6 Lighting system
5 Switch, revolving beacon (S110) sends a volt- Switch in ON position: D5: Diagnostic menu, see
age signal to Control unit, cab (D790-1). U = 24 V section 8 Control system
6 The door NC switch (S266-LE & S266-RI) Door open: U = 24 V Interior lighting cab, description page 73
sends a voltage signal to the cab control unit D6: Diagnostic menu, see
(D790-1). section 8 Control system
7 The switch for entry lighting (S141) sends a Switch in ON position: Entry lighting, description page 74
voltage signal to the cab control unit (D790-1). U = 24 V D7: Diagnostic menu, see
section 8 Control system,
8 Control unit, cab (D790-1) transmits "switch on Checked by control Section 11 Common electrics,
lights" messages on the CAN bus. system, error shown group 11.5.3.1 Cab control unit
9 Multi-function lever (S162) sends a voltage Lever in high beam po- Gear selector and multi-function lever,
signal to Control unit KIT (D790-2). sition: US162/56a = 24 V description page 11
D9: Diagnostic menu, see
10 Lever, direction indicator (S161) sends a volt- Left: US161/6 = 24 V D10: Diagnostic menu, see
age signal to Control unit KIT (D790-2). section 8 Control system,
Right: US161/1 = 24 V
11 Switch, interior lighting on Control unit KIT Checked by control D11: Diagnostic menu, see
(D790-2) sends a voltage signal to Control unit system, error shown section 8 Control system,
KIT (D790-2). with error code. group 8.4.2.9 LIGHTS, menu 9
12 Control unit KIT (D790-2) sends a "switch on Checked by control Section 11 Common electrics,
lights" message on the CAN bus. system, error shown group 11.5.3.11 KIT control unit
13 Control unit, cab (D790-1) supplies voltage to Checked by control Section 11 Common electrics,
the lights in and around the cab. system, error shown group 11.5.3.1 Cab control unit
14 The relay for cab roof work lights (K3017-1 and UK3017/30 = 24 V Working lights, cab, description page 73
K3017-2) is activated when the cab roof work
UK3017/85 = 0 V
lights are activated. It supplies voltage to the
cab roof work lights (E406L-1 E406R-1, Cab roof work lights
E406L-2 & E406R-2). on:
UK3017/86 = 24 V
UK3017/87 = 24 V
Cab roof work lights

off:
UK3017/86 = 0 V
UK3017/87 = 0 V

15 The cab roof work lights (E406L-1 E406R-1, Light on: U = 24 V Working lights, cab, description page 73
E406L-2 & E406R-2) come on when the cab D15: Diagnostic menu, see
roof work lights are activated. section 8 Control system,
16 Back-up lights, white (E405L & E405R) are Light on: U = 24 V Back-up lights, description page 71
switched on when reverse gear is selected. D16: Diagnostic menu, see
17 Revolving beacon (H428) is switched on when Light on: U = 24 V Revolving beacon, description page 72
the revolving working light is activated. D17: Diagnostic menu, see
18 Interior lighting (E434-1) comes on when a Light on: U = 24 V Interior lighting cab, description page 73
door is opened or if activated when the switch D18: Diagnostic menu, see
on the KIT control unit (D790-2). section 8 Control system,
19 Entry lighting (E433) comes on when activated Light on: U = 24 V Entry lighting, description page 74
with the entry lighting switch or when the inte- D19: Diagnostic menu, see
rior lighting comes on. section 8 Control system,
20 The brake light NO switch (S216) sends a volt- Brake pressure over Section 4 Brakes, group 4.3.8 Make-
age signal to the frame control unit (D797-1). 0.2 MPa: U = 24 V contact (closing switch) brake lights
21 The frame control unit (D797-1) supplies volt- Checked by control Section 11 Common electrics,
age to the machine lights. system, error shown group 11.5.3.2 Frame control unit
22 The direction indicators (H422, H423, H426 & Light on: U = 24 V Direction indicators, description
H427) come on when they or the warning lights page 71
are activated. D22: Diagnostic menu, see
23 The running lights (H416-1, H416-2, H417-1 & Light on: U = 24 V Running lights, description page 70
H417-2) come on together with the headlights. D23: Diagnostic menu, see
24 Headlights, low beam (E400L & E400R) are Light on: U = 24 V Headlights, description page 70
switched on when the headlight is activated. D24: Diagnostic menu, see

68 9 Frame, body, cab and accessories – 9.6 Lighting system
25 Headlights high beam (E402L-1 & E402R-1) Light on: U = 24 V Headlights, description page 70
are lit when high beam is activated. D25: Diagnostic menu, see
26 Tail lights, red (H412L & H412R) are switched Light on: U = 24 V Tail lights, description page 70
on when the headlight is activated. D26: Diagnostic menu, see
27 Brake lights (H411L & H411R) are switched on Light on: U = 24 V Brake lights, description page 70
when the brake is activated. D27: Diagnostic menu, see
28 The mast work lights (E404L-1 & E404R-1) Light on: U = 24 V Mast working lights, description page 72
come on when activated. D28: Diagnostic menu, see
29 The auxiliary mast work lights (E404L-4 & Light on: U = 24 V Mast working lights, description page 72
E404R-4) come on when the mast work lights D29: Diagnostic menu, see
are activated. section 8 Control system,
The front wing auxiliary work lights (E404L-4 & group 8.4.2.11 LIGHTS, menu 11
E404R-4) come on when the cab roof work
lights are activated.
30 The frame control unit (D797-2) supplies volt- Checked by control Section 11 Common electrics,
age to the machine lights. system, error shown group 11.5.3.3 Frame control unit
31 The auxiliary mast work lights (E404L-2 & Light on: U = 24 V Mast working lights, description page 72
E404R-2) come on when the mast work lights D31: Diagnostic menu, see
are activated. section 8 Control system,
The front wing auxiliary work lights (E404L-2 & group 8.4.2.11 LIGHTS, menu 11
E404R-2) come on when the cab roof work
lights are activated.
32 Control unit, attachment (D791-1) supplies Checked by control Section 11 Common electrics,
voltage to the attachment’s lights. system, error shown group 11.5.3.5 Attachment control unit
33 The twistlock attachment work lights (E404L-3 Light on: U = 24 V Working lights, attachment, description
& E404R-3) come on when activated. page 73
The work lights for lifting hook attachment with D33: Diagnostic menu, see
lock tongues (E404UL, E404UR, E404LL and section 8 Control system,
E404LR) come on when activated. group 8.4.2.13 LIGHTS, menu 13
34 The twistlock attachment auxiliary work lights Light on: U = 24 V Working lights, attachment, description
(E404L-5 and E404R-5) come on when page 73
activated. D34: Diagnostic menu, see

Lighting system, component location

page
–
The function of lighting is to increase safety during operation and load

handling.
NOTE
The machine has the following lights:
1 4 5 6 6 7 9
30 3,8,10
12
29
28
27
26
008397
22,23,24,25 21 19,20 18 17 16 15 11,13,14
1. Mast work lights (E404L-1 & E404R-1) 16. Entry lighting (E433)
2. Auxiliary mast work lights (E404L-4 & E404R-4) 17. Switches, see Controls and instruments, overview page 5
2. Relay, cab roof work lights (K3017-1 & K3017-2) 18. Switch, entry lighting (S141)
4. Multi-function lever (S162) 19. Frame control unit, option (D797-2)

5. Control unit KIT (D790-2) 20. Frame control unit (D797-1)
6. Interior lighting (E434-1) 21. Make-contact (closing switch) brake light (S216)
7. Cab roof work lights (E406L-1 & E406R-1) 22. Direction indicators, front (H422 & H423)
8. Auxiliary cab roof work lights (E406L-2 & E406R-2) 23. Running lights, front (H416-1 & H417-1)
9. Revolving beacon (H428) 24. Headlights, low beam (E400L & E400R)
Headlights, high beam (E402L-1 & E402R-1)
10. Control unit, cab (D790-1) 25. Auxiliary front wing work lights (E404L-4 & E404R-4)
11. Running lights, rear (H416-2 & H417-2) 26. Lifting hook attachment work lights (E404LL & E404LR)
12. Back-up lights, white (E405L & E405R) 27. Control unit, attachment (D791-1)

70 9 Frame, body, cab and accessories – 9.6.1 Headlights
13. Tail lights, red (H412L & H412R) 28. Twistlock attachment work lights (E404L & E404R)
Brake lights (H411L & H411R)
14. Direction indicators, rear (H426 & H427) 29. Auxiliary carriage work lights (E404L & E404R)
15. Door NC (normally closed) switch (S266-LE & S266-RI) 30. Lifting hook attachment work lights (E404UL & E404UR)
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system, group 8.4.2.3 LIGHTS, menu 3.
9.6.2 Running lights

Running lights, description
page
–
The running lights are fitted on the right and left-hand sides of the ma-
chine to provide surrounding traffic and the environment an indication
of the machine’s position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal goes to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.
9.6.3 Tail lights

Tail lights, description
page
–
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine’s position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal goes to the cab control unit (D790-1).
9.6.4 Brake light

Brake lights, description
page
–
The brake lights are fitted on the rear of the machine to provide sur-
rounding traffic and the environment an indication that the machine is
braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
NC switch). The signal travels to the frame control unit (D797-1), which
supplies power to the brake lights.

9 Frame, body, cab and accessories – 9.6.5 Back-up lights 71
see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.
9.6.5 Back-up lights

Back-up lights, description
page
–
The back-up lights are located on the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is reversing. In addition, this provides the operator enhanced visibility
when operating in darkness.
The reversing lights are controlled by the direction of travel. The signal
travels via the CAN bus.
9.6.6 Direction indicators

Direction indicators, description
page
–
The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction indicator is controlled by selecting with the switch (lever)
for direction indicators. The signal travels to the frame control unit
(D797-1).
9.6.7 Flashing hazard lights

Flashing hazard lights, description
page
–
Flashing hazard lights (Hazard) are used to warn the surroundings,

flashing hazard lights activate all direction indicators simultaneously.
The warning lights are controlled by selecting with the warning light
switch. The signal travels to the cab control unit (D790-1).
section 8 Control system, group 8.4.2.4 LIGHTS, menu 4 and
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.

72 9 Frame, body, cab and accessories – 9.6.8 Revolving beacon
9.6.8 Revolving beacon

Revolving beacon, description
page
–
A rotating beacon is located high on the machine’s cab. This is used

to provide surrounding traffic and the environment an indication that a
working vehicle is moving and at work. Indication to bystanders to ex-
ercise caution.
The rotating beacon is controlled by selecting with the rotating beacon
9.6.9 Working lights, mast

Mast working lights, description
page
–
Work lights on the mast provide enhanced view when load handling in
darkness.
The work lights are controlled by selecting with the mast work light
The mast can be equipped with two auxiliary work lights ( ).
Working lights, replacement (product alternative

page
–
Xenon lights)
DANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non 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.

9 Frame, body, cab and accessories – 9.6.10 Working lights, cab 73
9.6.10 Working lights, cab

Working lights, cab, description
page
–
Working lights on the cab provide visibility when handling a load in

darkness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.

page
–
Xenon lights)
See Working lights, replacement (product alternative Xenon lights)

page 72.
9.6.11 Interior lighting

Interior lighting cab, description
page
–
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background lighting in all switches, function keys, and rotary
controls. This is so that the operator can read their functions and
settings in darkness. Brightness is controlled with the plus and
minus keys.
9.6.12 Working lights, attachment

Working lights, attachment, description
page
–
Working lights on the attachment provide increased visibility when

handling a load in darkness.
The work lights are controlled by selecting with the attachment work
light switch. The signal travels to the cab control unit (D790-1).
The attachment can be equipped with two extra working lights ( ).

page
–
Xenon lights)

page 72.

74 9 Frame, body, cab and accessories – 9.6.13 Entry lighting
9.6.13 Entry lighting

Entry lighting, description
page
–
Entry lighting is controlled by selecting with the entry lighting switch on

the step or when interior lighting comes on. The signal travels to the
cab control unit (D790-1).
2
1
010026
1 Switch, entry lighting (S141)
2 Entry lighting
9.6.14 Work lights, front wing

Front wing work lights, lighting
page
–
Work lights on the front wing provide enhanced view when load han-
dling in darkness.
The work lights are controlled by selecting with the switch for cab roof
work lights.The signal travels to the cab control unit (D790-1).

page
–
Xenon lights)

page 72.

9 Frame, body, cab and accessories – 9.7 Signalling system 75
9.7 Signalling system

Signalling system, function description
page
–
NOTE
1 2 3 4
D2 D3 D17 17 6
7
D1 D4
15
16
D6
D6
D15 D13 D18
13 18
14 M
8 19
D790-1 D790-2 D795
D14 5
9
D797-1 D791-1
D10 20
D11
10 11 D21
21
010027
12
D12
Pos Description Signal description Reference

1 Switch, revolving beacon (S110) Switch in ON position: D1: Diagnostic menu, see section 8 Control sys-
sends a voltage signal to Control U = 24 V tem, group 8.4.2.6 LIGHTS, menu 6
unit, cab (D790-1).
2 Switch, flashing hazard lights (Haz- Switch in ON position: D2: Diagnostic menu, see section 8 Control sys-
ard) (S109) sends a voltage signal to U = 24 V tem, group 8.4.2.4 LIGHTS, menu 4
Control unit, cab (D790-1).
3 Switch, parking brake (S107) sends Switch in ON position: D3: Diagnostic menu, see section 8 Control sys-
a voltage signal to Control unit, cab U = 24 V tem group 8.4.5.4 HYD, menu 4
(D790-1).
4 The horn switch (S149-3) sends a Switch in ON position: D4: Diagnostic menu, see section 8 Control sys-
voltage signal to the cab control unit U = 24 V tem, group 8.4.3.5 CAB, menu 5
(D790-1).
5 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group 11.5.3.1 Cab
messages about activation on the system, error shown control unit (D790-1)
CAN bus. with error code.
6 Multi-function lever (S162) sends a Signal button pressed Gear selector and multi-function lever, description
voltage signal to Control unit KIT in: US162/H = 24 V page 11
(D790-2). D6: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.3.5 CAB, menu 5

76 9 Frame, body, cab and accessories – 9.7 Signalling system

7 Lever, direction indicator (S161) Left: US161/6 = 24 V D7: Diagnostic menu, see section 8 Control sys-
sends a voltage signal to Control unit tem, group 8.4.2.4 LIGHTS, menu 4
Right: US161/1 = 24 V
KIT (D790-2).
8 Control unit KIT (D790-2) sends Checked by control Section 11 Common electrics,
messages about activation on the system, error shown group 11.5.3.11 KIT control unit (D790-2)
CAN bus. with error code.
9 The frame control unit (D797-1) sup- Checked by control Section 11 Common electrics,
plies voltage to the machine lights system, error shown group 11.5.3.2 Frame control unit (D797-1)
and buzzers. with error code.
10 The direction indicators (H422, Light on: U = 24 V Direction indicators, description page 71
H423, H426 and H427) come on D10: Diagnostic menu, see section 8 Control sys-
when the warning lights are tem, group 8.4.2.5 LIGHTS, menu 5
activated.
11 The reversing lights (E405L and Light on: U = 24 V Back-up lights, description page 71
E405R) come on when reverse gear D11: Diagnostic menu, see section 8 Control sys-
is selected. tem, group 8.4.2.8 LIGHTS, menu 8
12 Back-up alarm (H965) is activated Reverse gear en- Reverse alarm, description page 79
when reverse gear is selected. gaged: U = 24 V D12: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.2.8 LIGHTS, menu 8
13 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 78
is activated. D13: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.3.5 CAB, menu 5
14 Revolving beacon (H428) is switched Light on: U = 24 V Revolving beacon, description page 72
on when the flashing hazard light is D14: Diagnostic menu, see section 8 Control sys-
activated. tem, group 8.4.2.6 LIGHTS, menu 6
15 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description page 78

when horn is activated. D15: Diagnostic menu, see section 8 Control sys-
UK3016/85 = 0 V
tem, group 8.4.2.6 LIGHTS, menu 6
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
16 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 78
the horn is activated.
17 Make-contact (closing switch) opera- Operator in seat: Sensor operator in seat, description page 22
tor-in-seat (S230) sends a voltage U = 24 V D17: Diagnostic menu, see section 8 Control sys-
signal to Control unit, cab (D790-1) tem, group 8.4.3.6 CAB, menu 6
when there is a load on the driver’s
seat.

9 Frame, body, cab and accessories – 9.7 Signalling system 77

18 In the event of warnings, Buzzer, cab Checked by control D18: Diagnostic menu, see section 8 Control sys-
(H853) is supplied voltage by Control system, error shown tem group 8.4.3.6 CAB, menu 6
unit KIT (D790-2) to draw the opera- with error code.
tor’s attention to the warning
message.
19 In the event of warnings, control unit A clicking sound is au- Section 11 Common electrics,
KID (D795) activates the warning dible when then termi- group 11.5.3.12 KID control unit (D795)
lamp to draw the operator’s attention nation resistor is
to the warning message. activated.
20 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5 At-
supplies voltage to the automatic system, error shown tachment control unit (D791-1)
spreading buzzer during automatic with error code.
spreading.
21 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling group 7.5.10 Buzzer, au-
(H9003) is activated when automatic tomatic spreading 20’-40’
spreading 20’-40’ is activated. D21: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.9.21 ATTACH, menu 21
NOTE
On machines with side lift attachment, an audible signal can also be given with the open twistlock button (S1002) on
the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon
contact" function is not active.

78 9 Frame, body, cab and accessories – 9.7.1 Horn
Signalling system, component location

page
–
The machine has the following signalling systems:
1 2 3 4 5 6
008395
19 18 17 16 15 14 13 12 10,11 9 8 7
1. Control unit, KID (D795) 11. Control unit, cab (D790-1)

2. Buzzer, cab (H853) 12. Make-contact (closing switch) operator-in-seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switches, see Controls and instruments, overview page 5
5. Direction indicator lever (S161) 15. Loud horn (H850-1)

6. Revolving beacon (H428) 16. Frame control unit (D797-1)
7. Reverse alarm (H965) 17. Direction indicators, front (H422 & H423)
8. Reversing lights (E405L & E405R) 18. Control unit, attachment (D791-1)
9. Direction indicators, rear (H426 & H427) 19. Buzzer automatic spreading (H9003)
10. Relay loud horn (K3016)
9.7.1 Horn
Horn, description
page
–
The horn is electromagnetic. Air horn can be selected ( ).

The horn is activated from the gear and multi-function lever or from the
horn switch ( ). The horn is located under the cab (the compressed
air horn is located on the cab’s front edge).
001247

section 8 Control system, group 8.4.3.5 CAB, menu 5..

9 Frame, body, cab and accessories – 9.7.2 Flashing hazard lights 79
9.7.2 Flashing hazard lights

Flashing hazard lights, description
page
–
See Flashing hazard lights, description page 71.
9.7.3 Revolving beacon

Revolving beacon, description
page
–
See Revolving beacon, description page 72.
9.7.4 Warning parking brake

Warning parking brake, description
page
–
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the operator’s seat (see Sensor operator in seat, descrip-
tion page 22) indicates to the control system if the operator leaves the
seat.
The buzzer is located in the steering wheel panel.
9.7.5 Back-up alarm

Reverse alarm, description
page
–
When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to be careful.

80 9 Frame, body, cab and accessories – 9.8 Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, general
page
–
The machine is prepared with a connector for customer accessories,

see section 11 Common electrics, group 11.5.2.1 Electronic box, cab.
Entertainment and communication, repair

page
–
Repairs should be left to authorised personnel.

9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors 81
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.
As an option, the cab can be equipped with windows of laminated

glass.
The rearview mirrors are of the convex mirror type. There is an interior
rearview mirror on all machines.
A E B 001512
A. Side windows
B. Windshield (front window)
C. Roof window
D. Rear window
E. Windshield (Side window front)
Silicone adhesive, handling advice

page
–
The window panes are secured with decor strips adhesive and silicone
adhesive.
NOTE
The purpose of this instruction is to describe how silicone adhe-
sive 923854.0100 should be handled in connection with replace-
ment of the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0100 is a quick-hardening, two-
component silicone adhesive that can withstand tempera-
tures between -50 C and +200 C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 C cuts hardening time
in half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired
hardening.
Fixing time:
10-20 minutes at 20 C
approx. 5 minutes at 60 C

82 9 Frame, body, cab and accessories – 9.9.1 Windscreen
Hardening time:
approx. 24 hours at 20 C
approx. 1 hour at 60 C
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not
be used at temperatures above +75 C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 C
and +20 C. Storage in a refrigerator or a colder environment
is recommended.
9.9.1 Windscreen
Windscreen, description
page
–
The windshield consists of the front window and side windows. The
windshield is attached to the cab with a key 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 opera-
tor’s station.
For location, see Glass/windows/mirrors, description page 81.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 81.

2 Remove the decor strip.
3 Remove the broken window pane and check that no remains of
glass or other particles remain in the window pane’s groove on
the strip. Cut silicone joints with a sharp tool.
Figure 1: Removing key strip

9 Frame, body, cab and accessories – 9.9.1 Windscreen 83
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 win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.
4 Clean all surfaces thoroughly. Remove old remains of silicone

with a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windscreen or a side window is to be replaced, then the
1 2 3
window panes must be adjusted so that the upper edge on the
side window has the same height as the upper edge of the roof
(see Figure 2) and so that the distance between windshield and
side window is as in Figure 3.
Use spacers against the roof member to ensure that the distanc-
es are maintained.
1
006268
1,0
1
Figure 2: Adjusting side window - cab window
1. Side window
2. Rubber strip
3. Cab frame / door opening
006269
1,0
Figure 3: Adjusting side window - windshield

1. Masking tape
7 Fit the decor strip around the whole window pane.
8 Apply Silicon adhesive 923854.0100 around the panes. Make the
new joint wider than the old one in order to create a good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.

84 9 Frame, body, cab and accessories – 9.9.2 Side window
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
9 Remove excess silicone adhesive from the outer vertical corners
with a tool made of cardboard as shown in Figure 4. Smooth out
the joints on the inside with a finger, wet with water or soapy
water.
10 Apply silicone adhesive 923854.0100 between the strip and win-
dow pane at the bottom edge of the front corners, so-called top
sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Align the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane’s
edges and by the protection over the frame’s sides. Then tighten
down the corner screws for the roof window.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
006272
out the joints with a finger, wet with water or soapy water.
Figure 4: Tool template for silicone joint, scale 1:1

IMPORTANT
Mark the window panes with "New adhesive. Do not
touch."
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.
9.9.2 Side window

Side window, description
page
–
The side windows are secured in the cab and doors with decor strips.
For further details, see Glass/windows/mirrors, description page 81.
Side window, replacement

page
–
NOTE
The method describes a general procedure.

9 Frame, body, cab and accessories – 9.9.2 Side window 85
2 Use special tools to detach the decor strip.
3 Remove the decor strip which runs around the whole window.
4 Carefully remove any remains of glass from the rubber strip.
5 Fit the new window, securing it at the bottom edge.

86 9 Frame, body, cab and accessories – 9.9.2 Side window
6 Spray soap solution on the window and rubber strip to facilitate

fitting.
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the decor strip with a special tool.

9 Pull the decor strip around the whole window.

9 Frame, body, cab and accessories – 9.9.2 Side window 87
10 Cut off the decor strip approx. 2 cm too long.

11 Fit the other end of the decor strip edge to edge.
12 Adjust the decor strip so that the correct fit is obtained.

88 9 Frame, body, cab and accessories – 9.9.3 Roof window
9.9.3 Roof window

Roof window, description
page
–
The roof window is made of polycarbonate plastic, which is a safety

feature for the operator, intended to protect the operator from falling
objects. The polycarbonate plastic is elastic.
Safety is maintained within a temperature interval of 120 C to -45 C
(becomes brittle at -110 C, glass conversion temperature 145 C).
The roof window has a patented surface layer that increases its resist-
ance to wear, UV light and chemicals.
The roof window is joined with the windshield. Joints between the win-
dow panes and between roof window and cab are sealed with silicone
adhesive. Place a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, description page 81.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing aromatic hydrocarbons, ketones, esters, and
chlorinated hydrocarbons.
Check the roof window’s surface at regular intervals,

and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!
Roof window, replacement

page
–
See Windscreen, replacement page 82, for the general procedure.

The roof window is combined with the windshield. The joint is sealed
with silicone. Add a new silicone seal when replacing.
9.9.4 Rear window

Rear window, description
page
–
The rear window is attached to the cab with a decor strip.
On machines with hydraulic sliding cab or hydraulic cab lift and

lower, the rear window can be opened to provide an emergency exit.
For further details, see Glass/windows/mirrors, description page 81.
Rear window, replacement

page
–
See Side window, replacement page 84 for the general procedure.

9 Frame, body, cab and accessories – 9.9.5 Rear view mirror 89
9.9.5 Rear view mirror

Rear view mirror, description
page
–
The cab has one rearview mirror located in the cab and external rear-
view mirrors out on the machine. The rearview mirrors give the opera-
tor a view around the machine.
9.9.6 Reversing camera

Reversing camera, description
page
–
The back-up camera is located at the rear edge of the horizontal coun-
terweight, at the back on the machine. It is designed to provide im-
proved vision when reversing. The back-up camera is waterproof and
has a microphone and infrared lighting for night vision. In addition, the
camera is equipped with automatic heating which is activated at ambi-
ent temperatures below +10 C.
1
2 The reversing camera sends colour images and audio to the monitor
in the cab; see Monitor, reversing camera, description page 89.
1
007425
3
1. IR-diodes
2. Camera
3. Microphone
9.9.7 Monitor, reversing camera

Monitor, reversing camera, description
page
–
The screen shows picture and sound from the back-up camera. The
CA.SE
L
1 picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle sig-
MENU
2 nals from two different cameras.

VOL
The monitor is mounted on a hinged bracket to the left in front of the
3 door in the cab.
BRI
4
007416
5
1. Choice of camera
2. Menu
3. Light intensity
4. Volume setting
5. On and off

90 9 Frame, body, cab and accessories – 9.10 Cab structure and suspension
9.10 Cab structure and

suspension
Cab structure and suspension, description
page
–
The cab is mounted in a cab undercarriage via strong rubber insulators

located on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points - one at each cor-
1 ner. Each insulator mounting has one rubber bushing and one bolt.
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.1 Cab frame

Cab frame, description
page
–
The cab frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped
loads. The frame must not be modified!
002210
Cab Spirit Delta

9 Frame, body, cab and accessories – 9.10.2 Doors 91
9.10.2 Doors
Doors, description
page
–
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
• openable window (passenger door )

Switches in the doors’ locks sense if the door is open. The switch is
used to turn on the interior lighting and warn of an open door.
section 8 Control system, group 8.4.2.9 LIGHTS, menu 9 or
8.4.11.5 MOVE-CAB, menu 1.
9.10.3 Cab substructure

Cab substructure, description
page
–
The cab is mounted on a cab undercarriage via strong rubber insula-

tors located on the underside of the cab. This is to minimise vibrations
from the frame to the cab.
The cab undercarriage is fitted on the machine’s chassis (frame) via a
mounting. The chassis mounting depends on whether the machine is
equipped with hydraulic cab tilt.

92 9 Frame, body, cab and accessories – 9.10.4 Tiltable cab
9.10.4 Tiltable cab

Tiltable cab, description
page
–
WARNING
If anybody goes under the tilted cab.
Extreme danger!
Check that nobody is underneath or near the cab

when it is tilted. Visibility is impaired.
NOTE
Operate the cab when the machine is stationary!
The cab can be hydraulically tilted 10° along its length axis.
When the load is to be lifted high up, the cab can be tilted back to im-
prove visibility and make the working position more ergonomic.
With the automatic/manual cab tilt switch in the automatic cab tilt po-
sition, the cab will be tilted when the mast reaches a predetermined lift
height.
The cab can be tilted up or down with the manual cab tilt switch. This
switch is also operative when the cab tilt switch is in the automatic
position.
For the cab to be tilted, machine speed must not exceed 5 km/h, the
driver’s doors must be closed and the parking brake or emergency
stop switch for servo circuits must not be activated.
If the cab is not in the lowest position, machine speed is limited to not
more than second gear and 5 km/h.

9 Frame, body, cab and accessories – 9.10.4 Tiltable cab 93

Parking brake Released Section 4 Brakes, group 4.5 Parking brake system.
Doors Closed Doors, description page 91
Speed < 5 km/h Section 8 Control system, group 8.2.3 Speed limitation
Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
6
3 1 4 1
0
0 2
D3 D4 D6
5 7
D790-1 D797-1
8
D797-2 12
9 D8
10
D9 12
B
T
A
TP
P LS LSPB
11
2 010028
1 The cab tilt shuttle valve sends a load P = 3.5 MPa Section 10 Common hydraulics,
signal to the hydraulic oil pumps. group 10.5.3 Shuttle valve
2 The hydraulic oil pumps pump oil from P = 190.5 MPa Hydraulic oil pump, description page 95
the hydraulic oil tank.
3 The automatic/manual cab tilt switch U = 24 V Controls and instruments, overview page 5
(S199-2) sends a voltage signal to the D3: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system, group 8.4.11.5 MOVE-CAB, menu 2

94 9 Frame, body, cab and accessories – 9.10.4 Tiltable cab
4 The manual cab tilt switch (S1010) cab U = 24 V Controls and instruments, overview page 5
up/down sends a voltage signal to the
cab control unit (D790-1).
5 If manual cab tilt is selected, the cab Checked by control sys- Section 11 Common electrics,
control unit (D790-1) transmits cab up or tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
cab down on the CAN bus. ror code.
6 If automatic cab tilt is selected, sensor U = 0-5 V Sensor for automatic cab tilt (B7211-1), de-
B7211-1 sends information to the frame scription page 99
control unit (D797-1) when the attach- D8: Diagnostic menu, see section 8 Control
ment reaches a predetermined lift system, group 8.4.11.5 MOVE-CAB, menu 2
height.
7 If automatic cab tilt is selected, the Checked by control sys- Section 11 Common electrics,
frame control unit (D797-1) transmits tem, error shown with er- group 11.5.3.2 Frame control unit (D797-1)
cab up or cab down on the CAN bus. ror code.
8 The cab up sensor (B769-1) and cab Cab up/cab down sensor, description
down sensor (B769-2) provide voltage page 99
information on cab position to the frame D10: Diagnostic menu, see section 8 Control
control unit (D797-2). system, group 8.4.11.5 MOVE-CAB, menu 3
9 The frame control unit (D797-2) acti- Checked by control sys- Section 11 Common electrics,
vates the cab up servo valve (Y6047) or tem, error shown with er- group 11.5.3.3 Frame control unit (D797-2)
the cab down servo valve. (Y6048). ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.11.5 MOVE-CAB, menu 4
10 The servo valve for cab up (Y6047) or Cab tilt control valve, description page 95
servo valve for cab down (Y6048) pres-
surises the tilt spool in the cab tilt control
valve.
11 The control valve’s tilt slide changes po- - Cab tilt control valve, description page 95
sition and pressurises the tilt cylinders.
12 The tilt cylinders angle the cab in rela- - Cab tilt hydraulic cylinders, description
tion to the cab undercarriage. page 98

draulics, Hydraulic diagram of basic machine.

9 Frame, body, cab and accessories – 9.10.4.1 Hydraulic oil pump 95

page
–
The tiltable cab is supplied pressure from a hydraulic oil pump; see
1 section 10 Common hydraulics, group 10.4.2 Axial piston pump with
variable displacement.
2
3
008082
1. Hydraulic oil pump and quick lift pump for load

handling.
filtering.
3. Main pump for steering and load handling.
9.10.4.2 Control valve, cab tilt

Cab tilt control valve, description
page
–
The control valve controls the speed and direction of the cab tilt func-
tion. The control valve is located on the right on the frame, in the area
beside the gearbox.
Electrically controlled pressure reduction valves (servo valves) con-
vert electric current to a small hydraulic pressure which is proportional
1 to the current, so-called servo pressure. The servo pressure operates
a spring-centred control spool in the control valve, and thus controls
2
the main flow.
1 Tilt slide
The tilt spool controls the direction and flow of oil to the tilt cylinders.
Servo valve, cab tilt up

The servo valve for cab tilt up controls the servo pressure to the tilt
spool, so that it controls the oil pressure for cab tilt upwards. The valve
3 is electrically controlled by the cab up solenoid valve (Y6047), which
is activated by the frame control unit (D797-2).
4
005614
section 8 Control system, group 8.4.11.5 MOVE-CAB, menu 4.
1. Tilt cylinder connection

2. Feed from hydraulic oil pump
3. Servo valve, cab up (Y6047)
4. Servo valve, cab down (Y6048)

96 9 Frame, body, cab and accessories – 9.10.4.2 Control valve, cab tilt
Servo valve, cab tilt down

The servo valve for cab tilt down, controls the servo pressure to the tilt
spool, so that it controls the oil pressure for cab tilt downwards. The
valve is electrically controlled by the cab down solenoid valve (Y6048),
which is activated by the frame control unit (D797-2).
Cab tilt control valve, replacement

page
–
NOTE
Safety.
3 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
4 Mark and disconnect the cable harness from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact, clean and in the correct position.
NOTE
Transfer one part at a time so that the marking is not
mixed up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
9 Connect the cable harness to the control valve according to the
marking.
10 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
position.

9 Frame, body, cab and accessories – 9.10.4.3 Cab tilt shuttle valve 97
12 Check the function.
CAUTION
product damage.
Activate the steering carefully and operate at the low-

est possible speed a couple of times to avoid
cavitation.
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 at the top of the level glass. Top up as needed.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the boom com-

pletely lowered and retracted.
9.10.4.3 Cab tilt shuttle valve

Cab tilt shuttle valve, description
page
–

010029
Cab tilt shuttle valve

98 9 Frame, body, cab and accessories – 9.10.4.4 Cab tilt brake valve
9.10.4.4 Cab tilt brake valve

Cab tilt brake valve, description
page
–
There are two brake valves situated between the cab tilt control valve
and the cab tilt cylinders. The brake valves are adjustable and choke
pressure to the tilt cylinders, which reduces the speed of cab tilting.
The brake valves are located on the control valve’s connections to the
hydraulic cylinders.
010032
Cab tilt brake valves
9.10.4.5 Cab tilt hydraulic cylinders

Cab tilt hydraulic cylinders, description
page
–
The lower parts of the hydraulic cylinders are fixed to the cab under-
carriage and the upper parts are fixed to the cab. The hydraulic cylin-
ders lift the front edge of the cab, thereby tilting it.
010033

page
–
9.10.4.6 Undercarriage of tiltable cab

Cab undercarriage cab tilt, description
page
–
The cab undercarriage for cab tilt comes in two sections, the part that
holds the cab has a hinge at the trailing edge which is located on the
frame, and the hydraulic cylinders are located at the leading edge be-
tween the parts.

9 Frame, body, cab and accessories – 9.10.4.7 Sensor for automatic cab tilt (B7211-1) 99
9.10.4.7 Sensor for automatic cab tilt (B7211-1)

Sensor for automatic cab tilt (B7211-1), description
page
–
The mast position sensor (B7211-1) activates cab tilt automatically.

The position sensor sends a signal to the frame control unit (D797-1).
Sensor for automatic cab tilt (B7211-1), checking and

page
–
adjusting
Check and adjust the position sensor as follows:
2 Check that the sensor is clean and free from dirt.
15 1 mm.
9.10.4.8 Sensor, cab up/cab down

Cab up/cab down sensor, description
page
–
The sensors indicate when the cab is tilted up (B769-1) or down

(B769-1). When the cab is not in its lower position, machine speed is
reduced to not more than 5 km/h.
Position sensor, checking and adjustment

page
–
Check and adjust the position sensor as follows:

2 Check that the sensors are clean and free from dirt.
5 1 mm.

100 9 Frame, body, cab and accessories – 9.11 Cab interior
9.11 Cab interior

9.11.1 Instrument and control panels
Steering wheel panel, description
page
–
The steering wheel panel is secured to the steering column and con-
tains warning and indicator lights, display (KID), function keys (KIT)
and switches.
Left-hand dashboard panel, description

page
–
The left instrument panel is located in the left corner of the cab. It con-
tains rotary controls, switches, and ventilation.
Panel for load handling functions, description

page
–
The panel, which is mounted on the driver’s seat, houses switches and
controls for load handling functions and a emergency stop switch to in-
terrupt load handling functions in progress.
On machines equipped with a control lever, it is located next to the
panel .
Steering wheel panel, replacement

page
–

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.

9 Frame, body, cab and accessories – 9.11.2 Interior fittings, plastic 101
4 Remove the bolts on the underside of the steering wheel panel.
5 Remove the bolts on the top of the steering wheel panel.
6 Unplug the connector from the multi-function levers, ignition key

lock, Control unit KIT (D790-2) and Control unit KID (D795).
7 Transfer the components to the new steering wheel cover.
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
page
–
The interior of the cab consists of recyclable material.
9.11.3 Interior fittings, textile

Interior fittings, textile, description
page
–
The interior of the cab consists of recyclable material.

102 9 Frame, body, cab and accessories – 9.11.4 Floor covering
9.11.4 Floor covering

Floor covering, description
page
–
The floor covering is a wear-resistant and recyclable material.
9.11.5 Insulation
Insulation, description
page
–
The cab insulation consists of recyclable material.
9.11.6 Sun visors

Sun visors, description
page
–
Sun blinds can be chosen for the front window (windscreen) and the
roof window.
1. Sun visor, front windshield: Can be raised and lowered using a
cord on the right side. Stops in selected position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window.
9.11.7 Terminal console

Terminal console, description
page
–
The function of terminal desk is to provide a work surface for a com-

puter/terminal. It is located to the right of the steering wheel, easily ac-
cessible for the operator.
008227
9.11.8 Reading-lamp
Reading lamp, description
page
–
The reading lamp is fitted on a jointed bracket to the right in front of the
door in the cab.

9 Frame, body, cab and accessories – 9.11.9 Writing desk 103
9.11.9 Writing desk

Writing desk, description
page
–
The writing table with reading light is located on a flexible attachment

to the right in front of the door in the cab. That is where work orders,
etc. can be fastened.
008228

104 9 Frame, body, cab and accessories – 9.12 Frame
9.12 Frame
Frame, description
page
–
The frame is a modular construction and consists of front section, rear

section, and a member pair. This construction provides advantages in
terms of rigidity and strength.
There are mounting points in the frame for engine, gearbox, drive axle,
steering axle, fuel and hydraulic tanks, cab, mast 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 coun-
terweights are designed to allow as good visibility as possible to the
rear.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
1 2 3 4
5
010030
1. Frame’s front section with drive axle mounting

2. Bracket for front wings
3. Engine compartment with mountings for engine and transmission
4. Cab mounting (4 points)
5. Frame’s rear section with counterweights
6. Steering axle mounting

9 Frame, body, cab and accessories – 9.13 Body structure 105
9.13 Body structure

Body structure, description
page
–
The body structure’s components comprise:
1 2 3
010031
1. Wings
2. Hood engine compartment
3. Counterweight
9.13.1 Wings
Wings, description
page
–
There are fenders over the wheels to protect from dirt thrown up by the
wheels during operation. The design of the counterweight (see Coun-
terweights, description page 106) acts as a mudguard for the rear
wheels.
The fenders can be equipped with extra mudguards when the ma-
chine’s work environment requires such ( ).
9.13.2 Hood engine compartment

Hood engine compartment, description
page
–
The machine’s engine compartment is protected by a hood.

The machine compartment for transmission and driveline/axle is pro-
tected by tread plate secured with retaining bolts. The tread plate is
designed to be walked on and is grooved to provide good grip.

106 9 Frame, body, cab and accessories – 9.13.3 Footsteps and hand rail
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
page
–
The cab area has footsteps for easy access. There is a rail by the
cab area.
9.13.4 Counterweights
Counterweights, description
page
–
The machine has counterweights to balance the machine’s lift capac-

ity and these may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for max-
imal leverage.
The machine has counterweights in the following locations:
• Under the steering axle
• Furthest back on the machine there are vertical counterweights
secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine’s lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller counter-
weights whose dimensions and quantity are adapted to balance
the machine’s lifting capacity.
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.

9 Frame, body, cab and accessories – 9.14 Central lubrication 107
9.14 Central lubrication

Central lubrication, checking
page
–
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
Overview central lubrication pump unit and distribution
troubleshoot the pump unit.
block. Example image.
1. Grease nipple, filling of grease
2. Safety valve
NOTE
3. Grease nipple, manual system lubrication The system can be lubricated manually through the grease
4. Indicator pin nipple on the distribution block (position 3).
5. Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.

108 9 Frame, body, cab and accessories – 9.14 Central lubrication
Central lubrication, adjusting lubrication times

page
–
The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. At replacement, the new pump unit should be set
in the same way as the old.
If the machine is not greased correctly, pause and run-time can be ad-
justed. Primarily, run-time should be adjusted so that all grease points
on the machine are greased every time. If large amounts of grease are
pressed out at all grease points, pause-time can be increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Test or extra greasing

Central lubrication can be operated manually by holding in the button
for manual operation (position 3) for 2 seconds. This starts an extra lu-
brication cycle.
Pause time
Pause-time is the length of the interval between greasings. The inter-
Example figure
val is adjusted in whole hours between 1 and 15 hours. Pause-time is
1. Setting pause time (red)
adjusted with the red handle (position 1)
2. Setting run time (blue)
3. Manual operation of pump
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
Run time is how long the pump is activated every time. Run time can
be adjusted between 2 and 30 minutes. Pause time is adjusted with
the blue handle (position 2).
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

9 Frame, body, cab and accessories – 9.14.1 Pump unit 109
9.14.1 Pump unit

Pump unit, description
page
–
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and run-
ning time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motor’s run and pause
time.
When the central lubrication works, it greases the grease points one
at a time in series. If a stop should occur in a grease point, the pres-
sure will increase and the safety valve will release grease and also the
following grease points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased Therefore, it is very important to
check the safety valve.
Example figure components central lubrication

1. Pump unit
2. Safety valve

110 9 Frame, body, cab and accessories – 9.14.2 Distribution block
9.14.2 Distribution block

Distribution block, description
page
–
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example figure components central lubrication through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
If there is clogging in the system, that line will be pressurised, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks’ connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3 Lines
Lines, description
page
–
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
Explosion pressure min. 60.0 MPa

9 Frame, body, cab and accessories – 9.15 Paint/coatings 111
9.15 Paint/coatings
Paint/coatings, description
page
–
The machine is painted using a single-layer paint, thickness 120 my.

For colour code (RAL) of machine in question, see machine card.
NOTE
Before touching up, the surfaces to be touched up must be thor-
oughly cleaned.
Please contact Cargotec for information about other surface treatment
and material colours.

112 9 Frame, body, cab and accessories – 9.15 Paint/coatings

10 Common hydraulics 1
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 Relief valve, attachment ........................................................................ 3
10.2.3 Pressure limiting valve ........................................................................... 4
10.2.4 Pipes and hoses .................................................................................... 4
10.3 Tanks and accumulators ............................................................................ 5
10.3.1 Tank ....................................................................................................... 5
10.3.2 Pipes and hoses .................................................................................... 5
10.4 Pumps ........................................................................................................ 6
10.4.1 Gear pump with fixed displacement ....................................................... 6
10.4.2 Axial piston pump with variable displacement ....................................... 9
10.4.3 Pipes and hoses .................................................................................. 18
10.5 Hoses, pipes and valves .......................................................................... 19
10.5.1 Pipes and hoses .................................................................................. 19
10.5.2 Priority valve ........................................................................................ 20
10.5.3 Shuttle valve ........................................................................................ 20
10.5.5 Collecting block, unfiltered returns ....................................................... 21
10.6 Temperature control, cleaning and hydraulic oil ....................................... 22
10.6.1 Tank heater .......................................................................................... 25
10.6.2 Cooler hydraulic oil .............................................................................. 26
10.6.3 Cooling fan ........................................................................................... 27
10.6.4 Sensor hydraulic oil temperature ......................................................... 27
10.6.5 Radiator bypass valve ......................................................................... 29
10.6.6 Breather filter hydraulic oil tank ........................................................... 30
10.6.8 Hydraulic oil ......................................................................................... 32
10.6.9 Fine filter hydraulic oil .......................................................................... 33
10.6.10 Pipes and hoses .................................................................................. 34
10.7 Other ........................................................................................................ 35
10.7.1 Hydraulic cylinders ............................................................................... 35

2 10 Common hydraulics

10 Common hydraulics 3
mm mm mm mm mm mm
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
page
–
The accumulator drain valve is located on the accumulator charging

valve. See section 4 Brakes, group 4.3.3 Accumulator charging valve.
009960
10.2.2 Relief valve, attachment

Relief valve attachment, description
page
–
The relieve valve sits on the pressure supply to the attachment on hy-
draulic oil pump 2. See section 7 Load handling, group 7.4.7 Attach-
ment relief valve.
009961
The illustration depicts an open valve

4 10 Common hydraulics – 10.2.3 Pressure limiting valve
10.2.3 Pressure limiting valve

Pressure limiting valve, description
page
–
The pressure limiting valve leads too high pressure in the hydraulic oil
supply to tank, protecting the hydraulic system against excessive
pressures.
The pressure limiting valve sits on the collecting block for pressure
supply from the load handling hydraulic oil pump and the quick-lift hy-
draulic oil pump on the hydraulics plate in front of the transmission.
009962

Pipes and hoses, general
page
–
See Pipes and hoses, general page 19.

10 Common hydraulics – 10.3 Tanks and accumulators 5
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
page
–
1 2 1 3 2 4 5 The hydraulic oil tank forms part of the side panel on the right side of
the machine. The oil filters for the working hydraulics are located in-
side 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 Tech-
nical data. The entire filter unit can be removed to facilitate access for
cleaning. There is a drain plug at the bottom of the tank.
The tank is equipped with filtered breather that allows volume changes
in the tank, due to temperature variations and use.
The oil level is checked on the sight glass on the tank’s side when all
hydraulic cylinders are in the bottom position.
1
008086
1. Hydraulic oil filter cover

2. Hydraulic oil filler plug
3. Level glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Hydraulic oil drain plugs
008087
1. Accumulator

page
–

6 10 Common hydraulics – 10.4 Pumps
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
–
A gear pump with fixed displacement supplies pressure to the brake

1 system and circulates hydraulic oil through the radiator and filter; see
section 4 Brakes, group 4.3.1 Hydraulic oil pump.
The gear pump pumps oil using two gears wheels that rotate opposite
each other. One is driven by the pump’s input shaft and the other ro-
tates freely. The gear pump’s flow is directly dependent on the speed
of the input shaft.
2
3
008082
1. Hydraulic oil pump and quick-lift pump for load

handling.
filtering.
3. Main pump for steering and load handling.
Gear pump, changing

page
–
NOTE
Safety.
3 Mark up and release the hydraulic hoses from the gear pump.
009963

10 Common hydraulics – 10.4.1 Gear pump with fixed displacement 7
4 Remove the gear pump.

Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters to the new gear pump.
009964
6 Remove the spacer ring from the gear pump or axial piston pump.
Clean the O rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush heat-resistant sealing silicone on the seal-
ing face against the gear pump, see section F Technical data.
NOTE
Only use silicon on the side facing the gear pump.
8 Fit the spacer ring on the axial piston pump.

8 10 Common hydraulics – 10.4.1 Gear pump with fixed displacement
9 Brush sealing silicone on the gear pump’s sealing against the

spacer ring, see section F Technical data.
10 Fit the gear pump and axial piston pump.
Install the pump and check that the gear engages in the shaft and
that the spacer ring is installed directly against the gear pump. In-
stall the pump’s attaching bolts.
11 Connect the hydraulic hoses to the gear pump.
NOTE
position.
009963
NOTE
14 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
008049
15 Check the oil level in the hydraulic system, fill if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter as well.
16 Check the brake pressure; see section 4 Brakes, group 4.3.1 Hy-
draulic oil pump.

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 9
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
page
–
description
The hydraulic oil pumps that supply the working hydraulics are of the
1
2 type variable axial piston pump, and are controlled by load signals de-
pending on the flow demand from each function.
Three pumps, of which two are assembled with a junction block, sup-
ply the working hydraulics. The junction block controls oil to and from
the pumps. On the junction block, there is a spacer block that contains
test connections for checking pump pressure. There are non-return
valves on the spacer block that prevent oil from being pumped around
between the pumps instead of out in the hydraulic system. On the
3 spacer block between the quick-lift hydraulic oil pump (position 2) and
4 the load handling hydraulic pump (position 1), there is a branching to
the attachment hydraulics with a separate non-return valve. The non-
009967
return valve houses the attachment relief valve; see Relief valve at-
1. Hydraulic oil pump for load handling. tachment, description page 3.
2. Hydraulic oil pump for quick-lift.
filtering.
4. Hydraulic oil pump for steering and load handling.

10 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

page
–
D790-1 D790-2
LS (21)
D797-1 D795 P
8,12,18 P (16)
LS
D8 D12 P
6 26
C 7 P
T
PS TP
5 1
P LS LSPB
EF PP
14 2 P
CF P
9 13,17,19,22 4 T LS
LS
15,20
T
23
11
24,27
C C
009148
10 16,21 3,25,28

1 The lift and tilt control valve sends a See pressure plate Servo Section 7 Load handling, group 7.2.5 Lift
load signal when a function is pressure lift and exten- and tilt control valve
activated. sion on left frame
member.
2 The steering shuttle valve sends the - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for steering and load handling.
3 The hydraulic oil pump for steering and See pressure plate Max. Axial piston pump with variable displace-
load handling increases the flow. pressure hydraulic oil ment, description page 9
pumps on left frame
member.
4 The priority valve prioritises pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority
from the hydraulic pump for steering ing pressure, on left valve.
and load handling to the steering valve frame member.
or the lever steering control valve over
the lift and tilt control valve.


5 The pressure reducer reduces the feed See pressure plate servo Section 7 Load handling, group 7.2.3 Pres-
pressure to servo pressure. pressure, on left frame sure reducer
member.
6 Accumulator servo pressure stores the See pressure plate servo Section 7 Load handling, group 7.2.4 Accu-
servo pressure. pressure, on left frame mulator servo circuit
member.
7 The servo filter cleans the servo oil up- - Section 7 Load handling, group 7.2.2 Servo
stream of the lift and tilt control valve. filter
8 If the quick-lift conditions are fulfilled, U = 24 V Section 7 Load handling, group 7.2 Lifting/
the KDU frame control unit (D797-1) lowering
activates the solenoid valve for quick- D8: Diagnostic menu, see section 8 Control
lift engagement (Y6062). system, group 8.4.5.6 HYD, menu 6.
9 The solenoid valve for quick-lift en- - Section 7 Load handling,

gagement (Y6062) opens and sends a group 7.2.12 Quick-lift valve block
load signal to the quick-lift hydraulic oil
pump.
If the conditions for quick-lift are not ful-
filled, the LS signal is directed to the
tank (quick-lift hydraulic oil pump off).
10 The quick-lift hydraulic oil pump in- See pressure plate Max. Axial piston pump with variable displace-
creases the flow. pressure hydraulic oil ment, description page 9
pumps on left frame
member.
11 The pressure limiting valve drains - Pressure limiting valve, description page 4
pressure to tank if the pressure in the
hydraulic system becomes too high.
12 If an attachment function is activated, U = 24 V Section 11 Common electrics,

the KDU frame control unit (D797-1) group 11.5.3.2 Frame control unit (D797-1)
activates the solenoid valve for main D12: Diagnostic menu, see section 8 Control
pump relief (Y6062-2). system, group 8.4.5.6 HYD, menu 6.
13 The solenoid valve for main pump relief - Section 7 Load handling, group 7.4.6 Valve
(Y6062-2) routes a relieved constant block, main pump relief
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
14 The attachment shuttle valve sends the - Shuttle valve, description page 20
for load handling.
15 The cab tilt shuttle valve sends the load - Shuttle valve, description page 20
signal on to the hydraulic oil pump for
load handling.


16 The hydraulic oil pump for load han- See pressure plate Max. Axial piston pump with variable displace-
dling increases the flow to the attach- pressure hydraulic oil ment, description page 9
ment control valve. pumps on left frame
member.
17 When solenoid valve for main pump re- - Section 7 Load handling, group 7.4.6 Valve
lief (Y6062-2) is not activated, the re- block, main pump relief
lieved pressure is directed to tank.
18 If cab tilt is activated, the KDU frame U = 24 V Section 11 Common electrics,

control unit option (D797-1) activates group 11.5.3.2 Frame control unit (D797-1)
the solenoid valve for main pump relief D12: Diagnostic menu, see section 8 Control
(Y6062-2). system, group 8.4.5.6 HYD, menu 6.
19 The solenoid valve for main pump relief - Section 7 Load handling, group 7.4.6 Valve
(Y6062-2) routes a relieved constant block, main pump relief
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
20 The cab tilt shuttle valve sends the load - Shuttle valve, description page 20
signal on to the hydraulic oil pump for
load handling.
21 The hydraulic oil pump for load han- See pressure plate Max. Axial piston pump with variable displace-
dling increases the flow to the cab tilt pressure hydraulic oil ment, description page 9
control valve. pumps on left frame
member.
22 When solenoid valve for main pump re- - Section 7 Load handling, group 7.4.6 Valve
lief (Y6062-2) is not activated, the re- block, main pump relief
lieved pressure is directed to tank.
23 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve.
24 The shuttle valve signal cable sends a - Shuttle valve, description page 20
for steering and load handling.
25 The hydraulic oil pump for steering and See pressure plate Steer- Axial piston pump with variable displace-
load handling increases the flow. ing pressure, on left ment, description page 9
frame member.
26 For control valve for lever steering - Section 5 Steering, group 5.2.10 Control
sends a load signal to the shuttle valve valve, mini-wheel/lever steering
when a function is activated.
27 The shuttle valve signal cable sends a - Shuttle valve, description page 20
load signal to the hydraulic oil pump for
steering and load handling.
28 The hydraulic oil pump for steering and - Axial piston pump with variable displace-
load handling increases the flow. ment, description page 9

Hydraulic oil pump, checking

page
–
NOTE
Safety.
es operating temperature, approx. 50 C.
2 Turn off engine.
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
3 5 Check the stand-by pressure for one pump at a time in the follow-
2
1 ing order:
Hydraulic oil pump for steering and load handling: 3.0 MPa
Hydraulic oil pump for quick-lift: 2.8 MPa
Hydraulic oil pump for load handling: 2.6 MPa
The settings apply to standard machine, certain machines can
have higher stand-by pressure. For correct stand-by pressure,
009965
see pressure plate. However, the difference in pressure between

the different pumps must always be maintained.
1. Hydraulic oil pump for steering and load handling 6 Increase engine speed to approx. 1100 rpm and run tilt function
2. Hydraulic oil pump for load handling against end-position (overflow).
3. Hydraulic oil pump for quick-lift
Tilt in the mast to the max. position and continue requesting max.
tilt in with the control lever. This causes tilt function overflow.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should correspond with the value on the pressure plate.
M Pa All pumps shall give the same pressure. The order between the
pumps is of no importance.
8 Turn off engine.
9 Transfer the pressure gauge to the next pump and repeat
steps 3–8 on all pumps.
009966


page
–
change
NOTE
Safety.
1 Park the machine with the mast fully extended and spreading
halfway 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 mast, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 32.
2 Disconnect the main power supply.
4 Detach the gear pump from the hydraulic oil pump (see Gear
pump, changing page 6) in order to replace the pump for steering
and load handling.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection on the gear
pump.
7 Mark the hydraulic hoses and disconnect them from the axial pis-
ton pump.
NOTE
009969
8 Attach hoisting equipment to the axial piston pump.

9 Remove the axial piston pump.
Remove the retaining bolts and lift the pump away.

10 Clean the flange on the gearbox, removing all silicone remnants.
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
position.
12 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.
13 Fit the axial piston pump in place.
Position the axial piston pump so that the pump shaft engages
the transmission’s gearing. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.
15 Connect the hydraulic hoses to the axial piston pump in accord-

ance with the marking.
NOTE
position.
009969

16 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to
step 20.
Clean the O rings’ contact surfaces on the spacer ring.
17 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the gear pump, see section F Technical data.
NOTE
Only use silicone on one side, the side facing the brake
pump.
18 Fit the spacer ring on the axial piston pump.
19 Brush sealing silicone on the gear pump’s sealing against the

spacer ring, see section F Technical data.
20 Fit the gear pump in place.
Place the gear pump on the axial piston pump and install the at-
taching bolts. Be careful so that the O-ring on the spacer ring is
located correctly and that the gear pump’s shaft engages the ax-
ial piston pump’s output shaft.
21 Bleed the axial piston pump, see Axial piston pump with variable
displacement, venting page 18.
CAUTION
Vent the axial piston pump before starting the engine.
The illustration shows a separate pump. The oil in the axial piston pump may cavitate and
cause product damage.

NOTE
24 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
25 Check the pump pressures, see Hydraulic oil pump, checking
page 13.
008049
26 Check the oil level in the hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as needed.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the hydraulic system as well.
CAUTION
Do not overfill!


18 10 Common hydraulics – 10.4.3 Pipes and hoses

page
–
venting
NOTE
Safety.
1 Remove the hydraulic oil tank breather filter.

2 Connect compressed air at max. pressure max. 10 kPa to the hy-
draulic oil tank’s connection for breather filter.
009970
3 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 connec-
tions when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather
filter.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tight.
7 Lower the mast and raise it again very slowly so that the pump
009969
operates under minimum load while air pockets are eliminated.

8 Turn off engine.
9 Wash the engine bay.

page
–

10 Common hydraulics – 10.5 Hoses, pipes and valves 19
10.5 Hoses, pipes and valves

page
–
Hoses with ORFS-couplings are used almost exclusively. For maxi-

mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the
connection.
• Never re-use oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil bar-
rels 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.

20 10 Common hydraulics – 10.5.2 Priority valve
10.5.2 Priority valve

Priority valve, description
page
–
See section 5 Steering, group 5.2.2 Priority valve.
10.5.3 Shuttle valve

page
–
1. Shuttle valve attachment 009973
2. Shuttle valve control
3. Cab tilt shuttle valve

A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
activated at the same time.
Depending on option, there are two or three shuttle valves. The shuttle
valves are located on the hydraulic plate in front of the transmission
and on cab tilt control valve .
The shuttle valves choose between the following control signals:

10 Common hydraulics – 10.5.5 Collecting block, unfiltered returns 21
1. Chooses between the load signal from the lift and tilt control valve
and the control signal from the attachment control valve. The shut-
tle valve sends control signals on to the steering shuttle valve or
the hydraulic oil pump for steering and load handling; see Axial
piston pump with variable displacement, description page 9.
2. Chooses between the load signal from the control valve for lifting/
lower and extension and control pressure from the control valve.
The shuttle valve sends the control signal on to control the hydrau-
lic oil pump for load handling; see Axial piston pump with variable
displacement, description page 9.
3.
Chooses between the load signal from the attachment shuttle
valve (position 1) or the cab tilt control valve to the hydraulic oil
pump for steering and load handling; see Axial piston pump with
variable displacement, description page 9.
This shuttle valve is fitted if the machine is equipped with a tiltable
cab.
10.5.5 Collecting block, unfiltered returns

Multiblock, unfiltered return lines, description
page
–
The block collects several return lines from different valves and leads
these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is located on the hydraulic plate in front of the transmission.
010020

22 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil
10.6 Temperature control,

cleaning and hydraulic oil
page
–
The oil of the hydraulic system is cooled and cleaned through circula-
tion through the radiator and filters. The radiator has a temperature-
regulated electric fan that prevents overheating.
Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter,
fine filter, hydraulic oil temperature sensor, and bypass valve.
The hydraulic oil pump for the brake system pumps oil (from the tank)
through the brake system’s cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases airflow through the cooler when a temperature reduction
is needed. When the oil is cold, a bypass valve opens and leads the
oil directly to the tank so that resistance through the cooler and filter
does not become too great. The bypass valve closes when the oil gets
hot and then instead leads the oil through the cooler and filter. The
temperature sensor regulates fan activation and temperature display.
The return oil from load handling and steering is filtered through the
hydraulic oil filter in the hydraulic oil tank.

10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 23
˚C
˚C
P
P
T
EF PP
14 9, 15
P D790-2
P CF D795
LS
T LS
T D797-1
L R
8, 10, 13
16
D7 D8
11 M
P T
6
2 3 4 12
1 1 1 1
5
008090
˚C 7

1 The hydraulic oil pumps pump oil from the See pressure plate on left Axial piston pump with variable dis-
hydraulic oil tank, frame beam. placement, function description page 10
2 The brake oil filter cleans the oil. - See Section 4 Brakes,
group 4.3.2 Brake oil filter
3 The accumulator charging valve directs oil Charge: See Section 4 Brakes, group 4.3.3
to charging of accumulators or through the P = 20.50.5 MPa Accumulator charging valve
brake system’s cooling circuit. Cooling: P < 0.1 MPa
4 The oil passes through the drive axle block. - See Section 4 Brakes, group 4.3.6 Drive
axle block
5 A small amount of oil is guided through the Fine filter hydraulic oil, description
fine filter and back to the hydraulic oil tank. page 33
6 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description page 26
7 The hydraulic oil temperature sensor - Sensor, hydraulic oil temperature, de-
(B776) sends the frame control unit scription page 27
(D797-1) a voltage signal proportional to D7: Diagnostic menu, see
the hydraulic oil temperature. section 8 Control system,
group 8.4.5.1 HYD, menu 1

24 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil

8 The frame control unit (D797-1) transmits Checked by the control Section 11 Common electrics,
oil temperature on the CAN bus. system, error indicated group 11.5.3.2 Frame control unit
9 The KID control unit (D795) shows oil tem- - Section 9 Frame, body, cab and acces-
perature in the operating menu hydraulic oil sories, group 9.1 Controls and
temperature. instruments
10 If the hydraulic oil temperature is high, the U = 24 V Cooling fan, description page 27
frame control unit (D797-1) supplies volt- D8: Diagnostic menu, see
age to the cooling fan. section 8 Control system,
11 The cooling fan increases the airflow - Cooling fan, description page 27
through the hydraulic oil cooler, thus in-
creasing cooling output.
12 If the pressure through the cooler is too P = 0.2 MPa Bypass valve, cooler, description
high, the thermal bypass valve opens and page 29
directs the oil past the cooler
13 If the hydraulic oil temperature is too high, Checked by the control Section 11 Common electrics, group
the frame control unit (D797-1) transmits a system; error shown with 11.5.3.2 Frame control unit (D797-1)
warning for high hydraulic oil temperature error code. D8: Diagnostic menu, see
on the CAN bus. section 8 Control system,
14 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and acces-
hydraulic oil temperature warning light. sories, group 9.1 Controls and
instruments
15 The KID control unit (D795) shows the er- Checked by the control Section 11 Common electrics,
ror code on the display. system; error shown with group 11.5.3.12 KID control unit (D795)
error code.
16 Return oil from the lift and tilt control valve - Bypass valve, cooler, description
and the attachment control valve is cleaned page 29
by the oil filters in the hydraulic oil tank.

10 Common hydraulics – 10.6.1 Tank heater 25
10.6.1 Tank heater

Tank heater, safety
page
–
CAUTION
The tank heater is connected to high voltage
(110 - 400 V).
High voltage.
Connection and reconnection of the tank heater may

only be performed by personnel authorised for work
with high voltage.
Tank heater, description

page
–
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs on high voltage. Heater output is adapted
through different connections and adaptation to different operating
voltages - 110, 230 or 400 V AC. Higher voltage generates higher
heater output. The heater is mounted in a hole in the connection cover
at the bottom of the short side of the tank.
The tank heater can be equipped with a programmable thermostat
which maintains the temperature at an even level. The thermostat is
fitted directly onto the heating element and can be adjusted with a
knob on the junction box. Recommended temperature setting is
009988
50-70 C.

26 10 Common hydraulics – 10.6.2 Cooler hydraulic oil
10.6.2 Cooler hydraulic oil

Hydraulic oil cooler, description
page
–
The working hydraulics use a through-flow cooler with electric cooling

fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes the cooler, which sits inside the side panel on
the right side behind the hydraulic oil tank.
009989
Hydraulic oil cooler, replacement

page
–
NOTE
Safety.

2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, chang-
ing page 32.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
1 oil in the cooler drain into the collection container.
2 NOTE
3 Plug all connections immediately to protect the hydraulic
4 Disconnect the cable harness from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Fit the cooler.
8 Connect the cable harness to the cooling fan.
009990
9 Connect the hydraulic hoses to the cooler.

1. Cooling fan
2. Hydraulic connections
NOTE
3. Cooler
Check that the O-rings are intact and installed correctly.

10 Common hydraulics – 10.6.3 Cooling fan 27
10 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing
page 32. The oil level should be visible in the sight glass.
CAUTION
Do not overfill!

10.6.3 Cooling fan

Cooling fan, description
page
–
The electric cooling fan is suctioning. The cooling fan is located at the
rear of the cooler. The fan draws air from the machine’s outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied voltage by the rear frame control unit (D797-1)
upon activation. The cooling fan is activated when temperature of the
oil in the hydraulic oil tank is 65 C and is deactivated when the tem-
perature is 55 C.
009991
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
page
–
The hydraulic oil temperature sensor (B776) detects the temperature

of the hydraulic oil. The sensor is located on the hydraulic oil tank’s
rear short end.
The sensor detects the oil temperature in the tank, determining the
accumulated heat in the hydraulic oil. Because of this, the cooling fan
may continue to run after the machine has been parked and
switched off.
The hydraulic oil temperature sensor (B776) is supplied voltage by the
rear frame control unit (D797-1) and sends the unit a voltage signal
proportional to oil temperature.
009992

28 10 Common hydraulics – 10.6.4 Sensor hydraulic oil temperature
Sensor, hydraulic oil temperature, replacement

page
–
NOTE
Safety.

2 Drain the oil from the hydraulic oil tank, see Hydraulic oil, chang-
ing page 32.
3 Disconnect the cable harness from Sensor, hydraulic oil temper-
ature (B776).
4 Replace Sensor, hydraulic oil temperature (B776).
NOTE
position.
5 Connect the cable harness to the sensor.
009992
Sensor, hydraulic oil temperature (B776)

page 32. The oil level should be visible in the level glass.
CAUTION
Do not overfill!

7 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYD 1(6) system, group 8.4.5.1 HYD, menu 1.
HYDRAULIC OIL
TEMP XXX TEMP indicates hydraulic oil temperature in C. Check that cor-
FAN XY rect temperature is shown.
000141
Diagnostic menu Hyd, menu 1

10 Common hydraulics – 10.6.5 Radiator bypass valve 29
10.6.5 Radiator bypass valve

Bypass valve, cooler, description
page
–
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.
009993
Bypass valve, cooler, replacement

page
–
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Machine in service position, section B Safety.

3 Drain the oil from the hydraulic oil tank, see Hydraulic oil, chang-
ing page 32.
4 Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old. Use Loctite when fitting the bypass valve.
009993
Bypass valve

30 10 Common hydraulics – 10.6.6 Breather filter hydraulic oil tank
page 32. The oil level should be visible in the sight glass.
IMPORTANT
Do not overfill!

10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
page
–
A breather filter of insert type is mounted on the hydraulic oil tank to

protect the tank from impurities. On top of the filter housing is an indi-
cator that shows when the filter is clogged and should be changed.
009970

Hydraulic oil filter, description
page
–
The oil in the hydraulic system is cleaned by two return filters located
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.
009994

10 Common hydraulics – 10.6.7 Hydraulic oil filter 31
Hydraulic oil filter, replacement

page
–
NOTE
Safety.
IMPORTANT
2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydrau-
lic oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter in-
sert as environmentally hazardous waste. Note the position of the
parts.
1. Cover for oil filter

2. Filling point hydraulic oil
5 Clean the filter holder’s parts. Be especially thorough with the
magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and the covers. Tighten the bolts crosswise.
8 Check the oil level in the hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as needed.
NOTE
Check the hydraulic oil level with the mast fully lowered and
Magnetic rod
the side lift attachment retracted.

32 10 Common hydraulics – 10.6.8 Hydraulic oil
10.6.8 Hydraulic oil

Hydraulic oil, changing
page
–
NOTE
Read the safety instructions for oil before working, see section F
Technical data.
IMPORTANT

2 Remove the filler cap and pump out the hydraulic oil into a
receptacle.
3 When most possible oil has been pumped out. Place a collection
container under the hydraulic oil tank’s drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained out.
1. Cover for oil filter NOTE

2. Filling point hydraulic oil Make sure that the seal washer is installed as well.
5 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, replacement
page 31.
6 Fill new hydraulic oil through the filler holes on the filters’ covers.
This results in filtering of the oil that is filled and protects the hy-
draulic system from impurities.
Fill oil until the oil level is in the middle of the level glass. For vol-
ume and grade, see section F Technical data.
IMPORTANT
Do not overfill!


10 Common hydraulics – 10.6.9 Fine filter hydraulic oil 33
10.6.9 Fine filter hydraulic oil

Fine filter hydraulic oil, description
page
–
The fine filter sits behind the hydraulic oil tank on the right side of the
machine. The filter is connected in parallel with the hydraulic oil filters
in the hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.
009968

34 10 Common hydraulics – 10.6.10 Pipes and hoses
Fine filter hydraulic oil, replacement

page
–
NOTE
Safety.
IMPORTANT

2 Remove the cover.
3 Take out a collection vessel.
4 Lift up the filter insert. Place it in a receptacle and let the hydraulic
oil drain.
5 Fit the new filter insert and refit the cover over the fine filter.

page
–

10 Common hydraulics – 10.7 Other 35
10.7 Other
10.7.1 Hydraulic cylinders
page
–
Fault tracing, leakage
CAUTION
All troubleshooting 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.
1 Carefully check the source of the leak before taking any action. It
may be possible to solve the problem without removing.
2 Check for external leakage:
• At cylinder face end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces. Both problems can be solved with the cyl-
inder in place.
• Between cylinder head and piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3 Check for internal leaks. Pressurise the cylinder and check if the
1. Piston rod
piston sinks back.
2. Scraper
3. Cylinder head This could be due to a worn piston seal.
4. Piston rod seal
5. O-ring with support ring
Dismantling of cylinders
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end CAUTION
9. Piston
10. Piston seal, double-acting
Always check before removing that the piston rod is
11. Example of weld
free from any paint remains. Also check that there are
no burrs or impact marks by connections and
couplings.
Make sure that the chamfer up to the chromium sur-

face of the piston rod is free from burrs and residual
paint.

36 10 Common hydraulics – 10.7.1 Hydraulic cylinders
1 Remove the cylinder from its mounting and undo the

connections.
2 Plug the cylinder connections and hoses without delay.
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the fol-
lowing descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium-plated with a
layer thickness of 20-50 my. Slight damage to the chromium-
plating may not necessarily be the direct cause of leakage.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and
piston rod. These are always the hardest to seal
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 enters at an angle, the seal lip on

the piston rod seal may be damaged and the sealing
function may be lost. This applies for all types of pis-
ton rod seals.

10 Common hydraulics – 10.7.1 Hydraulic cylinders 37
Function and removal of the seals
Piston rod seal

The piston rod seal is the seal that is located in the groove in the cyl-
2
inder head and seals against the piston rod. This seal is subject to ex-
tensive wear since it is both a dynamic and a static seal, i.e., it seals
1 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:
• Single V-seal
3 • Pre-stressed V-seal with support ring
• Compressible seal
The simple V seal has a V-shaped section with two lips that seal in
4
6 opposite directions. The hydraulic pressure works 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
001497
5 screwdriver on a sealing surface can have a devastating effect and

cause major leakage.
1. Hydraulic pressure
2. The sealing lip is pressed outward against the
piston rod
3. The sealing lip is pressed inward against the
cylinder head
4. Piston rod sealing surface
5. Cylinder head sealing surface
6. Screwdriver

The pretensioned V seal also has an O-ring in the seal’s V-shaped

2
space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the V
seal. Examine in the same manner. 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
3 it cannot touch and thereby damage a sealing surface. A mark from a
7
screwdriver on a sealing surface can have a devastating effect and
6 4 cause major leakage.
001498
5
piston rod
cylinder head
6. Screwdriver
7. O-ring

The compressible piston rod seal consists of a solid rubber profile

2
and provides a larger sealing surface than the V seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1
With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.
6
4
5
001499
5
piston rod
cylinder head
6. Screwdriver

Support ring and O-ring

The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that
it is not deformed. The O-ring is pressed against the support ring and
the sealing surface by the hydraulic pressure in the cylinder.
3
When the cylinder head is mounted in the barrel: Take extreme care
to avoid damaging the O-ring.
4
2
001506
1
2. O-ring
3. Support ring
Scraper
øD+10
The purpose of the scraper is to scrape the piston rod clean and pre-
1 vent impurities from entering the cylinder barrel.
The scraper is installed with a special installation tool, which has a
greater outer diameter than the scraper so that the press force against
2 the scraper ceases right when the scraper is pressed into position. If
the scraper were to be pressed in further, the metal casing will be de-
formed (see lower illustration), which would impair the function of the
4 scraper.
3 To prevent the scraper from bottoming in its recess in the cylinder
head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
1. Correct installation tool

2. Scraper, correctly installed
3. Cylinder head
4. Play between scraper and bottom of cylinder head
slot
5. Incorrect installation tool
6. Deformed scraper

A screwdriver can be used for removal. This must always be applied

1 against the outer edge of the scraper (see illustration). Carefully tap
the screwdriver down between the scraper and the cylinder head and
2 then pry out the scraper. Polish off any damage to the cylinder head.
CAUTION
No tool must be applied from the inside. This could
3 generate burrs on the cylinder head which in turn
could damage the piston rod. Burrs may also damage
the piston rod seal when installing the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
On the single-acting V-seal it is always the long side that seals

2
against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to pry the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is al-
ways inserted in the V shape so that it cannot touch and thereby dam-
age a sealing surface. A mark from a screwdriver on a sealing surface
3 can have a devastating effect and cause major leakage.
6 4
002370
5
2. Seal is pressed outward against the cylinder barrel
3. Seal is pressed inward against the piston
4. Cylinder barrel sealing surface
5. Piston sealing surface
6. Screwdriver

The seal must always be fitted as an assembly together with the

thrust ring.
Always assemble by hand. No tools should be used as they could eas-
ily damage the surface of the piston.
To facilitate assembly the seal can be heated in hot water to make
it soft.
Lubricate with hydraulic oil.
002950
5 4 3 1 6 Double-acting piston seal
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.
Exercise caution when fitting the piston in the cylinder barrel, making
2
002951
sure that the seal is not damaged by the cylinder barrel threads.
1. Moving sealing surface to cylinder barrel Dismantling:

2. Fixed sealing surface with piston
1 Remove guide rings and support rings.
3. Guide ring
4. Support ring 2 Move the seal body over to one side of the sealing groove.
5. Piston head 3 Press up the material so that there is a gap between seal
6. Cylinder barrel and piston.
4 Without damaging the surface of the piston - cut off the seal
with a knife.
5 Carefully examine the seal to find any damage that can 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 All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2 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.

Repairing the piston rod surface

A small impact mark on a piston rod may be sufficient to cause
1 2 3
leakage. The chromium plating on the piston rod has a thickness of
20-50 my and can be treated to make good minor damage. This may
be a satisfactory alternative to costly disassembly.
1 Locate the damage using your fingertips and fingernails.
4 2 Use a small, highly-polished hammer and work the surrounding

material inwards towards the damage, starting from the outside.
3 Instead of a small sharp mark there will now be a small uniform
concavity in the chromium plating.
4 Polish with emery cloth, progressing from number 240 to 600.
Wrap the emery cloth round a file to give it good support. Note
that there must always be chromium-plating present at the
damage.
5 It is important to treat small impact marks before disassembly and
assembly to avoid damaging the cylinder head.
6 Repairing larger damage on a piston rod:
002952
• fill the damage with weld metal, use chromium or stainless

1. Piston steel electrodes
2. Chromium-plating • remove all slag completely
3. Impact marks
• file the weld down to the same level as the chrome
4. Highly polished hammer
• polish evenly using emery cloth

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylin-
der barrel on steering cylinders because the O-ring in the cylinder
head jams in the retaining ring’s groove in the cylinder barrel. There-
fore it is best to remove the O-ring before trying to pull out the piston
rod from the cylinder.
1 Unscrew the end washer at the cylinder head.

2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
similar into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through
the hole.
9 Remove the lock ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

11 Common electrics 1
11 Common electrics
Table of Contents 11 Common electrics

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2 Electric protection ....................................................................................... 3
11.2.1 Battery disconnector .............................................................................. 3
11.2.2 Fuses ..................................................................................................... 3
11.2.3 Control breaker ...................................................................................... 3
11.3 Batteries ..................................................................................................... 4
11.3.1 Start battery ........................................................................................... 4
11.4 Alternator .................................................................................................... 6
11.4.1 Alternator ............................................................................................... 6
11.5 Distribution of electricity ............................................................................. 7
11.5.1 Voltage feed ........................................................................................... 7
11.5.2 Electronic box ...................................................................................... 15
11.5.3 Control units ......................................................................................... 17
11.5.5 Cable harness ...................................................................................... 26
11.6 Communication ........................................................................................ 38
11.6.1 CAN bus .............................................................................................. 38
11.6.2 Redundant CAN bus ............................................................................ 40
11.6.3 CAN bus drive-train ............................................................................. 43
11.6.4 Communication between PC and machine .......................................... 44
11.6.5 RMI (Remote Machine Interface) ......................................................... 45

2 11 Common electrics

11 Common electrics 3
11 Common electrics
mm mm mm mm mm mm
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
page
–
The positive terminals of the batteries connected in series are con-

nected to the machine’s electrical system via the battery disconnect
switch. The battery disconnector cuts off all power from the batteries
to the machine’s electrical system.
A
IMPORTANT
Never switch off the voltage with the battery discon-
nector when the engine is running. This could dam-
age the alternator.
The battery disconnector must not be used as control

breaker!
010051
A. Position of battery disconnector
11.2.2 Fuses
Fuses, changing
page
–
When checking and changing the main fuse:

1. Switch off the main current (battery disconnect switch).
2. Remove the plastic cover.
3. Check that fuses are intact. Change when needed.
The fuses are 50 A.
When checking and replacing the circuit fuses:
1. Switch off the main current (battery disconnect switch).
2. Remove the cover from the electronic box.
3. Check and, if necessary, replace fuses.
The fuse plate gives information about each fuse.
11.2.3 Control breaker

Emergency stop switch, description
page
–
See Emergency stop switch voltage (15E), function description

page 11.

4 11 Common electrics – 11.3 Batteries
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
The machine’s electrical system is supplied by two 12 V batteries con-

nected 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
page 6.
WARNING
The batteries’ electrolyte contains corrosive sulphu-
ric acid.
Risk of corrosive injuries, health hazard!
Use protective glasses and protective gloves when

working with the batteries. Immediately remove elec-
trolyte from the skin. Wash with soap and plenty of
water. If electrolyte gets in the eyes, rinse with plenty
of water and seek medical help immediately.
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the bat-

teries. Sparks could ignite the hydrogen gas, causing
an explosion. Disconnect the battery with the battery
disconnect switch.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of injury!
The battery’s terminals must not be connected to

each other or to common grounding point (frame).

11 Common electrics – 11.3.1 Start battery 5
Start battery, replacement

page
–

2 Disconnect the cables from the battery terminals, starting with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the nega-
tive cable last.
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.

6 11 Common electrics – 11.4 Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description
page
–
The alternator generates current during operation and supplies this to

the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
trol system, section 8.4.6.4 ENGINE, menu 4.
010052
Alternator, replacement
page
–
See supplier documentation, engine.

11 Common electrics – 11.5 Distribution of electricity 7
11.5 Distribution of electricity

11.5.1 Voltage feed
11.5.1.2 Redundant voltage feed of control
units
Redundant voltage feed of control units, function
page
–
description
D11 D8
686800
D795 D790-2 D797-1
11 8
6, 7 10 9
D790-1 D791 D797-2
D10 D9
- +
D793 D794
D2
D1 D3 D4 D5
1 2 3 4 5

1 The NC switch, operator’s door U = 24 V Section 9 Frame, body, cab and accessories,
(S 266-LE) or the NC switch, pas- group 9.10.2 Doors
senger door (S 266-RI) sends a D1: Diagnostic menu, see section 8 Control system,
voltage signal to the cab control group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5
unit (D790-1) when the door is MOVE-CAB, menu 1
opened.
2 The interior lighting switch of the U = 24 V Section 9 Frame, body, cab and accessories,
KIT control unit (D790-2) sends a group 9.6.12 Interior lighting
voltage signal to the cab control D2: Diagnostic menu, see section 8 Control system,
unit (D790-1). group 8.4.2.13 LIGHTS, menu 13
3 Switch, flashing hazard lights U = 24 V Section 9 Frame, body, cab and accessories,
(S109) sends a voltage signal to group 9.6.7 Warning lights
Control unit, cab (D790-1). D3: Diagnostic menu, see section 8 Control system,
4 When the ignition switch (S150) is U = 24 V Section 9 Frame, body, cab and accessories,
turned to position I, it sends a volt- group 9.1 Controls and instruments
age signal to the cab control unit D4: Diagnostics menu, see section 8 Control system,
(D790-1). group 8.4.1.5 CAN/POWER, menu 5

8 11 Common electrics – 11.5.1.2 Redundant voltage feed of control units

5 The switch for entry lighting (S141) U = 24 V Section 9 Frame, body, cab and accessories,
sends a voltage signal to the cab group 9.6 Lighting
control unit (D790-1). D5: Diagnostic menu, see section 8 Control system,
6 Control unit, cab (D790-1) acti- - Cab control unit (D790-1), description page 18
vates a hold circuit, which acti-
vates the control unit’s control
logic.
7 Control unit, cab (D790-1) acti- UK11:7 = 24 V Cab control unit (D790-1), description page 18
vates a redundant voltage feed to
U K11:8 = 24 V
other control units.
UK11:9 = 24 V
The cab control unit (D790-1) has
4 outputs for redundant voltage UK11:10 = 24 V
feed while other control units have
two inputs for redundant voltage
feed. In case of a malfunction of
one voltage feed the control unit is
supplied by the other feed.
8 Control unit, cab (D790-1) sup- UK2:7 = 24 V Frame control unit (D797-1), description page 19
plies voltage to the control logic of D8: Diagnostic menu, see section 8 Control system,
UK2:8 = 24 V
the other control units via the re- group 8.4.1.10 CAN/POWER, menu 10
dundant voltage feed.
9 UK2:7 = 24 V Frame control unit (D797-2), description page 20
UK2:8 = 24 V D9: Diagnostic menu, see section 8 Control system,

group 8.4.1.13 CAN/POWER, menu 13
10 UK2:7 = 24 V Attachment control unit (D791), description page 21
UK2:8 = 24 V D10: Diagnostics menu, see section 8 Control sys-

tem, group 8.4.1.15 CAN/POWER, menu 15
11 UK2:7 = 24 V D11: KID control unit (D795), description page 26
UK2:8 = 24 V Diagnostic menu, see section 8 Control system,


11 Common electrics – 11.5.1.3 Ignition voltage (15) 9
11.5.1.3 Ignition voltage (15)

Ignition voltage (15), function description
page
–

Battery disconnector In position 1 Battery disconnector, description page 3
Redundant voltage feed Activated. Redundant voltage feed of control units, function descrip-
tion page 7
Redundant CAN bus Communication established. Redundant CAN bus, description page 40
- +
K315-2
1 2 K315-1
7 3, 6
D1 D2 D3 3
D794
D793
11 D11
4, 5
D8 D10
D790-1 D791 D797-2
2, 8 10
9
D795 D790-2 D797-1
008687
D9

1 Switch, flashing hazard U = 24 V Section 9 Frame, body, cab and accessories,
lights (S109) sends a volt- group 9.6.7 Warning lights
age signal to Control unit, D1: Diagnostic menu, see section 8 Control system,
cab (D790-1). group 8.4.2.5 LIGHTS, menu 5
2 When the ignition switch U = 24 V Section 9 Frame, body, cab and accessories,
(S150) is turned to position I, group 9.1 Controls and instruments
it sends a voltage signal to D2: Diagnostic menu, see section 8 Control system,
the cab control unit group 8.4.1.5 CAN/POWER, menu 5
(D790-1).
3 The cab control unit U = 24 V Cab control unit (D790-1), description page 18
(D790-1) supplies voltage to D3: Diagnostic menu, see section 8 Control system,
ignition voltage relay K315-1 group 8.4.1.5 CAN/POWER, menu 5
in the frame electrical distri-
bution box and ignition volt-
age relay K315-2.

10 11 Common electrics – 11.5.1.3 Ignition voltage (15)

4 Ignition voltage relay U = 24 V -
K315-1 supplies voltage to
fuse holder in the cab elec-
trical distribution box and in
the frame electrical distribu-
tion box.
5 The fuses feed voltage to U = 24 V -

control units, relays, sole-
noid valves and other elec-
tronic components.
6 Ignition voltage relay U = 24 V Engine control unit (D794), description (Volvo

K315-2 supplies voltage to TAD760VE engine) page 23
the engine control unit
(D794).
7 The drive-train’s CAN-bus Checked by control sys- CAN bus drive-train, description page 43
establishes communication. tem, error shown with
error code.
8 Ignition voltage to Control UK1:2 = 24 V Cab control unit (D790-1), description page 18
unit, cab (D790-1). D8: Diagnostic menu, see section 8 Control system,
UK1:3 = 24 V
UK1:4 = 24 V
9 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-1), description page 19
UK2:9 = 24 V
UK2:10 = 24 V
10 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-2), description page 20
UK2:9 = 24 V
UK2:10 = 24 V
11 Ignition voltage to Control UA1 = 24 V Transmission control unit (D793), description page 22
unit, transmission (D793). D11: Diagnostic menu, see section 8 Control system,

11 Common electrics – 11.5.1.4 Emergency stop switch voltage (15E) 11
11.5.1.4 Emergency stop switch voltage (15E)

Emergency stop switch voltage (15E), function description
page
–

Redundant voltage Activated. Redundant voltage feed of control units, function description page 7
feed
Ignition voltage Activated. Ignition voltage (15), function description page 9
Control breaker Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and
instruments
D794
D793
D5
K3007
3, 4 6
K3009-1 K3009-2
- +
K3002
D4
D2
D7
D8
D790-1 D797-2 D797-1
1, 2, 5 7
8
D795 D790-2 D791
008688
1 Ignition voltage is activated by the cab con- Checked by control Ignition voltage (15), function description
trol unit (D790-1) system, error shown page 9
with error code.
2 Control unit, cab (D790-1) supplies voltage UK3009-1/86 = 24 V Cab control unit (D790-1), description
to Relay, emergency stop switch voltage page 18
(K3009-1) in the frame electronic box. D2: Diagnostic menu, see section 8 Control
system, group 8.4.1.6 CAN/POWER,
menu 6
3 Relay, emergency stop switch voltage UK3009-2/87 = 24 V Electronic box frame, description page 16
(K3009-1) supplies voltage to Relay, emer-
gency stop switch voltage (K3009-2) in the
frame electronic box.

12 11 Common electrics – 11.5.1.4 Emergency stop switch voltage (15E)

(K3009-1) also sends a voltage signal to the D4: Diagnostic menu, see section 8 Control
UK3009-2/87= 0 V
Control unit, cab (D790-1), which verifies system, group 8.4.1.6 CAN/POWER,
that Relay, emergency stop switch voltage menu 6
(K3009-1) is active but Relay, emergency
stop switch voltage (K3009-2) is inactive.
This verifies that the emergency stop switch
is working.
5 Control unit, cab (D790-1) activates Relay, UK3009-2/86 = 24 V Cab control unit (D790-1), description
emergency stop switch voltage (K3009-2) in page 18
the electronic box. D5: Diagnostic menu, see section 8 Control
system, group 8.4.1.6 CAN/POWER,
menu 6
K3009-2 supplies voltage to the emergency
stop switch circuit.
7 The control units are supplied with emer- Emergency stop Frame control unit (D797-2), description
gency stop switch voltage as long as emer- switch in home posi- page 20
gency stop switch is not pressed in. tion: UK2:1 = 24 V D7: Diagnostic menu, see section 8 Control
The control unit on the attachment is only system , group 8.4.1.13 CAN/POWER,
supplied emergency stop switch voltage, menu 13
thus all attachment functions stop if the
8 Emergency stop Attachment control unit (D791), description
emergency stop switch is activated.
switch in home posi- page 21
If the emergency stop switch is pressed, ig- tion: UK2:1 = 24 V D8: Diagnostic menu, see section 8 Control
nition voltage to the cab control unit (D790-
Emergency stop system, group 8.4.1.15 CAN/POWER,
1) is cut off, thereby cutting off control cur-
switch in home posi- menu 15
rent to emergency stop switch voltage relay
K3009-1, emergency stop switch voltage re- tion: UK2:9 = 24 V
lay K3009-2, the tilt relay (K3002) and the Emergency stop
lift/lower relay (K3007). The power supply to switch in home posi-
the control units is cut off and the functions tion: UK2:10 = 24 V
cease.
Emergency stop
As an extra safety measure, the cab control switch in home posi-
unit (D790-1) also transmits the status of the tion: UK2:11 = 24 V
emergency stop switch the CAN bus. Thus,
functions are also cut off at the signal level.

11 Common electrics – 11.5.1.5 Voltage converter 13
Emergency stop switch, checking

page
–
1 Start the machine and active any load handling function.

2 Activate lift
3 Press in the emergency stop switch and check that the lift move-
ment stops.
4 Reset the emergency stop switch (turn in the direction of the ar-
rows) and check that the lift function is working again.
004770
Control breaker
11.5.1.5 Voltage converter

Voltage converter, description
page
–
The voltage converter is located under a protective casing to the left

behind the driver’s seat.
The voltage converter converts 24 Volt to 12 Volt. 12 V voltage is avail-
able for accessories by via connector X067 in the cab’s electronic box.
(Contains 15-, 30-voltage, ground, and 12V).
12 V voltage is also available on the outlet on the dashboard panel,
see section 9 Frame, body, cab and accessories group 9.1 Controls
and instruments.
CAUTION
The max. output of the voltage converter is 12 V/20 A
(including the radio).

14 11 Common electrics – 11.5.1.5 Voltage converter
Voltage converter, replacement

page
–

2 Remove the covers behind the driver’s seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located diagonally behind the

driver’s seat.

11 Common electrics – 11.5.2 Electronic box 15
11.5.2 Electronic box

11.5.2.1 Electronic box, cab
Electronic box, cab, description
page
–
The electronic box is mounted on the rear wall of the cab, on the left.
7 Located there are:
• Control unit cab (D790-1).
6 • Circuit fuses for cab battery voltage (30), ignition voltage (15)
F58-4 and circuit fuses for cab ignition voltage (15) F58-5.
• 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.
1 • Connector customer accessory. Output voltage 24 V, max. 10 A.
Connector 9-pin Universal mate-n-lock. For part number see
2
Spare parts catalogue.
3 The connector contains the following connections:

1. Ignition voltage.
4
2. Battery voltage.
5 3. Ground.
4. 12 V voltage from the voltage converter.
008693
NOTE
1. Control unit cab (D790-1) This connector is not fitted on the machine if the machine is
2. Diagnostic socket, machine equipped with voltage converter.
3. Diagnostic socket, CAN bus, drivetrain
4. Fuse holder for circuit fuses, cab battery
voltage (30) and ignition voltage (15) F58-4 (upper)
and circuit fuses, cab ignition voltage (15) F58-5
CAUTION
(lower).
Connector X067 is to be used to connect auxiliary
5. Voltage converter
electrical equipment. Use of other connections could
6. Termination resistor
overload the wiring and cause product damage.
7. Connector customer accessory 24V / 10A

16 11 Common electrics – 11.5.2.2 Electronic box frame
11.5.2.2 Electronic box frame

Electronic box frame, description
page
–
The electronic box is fitted on the side of the machine. Also located
5 6
4 there are:
7
3 • Circuit fuses.
2
8 • Socket for communication with the engine and transmission; see
1
Communication between PC and machine, description page 44.
• Main fuses.
9
• Control unit, transmission (D793)
10
• Power relays for voltage feed to the machine’s functions.
11
12
13
007958
14
1. Circuit fuses, emergency stop switch voltage
(15E)F58-3
2. Circuit fuses, ignition voltage (15) F58-2
3. Circuit fuses, battery voltage (30) F58-1
4. Engine diagnostic socket, VODIA (Volvo engine)
5. Transmission diagnostic socket
6. Main fuses
7. Transmission control unit (D793)
8. Attachment connection terminal
9. Lift/lower relay K3007
10. Tilt in/out relay K3002
11. Ignition switch relay K315-2
12. Ignition switch power relay K315-1
13. Emergency stop switch power relay K3009-1
14. Emergency stop switch power relay K3009-2
-
1
-
2
- 1
3
-
4
5 -
-
6
007184
1. Termination resistor

11 Common electrics – 11.5.3 Control units 17
11.5.3 Control units

Control units, location
page
–
1 2 3 4
009172
9 8 7 6
1. Control unit, attachment (D791-1) 6. Control unit, Volvo engine (D794)

2. Control unit, KID (D795) 7. Engine control unit, Cummins (D794)
3. Control unit KIT (D790-2) 8. Frame control unit (D797-1)
4. Control unit, cab (D790-1) 9. Frame control unit, option (D797-2)

5. Control unit, transmission (D793)

18 11 Common electrics – 11.5.3.1 Control unit, cab (D790-1)
11.5.3.1 Control unit, cab (D790-1)

Cab control unit (D790-1), description
page
–
The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3
000041
2 Control unit, cab has four indicator lights that indicate the control unit’s
1. Connection terminals for fan, work lights, wind- function (see illustration).
screen wiper
2. Connection terminals, other Lamp 1 Green light on when there is battery voltage to the unit.
3. Light 1, battery voltage The light is physically controlled by voltage feed to the
4. Light 2, redundant voltage feed, redundant CAN control unit.
bus and power supply Lamp 2 Flashes green when redundant voltage feed to control
5. Light 3, communication units and redundant CAN bus communication are ac-
6. Light 4, fault indication tive. No power in system.
Green light when power electronics and 15-voltage are
supplied voltage.
Lamp 3 Long single flash yellow during communication with

Control unit, display (D795). This is a basic condition of
fault tracing.
Short single flash yellow during communication with
Control unit, engine (D794) and Control unit, transmis-
sion (D793).
Double flash yellow (short and long flash) during com-
munication with the display and engine or
transmission.
Lamp 4 Red light in the event of active error.
Control unit cab, replacement

page
–

2 Remove the cover from the electronic box.
3 Detach the connectors from Control unit, cab (D790-1).
4 Replace the control unit.
5 Check that the new control unit corresponds with the machine’s
forklift number (Z-number).
6 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN.

11 Common electrics – 11.5.3.2 Frame control unit (D797-1) 19
11.5.3.2 Frame control unit (D797-1)

Frame control unit (D797-1), description
page
–
The frame control unit (D797-1) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Lamp 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
Lamp 2 Flashes green when one or more of the following is

missing: redundant voltage feed left, redundant volt-
000043
age feed right or 15-voltage.
6 5 Green light when redundant voltage feed left, redun-
1. Light 1, battery voltage dant voltage feed right and 15-voltage are supplied
2. Light 2, redundant voltage feed and power supply voltage.
3. Light 3, communication
Lamp 3 Single yellow flash during communication with the KID
4. Light 4, fault indication
control unit (D795) or cab control unit (D790-1).
5. Control signals (input and output signals)
6. Power feed (redundant voltage feed control units, Double yellow flash during communication with the KID
redundant CAN bus) and input data control unit (D795) and the cab control unit (D790-1).
Frame control unit (D797-1), replacement

page
–

2 Detach the cables from the frame control unit (D797-1).
group 8.5.2.1 Calibrate SCALE.

20 11 Common electrics – 11.5.3.3 Frame control unit (D797-2)
11.5.3.3 Frame control unit (D797-2)

Frame control unit (D797-2), description
page
–
The frame control unit (D797-2) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
2
function (see illustration).
3
Lamp 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.

age feed right or 15-voltage.
000043
6 5 Green light when redundant voltage feed left, redun-

1. Light 1, battery voltage dant voltage feed right and 15-voltage are supplied
2. Light 2, redundant voltage feed and power supply voltage.
3. Light 3, communication
6. Power feed (redundant voltage feed control units, Double yellow flash during communication with the KID
redundant CAN bus) and input data control unit (D795) and the cab control unit (D790-1).
Frame control unit (D797-2), replacement

page
–

2 Detach the cables from the frame control unit (KDU D797-2).
group 8.5.2.2 Calibrate STEERING.

11 Common electrics – 11.5.3.5 Attachment control unit (D791) 21
11.5.3.5 Attachment control unit (D791)

Attachment control unit (D791), description
page
–
The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves of the side lift
attachment.
2
3 function (see illustration).
4 Lamp 1 Green light on when there is battery voltage to the unit.

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

000043
6 5 age feed right or 15-voltage.
1. Light 1, battery voltage Green light when redundant voltage feed left, redun-
2. Light 2, redundant voltage feed and power supply dant voltage feed right and 15-voltage are supplied
3. Light 3, communication voltage.
6. Power feed (redundant voltage feed control units,
redundant CAN bus) and input data Double yellow flash during communication with the KID
control unit (D795) and the cab control unit (D790-1).
Control unit, attachment, replacement

page
–

2 Disconnect the cable harness from the control unit.
5 Check the initiation values for attachment functions; see section
8 Control system, group 8.5.1.2 ATTACHMENT.
6 The control unit is not calibrated.

22 11 Common electrics – 11.5.3.9 Control unit, transmission (D793)
11.5.3.9 Control unit, transmission (D793)

Transmission control unit (D793), description
page
–
The transmission control unit (D793) is part of drivetrain control and

1 2 3
handles gearbox function, selection of gear at load and engine
speed, etc.
The transmission control unit (D793) is connected via separate CAN
D
M bus communication to the engine, which is connected to the cab con-
E
F S trol unit (D790-1). The cab control unit (D790-1) sends drivetrain infor-
mation on to other units.
The control unit has two function keys and three status lights
(see figure).
000045
Function button M Select display group.
1. Display Function button S Select display group mode.
2. Status lights
3. Function keys Status light D Yellow light indicates test mode.
Status light E Yellow light indicates fault in unit.
Status light F Red light during reset.
Control units can show information in the display in three display

groups with various status information. The M and S function keys are
used to navigate in the display and select display group and status
information.
The following status information can be shown in the display:
Display group I
• GPOS - shows transmission’s direction of rotation
• VSPD - shows speed in km/h
• dist - shows distance driven in km or miles
Display group II
• CPOS - shows gear position
• Tspd - shows measured turbine speed in km/h or mph
• Espd - shows measured engine speed in rpm
• Ospd - shows measured speed out from the transmission in rpm
• Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
• TQ I - shows measured torque (Nm) of transmission in
• Ttmp - shows measured temperature in the oil sump (Celsius or
Fahrenheit)
• Ctmp - shows measured temperature in the converter (Celsius or
Fahrenheit)
Display group III
• Err - shows error codes (current and history)

11 Common electrics – 11.5.3.10 Control unit, engine (D794) 23
Control unit, transmission, replacement

page
–

2 Disconnect the cable harness from Control unit, transmission
(D793).
1
group 8.5.2.3 Calibrate DRIVETRAIN and section 2 Transmis-
sion, group 2.8 Control system, transmission.
007959
11.5.3.10 Control unit, engine (D794)

Engine control unit (D794), description
page
–

The engine control unit (D794) is part of drivetrain control and handles
1 2 3
engine function, fuel injection, etc.
The engine control unit EDC (D794) is connected via separate CAN
bus communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
The control unit is mounted on the engine and has no function buttons
or display. Everything is handled via the CAN bus and an external con-
trol system. The diagnostic socket for direct communication with the
engine via Volvo’s diagnostic tool VODIA is found in the frame electri-
007423
cal distribution box; see Communication between PC and machine,

1. Connector OEM description page 44.
2. Connector, Actuator The control unit monitors the following values in order to optimise en-
3. Connector, Sensor gine performance.
• engine speed
• camshaft position
• boost pressure
• charge air temperature
• coolant temperature
• oil 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 cor-
rect fuel volume and to check the condition of the engine.

24 11 Common electrics – 11.5.3.10 Control unit, engine (D794)
Engine control unit (D794), description

page
–
(Cummins QSB6.7 engine)

The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
1 The engine control unit EDC (D794) is connected via separate CAN
bus communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
2 information on to other units.
The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
3
trol system.
The control unit monitors the following values in order to optimise en-
gine performance.
4
• engine speed
• camshaft position
010053
• boost pressure
1. Connector from Cummins wiring • charge air temperature
2. Connector XD794-3 • coolant temperature
3. Connector from Cummins wiring
4. Connector XD794-3 • oil 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 cor-
rect fuel volume and to check the condition of the engine.
Control unit, engine, replacement

page
–
See supplier documentation engine.
CAUTION
Each control unit is individually calibrated to the en-
gine in question. Switching of control units between
engines is absolutely forbidden.

11 Common electrics – 11.5.3.11 Control unit KIT (D790-2) 25
11.5.3.11 Control unit KIT (D790-2)

KIT control unit (D790-2), description
page
–
The KIT control unit (D790-2) handles functions for the gear and multi-
1 2
function lever, the direction indicator switch and start key positions II
and III. It also handles the key panel (2) for the control system and its
panel for warning and indicator lights (1).
Control unit KIT (D790-2) has several individual function keys and in-
dicator lights (see illustration).
See the operator’s manual for detailed information on warning and in-
dicator lights and function keys.
000049
1. Panel, warning and indicator lights

2. Panel, keys
KIT control unit (D790-2), replacement

page
–

panel.
3 Detach the KIT control unit (D790-2) from the steering wheel
panel.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 The KIT control unit (D790-2) is not calibrated.

26 11 Common electrics – 11.5.3.12 Control unit, KID (D795)
11.5.3.12 Control unit, KID (D795)

KID control unit (D795), description
page
–
Control unit KID (D795) displays to the operator information sent by

1 2 the control system, such as speed, in the form of messages, status,
error indications, etc.
There is an indicator light to the right of the display that is activated
with a red light when there is a serious malfunction in the control sys-
tem. Error code and information are shown in display.
See the operator’s manual for detailed information about the display.
000051
1. LCD-display
2. Series of diodes that serve as an indicator light for
serious malfunction.
KID control unit (D795), replacement

page
–

panel.
3 Detach the connector from the KID control unit (D795).
4 Detach the KID control unit (D795) from the steering wheel panel.
6 The KID control unit (D795) is not calibrated.
11.5.5 Cable harness

Connectors, overview
page
–
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
Contact Location Function

X001 Control unit, cab (D790-1) Power supply and ground connection Control unit, cab (D790-1)
X002 Control unit, cab (D790-1) Front windscreen wiper

Heater fan
Actuator motor, recirculation
Rear window wiper
Motor, rotating beacon
Back-up lights

11 Common electrics – 11.5.5 Cable harness 27

X004 Control unit, cab (D790-1) Water valve
Air distributor
Interior temperature sensor
Ambient temperature sensor
Temperature sensor, outlet fan
Sensor, temperature refrigerant
Air conditioning sensor
Front windscreen wiper motor
X005 Control unit, cab (D790-1) Switch, left panel

Switch, option
Window washer, roof rear
Switch flashing hazard lights (Hazard)
Setting fan speed
Setting temperature
Air distribution
Fan and recirculation controls
Accelerator
Alignment bypass
X006 Control unit, cab (D790-1) Instrument illumination

Switch, working lights
Switch, rotating beacon
Switch, headlights
Switch, option
Seat heater
Accelerator
Declutch pedal
X007 Control unit, cab (D790-1) Control lever

Twistlock
Spreading (positioning)

28 11 Common electrics – 11.5.5 Cable harness

X008 Control unit, cab (D790-1) Switch, levelling
Switch, spreading
Switch, bypass
Emergency stop switch
Switch parking brake
Switch, reversible operator’s seat/cab tilt
Sensor twistlocks
Switch 30-35 stop
Switch, aut. 20-40
Switch, option
Instrument illumination
Switch, electric servo panel
X009 Control unit, cab (D790-1) Background illumination, switches

Joystick control or mini-wheel
Switch, horn
X009-2 Control unit, cab (D790-1) Control lever
X010 Control unit, cab (D790-1) Sensor, alignment

Water valve
Horn
Relay, seat heating
Relay, working lights
Hour counter
Relay, compressor
Control current relay K315-1, K3009-1, K3009-2, K315-2, K3002 and
K3007
Front windscreen washing
Windscreen wiper, roof
X011 Control unit, cab (D790-1) Ignition

Break contacts (opening switches), cab doors
Switch, entry lighting
Interior lighting
Redundant feed, cab control unit (D790-1)
Horn
Break contact (opening switch), seat
Feedback relay K3009-1
X012 Control unit, cab (D790-1) Windscreen wiper, rear

Windscreen wiper, roof


X013 Control unit, cab (D790-1) CAN bus
RS232
X015 Control unit KIT (D790-2) CAN bus

Power supply and ground connection Control unit KIT (D790-2)
X016 Control unit KIT (D790-2) Ignition
X017 Control unit KIT (D790-2) Switch, horn

Control, windscreen wipers
Control, gear
Control, high and low beams
X018 Control unit KIT (D790-2) Sensor steering wheel movement

Buzzer
Switch, direction indicators
Switch, interior lighting
X020 Control unit, KID (D795) CAN bus

RS232
Power supply and ground connection Control unit KID (D795)
X033 Air conditioning Control, fan

Control, temperature
Control, air distribution
Fan and recirculation controls
Instrument illumination
X034 Air conditioning Heater fan

Water valve
X035 Air conditioning Valve, air distribution

Interior temperature sensor
Temperature sensor, outlet fan
X036 Air conditioning Actuator motor, recirculation

Sensor, temperature refrigerant
X038 Instrument panel, cab Accelerator

Declutch pedal


X039 Electronic box, cab Relay, compressor air-suspension seat
Break contact (opening switch), cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
Air conditioning sensor
Ambient temperature sensor
X040 Electronic box, cab Alignment bypass

Window washer, roof/rear
Accelerator
X048 Electronic box, cab Termination resistor
X049 Electronic box, cab Termination resistor
X050 Electronic box, cab RS232 Control unit, cab (D790-1)
X051 Electronic box, cab Feedback relay K3009-1

Power supply, Control unit, cab (D790-1)
CAN bus
X052 Electronic box, cab CAN bus

Control relays K315-1, K3009-1, K3009-2 and K315-2
X054 Electronic box, cab Interior lighting

Back-up lights
Revolving beacon
X055 Electronic box, cab Windscreen wiper, roof

Power, CD player
Power, COM radio
X056 Electronic box, cab Revolving beacon

Working lights, cab
X057 Electronic box, cab Windscreen wiper, rear
X058 Electronic box, cab Motor, windscreen washing

Engine heater start inhibitor, bridged

Interior lighting


X060A Extension X060 CAN bus
Interior lighting
X061 Electronic box, cab Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
X061A Extension X061 Ground connection, Control unit, KID (D795)

Ground connection, Control unit KIT (D790-2)
X062 Electronic box, cab Horn

Compressed air horn
Map lighting
Cigarette lighter 12V
Windscreen wiper, front
Heater fan motor
Motor, recirculation
X063 Electronic box, cab Sensor, operator-in-seat

Seat heater
Compressed-air damped seat
X065 Electronic box, cab Ambient temperature sensor
X066 Electronic box, cab Accelerator

Interior lighting
X067 Electronic box, cab Customisation
X069 Electronic box, cab Sensor, twistlock open/closed

Twistlock relay
Spreading relay
X070 Electronic box, cab Sensor twistlocks

Spreading relay
RMI
X072 To Right Behind Seat Current outlet
X080 Instrument panel, cab Switch, mast/attachment work lights

Switch, high beam
Switch, rotating beacon
Switch, seat heater
Switch, seat heater


X081 Instrument panel, cab Switch, seat heater
Extra sensors
Hour counter
X082 Instrument panel, cab NC switch, cab doors
X090 Electric servo panel, cab Electric servo

Electric servo, lift/lower
Electric servo, tilt
Electric servo, side shift
Electric servo, spreading
Electric servo, auxiliary
X091 Electric servo panel, cab Horn

Switch, spreading
Switch, twistlock
Switch, levelling
X092 Electric servo panel, cab Switch, twistlock

Reversible operator's seat
X168 Electronic box frame Power supply attachment control unit
X201 Electronic box frame Ground connection and power supply, Control unit, transmission
(D793)
X203 Electronic box frame Termination resistor
X204 Front edge of frame Mast work lights
X205 Electronic box frame CAN bus

Control unit, transmission (D793)
X207 Front edge of frame Sensor, alignment

Sensor twistlocks
X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, attachment control unit (D791)
X210 Between engine and gearbox Power supply and ground connection Control unit, engine (D794)
CAN bus, Control unit, engine (D794)
X211 Frame control unit (D797-1) 42-pin connector to frame control unit (D797-1)


X212 Frame control unit (D797-1) Power supply and ground connection, frame control unit (D797-1)
Temperature hydraulic oil
Emergency stop switch voltage
Sensor fuel level
D+ alternator
X214 Front edge of frame CAN bus, frame control unit (D797-2)
CAN bus, attachment control unit (D791)
X215 Electronic box frame Power supply attachment control unit
X221 Frame control unit (D797-2) 42-pin connector to frame control unit (D797-2)
X222 Frame control unit (D797-2) Power supply and ground connection, frame control unit (D797-2)
X230 Beneath driver’s seat Sensor, operator-in-seat
X235 Front edge of frame Lift/lower valve

Tilt valve
Mast valves
X240 Front edge of frame Voltage feed
X241 Front edge of frame Option
X242 Front edge of frame Option
X243 Front edge of frame Low beam rear

High beam rear
Tail light front
Switch, reversible operator’s seat
Control valve, reversible operator’s seat
Directional control valve, steering forward/rearward
X244 Front edge of frame Side shift valve

Spreading valve
Control valve load handling
Control valve mini-wheel/joystick control
X245 Under cab Switch, reversible operator’s seat

Position sensor, reversible operator’s seat
X247 Front edge of frame Brake light forward
X248 Front edge of frame Mast position sensor

Position sensor, automatic cab tilt


X251 Control unit, transmission (D793), 30-pin connector for Control unit, transmission (D793)
electronic box frame
X252 Control unit, transmission (D793), 18-pin connector for Control unit, transmission (D793)
electronic box frame
X253 Gearbox Solenoid valves, transmission

Pressure sensor, transmission
X259 Gearbox Temperature sensor, transmission oil to cooler
X261 Electronic box frame RS232 Control unit, transmission (D793)
X264 Electronic box frame Solenoid valve brake transmission
X270 Lamp bracket left front High and low beams

Direction indicators
Side marker lights
X271 Lamp bracket right front High and low beams

Side marker lights
X272 Lamp bracket left rear Tail lights

Brake light
Side marker lights
X273 Lamp bracket right rear Tail lights

Brake light
Side marker lights
X275 Rear edge of frame Tail lights

Brake light
Side marker lights
Back-up alarm
X276 Under cab Entry lighting

X278 Between engine and gearbox Compressor air conditioning

Relay, start key
X279 Control unit, engine (D794) Power supply and ground connection Control unit, engine (D794)
CAN bus Drive-train
X280 Engine Coolant level
X301 Mast Mast position sensor
X302 Mast Position sensor, automatic cab tilt


X400 Attachment control unit (D791) Power supply and ground connection, attachment control unit (D791)
X401 Attachment control unit (D791) CAN bus, attachment control unit
X403 Carriage middle Sensor, alignment right side

Sensor, twistlocks right side
Work lighting, right side
X404 Carriage middle Sensor, alignment left side

Sensor, twistlocks left side
Work lighting, left side
X415 Attachment, right side Indicator light locked twistlocks

Indicator light, unlocked twistlocks
Indicator light alignment
X421 Attachment control unit (D791) 42-pin connector for Control unit attachment (D791)
X422 Attachment control unit (D791) Power supply and earth connection, Control unit attachment (D791)
CAN bus Control unit attachment option (D791)
X425 Carriage middle Sensor, stop at 30’ left

Sensor, end position 20-40’ left
X426 Carriage middle Sensor, stop at 30’ right

Sensor, end position 20-40’ right
X428 Cab Revolving beacon
X612 Air conditioning Actuator motor, recirculation
X645 Engine Compressor air conditioning
X651 Cab Motor, windscreen washing
X657 Cab Heater fan
X660 Engine Alternator
X690 Cab Accelerator
X759 Engine Coolant level
X774 Cab Ambient temperature
X775 Cab Temperature sensor, cab, fan, refrigerant
X815 Cab Power assisted system
X825 Cab Mini-wheel
X900 Cab CD player
X901 Voltage converter, cab Voltage converter 24 V/12 V

Socket 24 V

Signal types, general

page
–
The machine’s control units use a number of different types of signals

to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type Explanation Application area
Analogue input signals
Rheostat Resistance input 0–200 . Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is equiva- E.g. hydraulic oil temper-
lent to temperature and the work range of approx. -40 to 150 C. ature sensor and air con-
There are two different resistance curves, one for Control unit, cab ditioning temperature
(D790-1) and one for the frame and attachment control units. sensor.
Accuracy is 0.5 C in the interval 0 –100 C (sensor’s measurement in-

accuracy not included). Outside of the interval 0 –100 C, accuracy is
2 C.
Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the spool in a solenoid valve gets hot, resistance drops. This gen- tional solenoid valves.
erates a lower current through the valve spool, which can cause the
valve’s servo pressure to remain constant. An internal ammeter measures
current in the circuit and regulates the voltage level in order to maintain
the desired current value in the valve spool.
Voltage out, PNP A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. interior lighting and
PWM a grounding point as reference. background illumination
in switches.
Voltage out, re- A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
versed polarity, 24 V as reference.
NPN PWM
Digital input signals
Digital input signal Signal in, U < 5 V generates logical zero (0) E.g. input signal from a
with pull down and Signal in, U > 16 V generates logical one (1) circuit breaker with
search lighting search lighting.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logical zero (0) E.g. position sensors
with pull down Signal in, U > 12 V generates logical one (1) (inductive sensors) and
brake pressure (pressure
If there is no signal in, the input is grounded. switches).
Bandwidth 300 Hz, i.e. designed for slow sensors.

Signal type Explanation Application area
Digital outputs
High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. side marker lights,
1.5 A Max. load 1.5 A solenoid valves.
Open load 0.15 A

Max. instantaneous current load, 8 A
High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. working lights and
5A Max. load 5 A wiper motors.
Open load 0.9 A

High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A Max. load 10 A This output is only found
Open load 1.9 A on the frame and attach-
ment control units.
H-bridge Logical one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. air conditioning wa-
U=0V ter valve (works in both
Max. load 0.5 A directions).
Open load 0.15 A

The H-bridge works with two outputs in a pair. At logic one (1), one output
gives voltage while the other output is grounded. At logic zero (0), the out-
puts switch voltage levels.

38 11 Common electrics – 11.6 Communication
11.6 Communication
11.6.1 CAN bus
CAN bus, description
page
–
Communication between the control units takes place using so-called

1 2
"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 sim-
120 ohm 120 ohm
ple 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:
5 5
• that the signal traffic is carried by "twisted pair" cables.
3
4 • that termination resistors (position 1) are necessary (adapted to
2 cables’ impedance) so that the pulse train (position 4) should ob-
U [V]
tain a sharp signal.

• that the signal valve is given as the potential difference between
3 the cables, CAN + and CAN - (position 2 and 3).
000026
t [S]
• form of signal messages.
Messages run in time and signal goes high
(voltage high) or low (voltage low).
1. Terminating resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
B C D E F G CAN works in messages sent in frames of 8 bytes (64 bits). A com-

000027
plete message is approx. 100 bits long. The illustration shows how a
t [S]
message is structured.
Messages run in time and signal goes high
(voltage high) or low (voltage low). Start bit (B)
A. Length message Indicates that the transmission of a frame, i.e. a message, is now
B. Start bit beginning.
C. Identity field/Priority Identity field (C)
D. Control field (length of data segment)
Indicates what kind of information the message contains, e.g. meas-
E. Data segment
urement information on engine speed.
F. Checksum for error detection
G. Acknowledge bit Does not indicate address to control unit. CAN does not work with ad-
dressing. All control units receive messages and send them on.

11 Common electrics – 11.6.1 CAN bus 39
Control field (D)

Indicates how the length of the data segment that follows.
Data segment (E)
Contains the information to be conveyed to control units in the
network.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logic one (1) when the mes-
sage is sent. The first control unit to receive the message sends it on
and sets the bit to logic zero (0).
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]
has 1.5 V. As a worst case scenario, the potential difference can be

0,5 V 0.5 V and still be approved. In practice, a potential difference of 2 V is
recommended for reliable communication.
Pulse trains can only be observed using an oscilloscope, NOT with a
1,5 V digital multimeter.
When a message is sent, all control units in the network listen. Mes-
sages are saved in the control unit and relevant information is proc-
essed. The control unit that receives the message first confirms
000028
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one
Potential levels CAN + and CAN -
control unit.
One control unit at a time sends the message. Other control units lis-
ten and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest prior-
ity (highest value in identity field) is concluded. This means that mes-
sages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the
network.
Different bus systems can be used e.g. random sending or primary
(master) / secondary (slave).

40 11 Common electrics – 11.6.2 Redundant CAN bus
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN pro-
tocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages
(division)
• how control units are addressed in the network
• how bits in the message’s data field should be interpreted
11.6.2 Redundant CAN bus

Redundant CAN bus, description
page
–
The redundant CAN bus handles communication between all of the

D791 D790-1 D790-2 D795 machine’s control units except the transmission control unit (D793)
CAN R CAN L CAN R CAN L CAN R CAN L
and the engine control unit (D794). These have a separate CAN bus;
see CAN bus drive-train, description page 43.
CAN L CAN R CAN L CAN R
009750
D797-2 D797-1
Outline view, redundant CAN bus

Redundant CAN bus means that the control units are connected to a
D790-1 D791 D797-1 network that communicates via a CAN bus (see CAN bus, description
CAN L CAN R CAN L CAN R CAN L CAN R
page 38) and that there are double communication routes on the net-
4 1 2 work. The network is divided into control units and segments (seg-
3 ments are cables between the control units). The number of active
CAN R CAN L
segments depends on the number of control units the machine has,
009752
D795 which depends on the machine’s equipment level (options).
Segment numbering starts from the CAN-R (right)

connection
The network is built on the CAN kingdom principle, which means that
D790-1 D791 D797-2 D797-1 one control unit is central and is the master unit. In this case, it is the
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R
cab control unit (D790-1). Other control units in the network are sec-
5 1 2 3 ondary (slaves) and handle special areas, e.g. machine components.
4 The control units have two CAN bus connections - CAN L (left) and
CAN R CAN L
CAN R (right). The control units are connected to one another in series
009751
D795
in a loop.
Segment numbering with optional equipment without The redundant CAN bus can handle the loss of a segment. The link is
cab tilt analysed upon start-up. If a segment is faulty, messages are sent via
another route.
If several segments are lost, one or more control units lose communi-
cation and work independently, often with significantly limited
functionality.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only
shows an error code for the first faulty out segment.

11 Common electrics – 11.6.2 Redundant CAN bus 41
Connection of redundant CAN bus
Condition Reference Reference

value
Battery disconnector In position 1 Battery disconnector, description page 3
Redundant voltage feed Activated. Redundant voltage feed of control units, function description page 7
S1
S4
2
D791
7
014795
1 Control unit, cab (D790-1) establishes Checked by control sys- Cab control unit (D790-1), description
redundant CAN bus communication by tem, error shown with er- page 18
sending a request on the CAN bus via ror code. Diagnostic menu, see section 8 Control sys-
CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
and 8.4.1.2 CAN/POWER, menu 2
2 The attachment control unit (D791) A clicking sound is audi- Attachment control unit (D791), description
sends a response back on the CAN bus ble when then termina- page 21
via CAN L and sends the request on via tion resistor is activated. Diagnostic menu, see section 8 Control sys-
CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
3 The frame control unit (D797-2) sends a A clicking sound is audi- Frame control unit (D797-2), description
response back on the CAN bus via CAN ble when then termina- page 20
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.

42 11 Common electrics – 11.6.2 Redundant CAN bus

4 The frame control unit (D797-1) sends a A clicking sound is audi- Frame control unit (D797-1), description
response back on the CAN bus via CAN ble when then termina- page 19
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.
5 Control unit KID (D795) sends a re- A clicking sound is audi- KID control unit (D795), description page 26
sponse back on the CAN bus via CAN L ble when then termina- Diagnostic menu, see section 8 Control sys-
and sends the request on via CAN R. tion resistor is activated. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
6 The KIT control unit (D790-2) is not con- A clicking sound is audi- KIT control unit (D790-2), description
nected to the redundant CAN bus. The ble when then termina- page 25
KIT control unit (D790-2) does not com- tion resistor is activated.
municate until ignition voltage (15) is
activated.
7 If all control units have responded, the Checked by control sys- Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) deactivates tem, error shown with er- tem, group 8.4.1.1 CAN/POWER, menu 1
the segment to the attachment control ror code. and 8.4.1.2 CAN/POWER, menu 2
unit (D791).
If a control unit has not responded, then
Control unit, cab (D790-1) uses both
CAN L and CAN R to keep communica-
tion open and analyses which segment
is faulty.

11 Common electrics – 11.6.3 CAN bus drive-train 43
11.6.3 CAN bus drive-train

CAN bus drive-train, description
page
–
The drive-train CAN bus is based on the SAE J1939 standard where
4 6
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)
for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
The engine and transmission control units come from the respective
engine and transmission suppliers.
The machine uses only one model of gearbox, but there are several
engine alternatives. All engine alternatives use the standard, therefore
the messages are based on the same structure regardless of which
engine is used.
Communication with Control unit, engine (D794) and Control unit,
transmission (D793) are separate from the redundant CAN bus.
section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Engine control unit (D794)
4. Engine
6. Transmission

44 11 Common electrics – 11.6.4 Communication between PC and machine
11.6.4 Communication between PC and

machine
Communication between PC and machine,
page
–
description
The machine has three or four sockets for communication between
control units and PC. Two are located in electronic box cab and one or
1
two in electronic box cab frame. It is the socket for communication with
engine alternative Volvo that varies.
2 Sockets for programming control units in electrical distribution box cab
(position 1) are used for programming the control units in the cab, on
the frame, and on the attachment.
Socket for drivetrain CAN bus in the electrical distribution box cab (po-
sition 2) is used for communicating with the engine and transmission
via CAN bus.
The VODIA socket in the frame electronic box (position 3) is used to
connect the Volvo’s diagnostic tool - VODIA.
The socket for transmission control unit (D793) programming in the
frame electrical distribution box (position 4) is used to program the
transmission control unit (D793).
For further details on communication between computer and machine,
3 contact Kalmar Industries AB.
4
010054
1. Diagnostic socket machine

2. Engine diagnostic socket (Cummins engine),
drivetrain CAN bus
3. Engine diagnostic socket, VODIA (Volvo engine)
4. Diagnostic socket transmission

11 Common electrics – 11.6.5 RMI (Remote Machine Interface) 45
11.6.5 RMI (Remote Machine Interface)

RMI (Remote Machine Interface), description
page
–
Remote Machine Interface is a tool for listening to the machine at a

distance. The interface consists of a control unit which is connected to
007443
the machine, antenna for communication and GPS-antenna ( ) for
positioning.
RMI-interface
The interface records the communication on the CAN-bus and sends
the information to a central RMI-server. The control unit in the machine
can sends the information via GSM, GPRS, WLAN, Radio-modem,
SMS, or e-mail in case of a malfunction.
From the RMI-server, data from the machine can be analysed and
processed to read out different values. For example, when it is time for
service or if there are error codes stored in the machine.
As an option, there is a GPS-antenna, making it possible to read

off the machine’s position.
NOTE
RMI only sends data from the machine, no data can be sent to
the machine. RMI cannot be used to control the machine.

46 11 Common electrics – 11.6.5 RMI (Remote Machine Interface)

D Error codes 1
D Error codes
Table of Contents D Error codes

mm mm mm mm mm mm
Error codes ..................................................................................................... 3

Error codes, explanation ........................................................................................ 3
Error code menu, description ................................................................................. 4
Reading out error code ........................................................................................... 7
1 Engine ............................................................................................................. 9
Error codes engine, general ................................................................................... 9
Error codes engine (engine alternative Cummins QSB6.7) ................................. 10
Error codes engine (engine alternative Volvo TAD760VE) .................................. 36
2 Transmission................................................................................................ 53
Error codes transmission ...................................................................................... 53
8 Control system ............................................................................................. 63
Error codes machine ............................................................................................ 63

2 D Error codes

D Error codes – Error codes 3
Error codes
mm mm mm mm mm mm
Error codes, explanation

page
–
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:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's
D E generated.
• Limitation, in case of certain error codes certain functions are im-
B
000389
paired or limited to protect the machine and operator.

• Action, information of what should be checked to find the cause of
B. Error code level (symbol)
the error code.
C. Error code number
D. Cause of error (symbol) • Diagnostic menu, reference to suitable diagnostic menu to rectify
E. Function (symbol) the problem, read signal value or check the function.
In addition to the explanation of the display figure, the description
of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
group for further information about functions and components.
• Function group is a reference to which function group the error
code is associated. This field is used to search for more informa-
tion as necessary. Different types of information can be localised
with the function group.
Sections 0-12 contain a description of the function and its compo-
nents, component location and work instructions for different
tasks.

4 D Error codes – Error codes
Error code menu, description

page
–
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
D E • Field B: Error code level is shown with a symbol.

• Field C: Shows error code.
B
000389
• Field D: Shows type of error.
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator’s
manual.
Field B: Error code level

The control and monitoring system gives error code information in
three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351
• Information
C Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
D E See section 6 Inspection and maintenance in the Operator’s
manual.
000352
The error code is stored in the error code list under operating
menu for service.

Field C: Error code number

The control and monitoring system gives error codes from three
sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
8. Level too high/low
7 8 9
9. Incorrect signal to bulb.
11. Incorrect signal to engine.
10 11
002058

Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift, attachment
4. Length adjustment attachment
4 5 6
5. Levelling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks
10 11 12 11. Rotation forks

12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15
15. Steering
16. Engine
17. Transmission
16 17 18
18. Central lubrication
19. Control unit
20. Hardware-related error
19 20 21 21. Cab
22. Air conditioning
23. Fuel system
22 23 24 24. Headlights
25. Windscreen wipers
26. Battery voltage
25 26 27 27. Bulb for lighting
010153

Reading out error code

page
–
NOTE
In the event of an error code, perform the actions recommended
in the error code table to identify the fault.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading error codes, otherwise
there is a risk of missing error codes.
1 Turn the start key to position I.
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.
2 Navigate to the service menu and press Enter.

000056
3 Safety menu is shown. Hold Enter depressed for at least two

seconds.
1 23
4 5
000060
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number togeth-
er with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.

5 Note error code number (field C) to avoid forgetting.

C
• Error code level is shown with a symbol in field B
D E • Error code is shown in field C
B • Error cause is shown with a symbol in field D
000389
• The function affected by the error is shown with a symbol in
field E
The book symbol is an instruction for the operator to read the
operator’s manual.
6 Use the error code tables to find more information about the error
code.
7 After the remedial action, check that no active error codes remain
for the function in question.

D Error codes – 1 Engine 9
1 Engine
mm mm mm mm mm mm
Error codes engine, general

page
–
When contacting engine suppliers, use Volvo/Cummins codes.

• Display indicates error code according to SAE J1939
SPN / FMI
• Flash indicates error code according to a flash code specified by
the engine supplier.
• J1587 indicates error code according to SAE J1587 (for Volvo:
Vodia).
PID, PPID, SID, PSID / FMI
Table 1. Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical problem. Abnormal frequency.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical problem. Abnormally wide variations.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Too high value. Data valid but above normal operating range - Least severe level
16 Too high value. Data valid but above normal operational range, moderately severe
level
17 Too low value. Data valid but below normal operational range, the least severe level
18 Too low value. Data valid but below normal operational range, moderately severe
level
19 Communication error. Received network data incorrect
20-30 Reserved for SAE-assignment
31 FMI is not available or the condition that is Not available or condition exists
identified by the SPN exists.

10 D Error codes – 1 Engine
Error codes engine (engine

–
alternative Cummins QSB6.7)

Description Limitation Action Connections Diagnostic
and menu
components
Code J1587
84 / 2 P084 / 2 Machine Speed Sensor Engine speed limited Check the ca- D794 ENGINE,
Circuit - Data Erratic, In- to Maximum Engine ble harness menu 2
termittent or Incorrect. Speed without VSS between con-
The ECU 794 lost the ma- parameter value. trol unit and
chine speed signal. Cruise control, Gear- component.
Down Protection, and Check the
Road Speed Gover- sensor.
nor will not work.
84 / 10 P084 / 10 Machine Speed Sensor Engine speed limited Check the ca- D794 ENGINE,
Circuit Tampering Has to Maximum Engine ble harness menu 2
Been Detected - Abnor- Speed without VSS between con-
mal Rate of Change. parameter value. trol unit and
Invalid or inappropriate Cruise control, Gear- component.
machine speed signal. Down Protection, and Check the
Signal indicates an inter- Road Speed Gover- sensor.
mittent connection or nor will not work.
VSS tampering.
91 / 0 P91 / 0 Accelerator Pedal or Le- Severe derate in - - ENGINE,
ver Position Sensor 1 - power output of the menu 1
Data Valid but Above engine. Limp home
Normal Operational power only.
Range - Most Severe
Level. A frequency of
more than 1500 Hz has
been detected at the fre-
quency throttle input to
the ECU 794.
91 / 1 P91 / 1 Accelerator Pedal or Le- Severe derate in - - ENGINE,
ver Position 1 Sensor Cir- power output of the menu 1
cuit Frequency - Data engine. Limp home
Valid but Below Normal power only.
Operational Range - Most
Severe Level. A frequen-
cy of less than 100 HZ
has been detected at the
frequency throttle input to
the ECU 794.


and menu
components
Code J1587
91 / 19 P91 SAE J1939 Multiplexing Engine may only idle Use diagnos- - -
Accelerator Pedal or Le- or engine will not ac- tic menu to
ver Sensor System Error - celerate to full speed. find incorrect
Received Network Data segment.
Error. The OEM machine
electronic control unit
(VECU) detected a fault
with its accelerator pedal.
91 / 2 P31 / 2 Position sensor accelera- - - ENGINE,
tor pedal menu 1
91 / 3 P091 / 3 Accelerator Pedal or Le- Severe derate in Check the ca- - ENGINE,
ver Position Sensor Cir- power output of the ble harness menu 1
cuit - Shorted High. High engine. Limp home between con-
voltage detected at accel- capability only. trol unit and
erator pedal or lever posi- component.
tion circuit. Check the
component.
91 / 4 P091 / 4 Accelerator Pedal or Le- Severe derate in Check the ca- - ENGINE,
ver Position Sensor Cir- power output of the ble harness menu 1
cuit - Voltage Below engine. Limp home between con-
Normal or Shorted to Low capability only. trol unit and
Source. Low voltage de- component.
tected at accelerator ped- Check the
al or lever position signal component.
circuit.
94 / 1 P94 / 1 Fuel pump delivery pres- Possibly hard to start; - D794 -
sure - data valid but below power; possible
low normal operational engine smoke. En-
range - moderately se- gine can possibly not
vere level. The ECU 794 start.
has detected the fuel
pressure in the fuel rail is
lower than the command-
ed performance.
94 / 2 P094 / 2 Injector Metering Rail 1 The ECU 794 will es- - D794 -
Pressure - Data Erratic, timate fuel pressure,
Intermittent, or Incorrect. and power is re-
The ECU 794 has detect- duced.
ed that the fuel pressure
signal is not changing.


and menu
components
Code J1587
94 / 18 P94 / 0 Fuel pump delivery pres- None or possible en- - D794 -
sure - data valid but gine noise associated
above normal operational with higher injection
range - moderately se- pressures (especial-
vere level. The ECU 794 ly at idle or light load).
has detected fuel pres- Engine power is
sure in the fuel rail that is reduced.
higher than the com-
manded pressure.
97 / 3 P097 / 3 Water-in-fuel indicator None on perform- Check the ca- D794 -
sensor circuit - Voltage ance. No water-in- ble harness
above normal or short fuel warning between con-
circuited to high source. available. trol unit and
High voltage detected at component.
the water-in-fuel circuit. Check the
sensor.
97 / 4 P097 / 4 Water-in-fuel indicator None on perform- Check the ca- D794 -
sensor circuit - Voltage ance. No water-in- ble harness
below normal or short fuel warning between con-
circuited to low source. available. trol unit and
Low voltage detected at component.
the water-in-fuel circuit. Check the
sensor.
97 / 15 P097 / 0 Water-in-fuel indicator - Possible white Drain water - -
Data valid but above nor- smoke, loss of power, from the fuel.
mal operational range - or hard starting.
least severe level. Water
has been detected in the
fuel filter.
100 / 1 P100 / 1 Engine Oil Rifle Pressure Progressive power Check the oil - ENGINE,
- Data Valid but Below derate increasing in level in the en- menu 6
Normal Operational severity from time af- gine; fill if
Range - Most Severe ter alert. If the Engine necessary.
Level. Oil pressure signal Protection Shutdown
indicates oil pressure is feature is enabled,
below the engine protec- engine will shut down
tion critical limit. 30 seconds after the
red STOP lamp starts
flashing.


and menu
components
Code J1587
100 / 2 P100 / 2 Oil Pressure Switch Sen- None on perform- Check the ca- D794 ENGINE,
sor Circuit - Data Erratic, ance. No engine pro- ble harness menu 6
Intermittent or Incorrect. tection for oil between con-
An error in the engine oil pressure. trol unit and
pressure switch signal component.
was detected by the Check the
ECU 794. sensor.
100 / 3 P100 / 3 Oil Pressure Sensor Cir- None on perform- Check the ca- D794 ENGINE,
cuit - Voltage Above Nor- ance. No engine pro- ble harness menu 6
mal, or Shorted to High tection for oil between con-
Source. High signal volt- pressure. trol unit and
age detected at the en- component.
gine oil pressure circuit. Check the
sensor.
100 / 4 P100 / 4 Oil Pressure Sensor Cir- None on perform- Check the ca- D794 ENGINE,
cuit - Voltage Below Nor- ance. No engine pro- ble harness menu 6
mal, or Shorted to Low tection for oil between con-
Source. Low signal volt- pressure. trol unit and
gine oil pressure circuit. Check the
sensor.
100 / 18 P100 / 1 Engine Oil Rifle Pressure None on Check the oil - ENGINE,
- Data Valid but Below performance. level in the en- menu 6
Normal Operational gine; fill if
Range - Moderately Se- necessary.
vere Level. Engine oil
pressure signal indicates
engine oil pressure is be-
low the engine protection
warning limit.
102 / 2 P102 /2 Intake Manifold Pressure Engine power derate. Check the ca- D794 ENGINE,
Sensor Circuit - Data Er- ble harness menu 6
ratic, Intermittent or Incor- between con-
rect. The ECU 794 has trol unit and
detected an intake mani- component.
fold pressure signal that Check the
is too high or low for cur- sensor.
rent engine operating
conditions.


and menu
components
Code J1587
102 / 2 P102 /2 Intake manifold pressure Derate in power out- Check the ca- D794 ENGINE,
sensor circuit - data incor- put of the engine. ble harness menu 6
rect. An error in the intake between con-
manifold pressure sensor trol unit and
signal was detected by component.
the ECU 794. Check the
sensor.
102 / 3 P102 / 3 Intake Manifold Pressure Derate in power out- Check the ca- D794 ENGINE,
Sensor Circuit - Voltage put of the engine. ble harness menu 6
Above Normal or Shorted between con-
to High Source. High sig- trol unit and
nal voltage detected at component.
the intake manifold pres- Check the
sure circuit. sensor.
102 / 4 P102 / 4 Intake Manifold Pressure Derate in power out- Check the ca- D794 ENGINE,
Sensor Circuit - Voltage put of the engine. ble harness menu 6
Below Normal or Shorted between con-
to Low Source. Low sig- trol unit and
the intake manifold pres- Check the
sure circuit. sensor.
103 / 10 P103 / 10 Turbocharger speed - Possible-low-power Check the ca- D794 -
invalid rate of change de- estimated turbo- ble harness
tected. The turbocharger charger speed will be between con-
speed sensor has detect- used. trol unit and
ed an erroneous speed component.
value. Check the
sensor.
103 / 16 P103 / 0 Turbocharger Number 1 Engine power derate. Check the D794 -
speed high - warning lev- The ECU 794 uses component
el. High turbocharger an estimated turbo-
speed has been detected. charger speed.
103 / 18 P103 / 1 Turbocharger number 1 Engine power derate. Check the D794 -
speed low - warning level. The ECU 794 uses component
Low turbocharger speed an estimated turbo-
detected by the ECU 794. charger speed.


and menu
components
Code J1587
105 / 0 P105 / 0 Intake Manifold 1 Tem- Progressive power Check the - ENGINE,
perature - Data Valid but derate increasing in coolant level menu 7
Above Normal Operation- severity from time af- in the engine;
al Range - Most Severe ter alert. If the Engine fill if
Level. Intake manifold air Protection Shutdown necessary.
temperature signal indi- feature is enabled, Check that the
cates intake manifold air engine will shut down charge air
temperature above en- 30 seconds after the cooler is
gine protection critical red STOP lamp starts clean, clean if
limit. flashing. necessary.
Check that fan
belts are in-
tact. Check
the sensor.
105 / 3 P105 / 3 Intake Manifold Air Tem- Possible white Check cable D794 ENGINE,
perature Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Above Normal or ON if controlled by tween control
Shorted to High Source. the ECU 794. No en- unit and
High signal voltage de- gine protection for in- component.
tected at intake manifold take manifold air Check the
air temperature circuit. temperature. sensor.
105 / 4 P105 / 4 Intake Manifold Air Tem- Possible white Check cable D794 ENGINE,
perature Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Below Normal or ON if controlled by tween control
Shorted to Low Source. the ECU 794. No en- unit and
Low signal voltage de- gine protection for in- component.
tected at intake manifold take manifold air Check the
air temperature circuit. temperature. sensor.
105 / 15 P105 / 0 Intake Manifold Tempera- Progressive power Check the D794 ENGINE,
ture High - Data Valid but derate increasing in coolant level menu 7
Above Normal Operation- severity from time of in the engine;
al Range - Least Severe alert. fill if
Level. Intake manifold air necessary.
temperature signal indi- Check that the
cates intake manifold air charge air
temperature above en- cooler is
gine protection warning clean, clean if
limit. necessary.
Check that fan
belts are in-
tact. Check
the sensor.


and menu
components
Code J1587
108 / 2 P108 / 2 Barometric pressure: Engine power derate. Check cable - -
Data erratic, intermittent, harness be-
or incorrect. The ambient tween control
air pressure sensor reads unit and
an erratic value upon component.
activation. Check the
sensor.
108 / 3 P108 / 3 Barometric Pressure Engine power derate. Check cable D794 -
Sensor Circuit - Voltage harness be-
Above Normal, or Short- tween control
ed to High Source. High unit and
signal voltage detected at component.
barometric pressure Check the
circuit. sensor.
108 / 4 P108 / 4 Barometric Pressure Engine power derate. Check cable D794 -
Sensor Circuit - Voltage harness be-
Below Normal, or Shorted tween control
to Low Source. Low sig- unit and
barometric pressure Check the
circuit. sensor.
110 / 0 P110 / 0 Engine Coolant Temper- Progressive power Check the - ENGINE,
ature - Data Valid but derate increasing in coolant level. menu 7
Above Normal Operation- severity from time af- Check that ra-
al Range - Most Severe ter alert. If the Engine diator is clean.
Level. Engine coolant Protection Shutdown
temperature signal indi- Check if there
feature is enabled,
cates engine coolant tem- is air in cool-
engine will shut down
perature above engine ant system.
30 seconds after the
protection critical limit. red STOP lamp starts Check the cap
flashing. on the expan-
sion tank.
Check the
sensor.
Check the
thermostat.
110 / 2 P110 / 2 Engine Coolant Temper- The ECU 794 will es- Check cable D794 ENGINE,
ature - Data Erratic, Inter- timate engine coolant harness be- menu 7
mittent, or Incorrect. The temperature. tween control
engine coolant tempera- unit and
ture reading is not component.
changed with engine op- Check the
erating conditions. sensor.


and menu
components
Code J1587
110 / 3 P110 / 3 Engine Coolant Temper- Possible white Check cable D794 ENGINE,
ature 1 Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Above Normal or ON if controlled by tween control
Shorted to High Source. ECU 794. No engine unit and
High signal voltage or protection for engine component.
open circuit detected at coolant temperature. Check the
engine coolant tempera- sensor.
ture circuit.
110 / 4 P110 / 4 Engine Coolant Temper- Possible white Check cable D794 ENGINE,
ature 1 Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Below Normal or ON if controlled by tween control
Shorted to Low Source. ECU 794. No engine unit and
Low signal voltage de- protection for engine component.
tected at engine coolant coolant temperature. Check the
temperature circuit. sensor.
110 / 15 P110 / 0 Engine Coolant Temper- Progressive power Check the D794 ENGINE,
ature High - Data Valid derate increasing in coolant level. menu 7
but Above Normal Opera- severity from time of Check that ra-
tional Range - Least Se- alert. diator is clean.
vere Level. Engine
coolant temperature sig- Check if there
nal indicates coolant tem- is air in cool-
ant system.
perature is above the
engine coolant tempera- Check the cap
ture engine protection on the expan-
warning limit. sion tank.
Check the
sensor.
Check the
thermostat.


and menu
components
Code J1587
110 / 16 P110 / 0 Engine Coolant Temper- Progressive power Check the D794 ENGINE,
ature - Data Valid but derate increasing in coolant level. menu 7
Above Normal Operation- severity from time of Check that ra-
al Range - Moderately alert. diator is clean.
Severe Level. Engine
Check if there
coolant temperature sig-
is air in cool-
nal indicates engine cool-
ant system.
ant temperature is above
engine protection warn- Check the cap
ing limit. on the expan-
sion tank.
Check the
sensor.
Check the
thermostat.
111 / 1 P111 / 1 Coolant Level - Data Val- Progressive power Check the - -
id but Below Normal Op- derate increasing in coolant level;
erational Range - Most severity from time af- fill if
Severe Level. Low engine ter alert. If the engine necessary.
coolant level detected. protection shutdown Check the
feature is enabled, sensor.
engine will shut down
30 seconds after the
red STOP lamp starts
flashing.
111 / 3 P111 / 3 Coolant Level Sensor Cir- None on Check cable D794 -
cuit - Voltage Above Nor- performance. harness be-
mal or Shorted to High tween control
Source. High signal volt- unit and
age detected at engine component.
coolant level circuit. Check the
sensor.
111 / 4 P111 / 4 Coolant Level Sensor Cir- None on Check cable D794 -
cuit - Voltage Below Nor- performance. harness be-
mal or Shorted to Low tween control
Source. Low signal volt- unit and
gine coolant level circuit. Check the
sensor.


and menu
components
Code J1587
157 / 0 P94 / 0 Injector Metering Rail None or possible en- - D794 -
Number 1 Pressure - gine noise associated
Data Valid But Above with higher injection
Normal Operating Range pressures (especial-
- Most Severe Level. The ly at idle or light load).
ECU 794 has detected Engine power is
that fuel pressure in the reduced.
rail fuel is higher than the
commanded pressure.
157 / 2 P157 / 2 Injector Metering Rail 1 The ECU 794 will es- - D794 -
Pressure - Data Erratic, timate fuel pressure,
Intermittent, or Incorrect. and power is
the ECU 794 has detect- reduced.
ed that the fuel pressure
signal is not changing.
157 / 3 P157 / 3 Injector Metering Rail Power and or speed - D794 -
Number 1 Pressure Sen- derate.
sor Circuit - Voltage
Above Normal or Shorted
to High Source. High sig-
nal voltage detected at
rail fuel pressure sensor
circuit.
157 / 4 P157 / 4 Injector Metering Rail Power and or speed - D794 -
Number 1 Pressure Sen- derate.
sor Circuit - Voltage Be-
low Normal or Shorted to
Low Source. Low signal
voltage detected at the
rail fuel pressure sensor
circuit.
157 / 16 P157 / 0 Injector Metering Rail 1 None or possible en- - D794 -
Pressure - Data Valid but gine noise associated
Above Normal Operation- with higher injection
al Range - Moderately pressures (especial-
Severe Level. The ly at idle or light load).
ECU 794 has detected Engine power is
that fuel pressure is high- reduced.
er than commanded
pressure.


and menu
components
Code J1587
157 / 18 P157 / 1 Fuel Pump Delivery Pres- Possibly hard to start, - D794 -
sure Low - Data Valid but low power, or engine
Below Normal Operation- smoke. Engine can
al Range - Moderately possibly not start.
Severe Level. The
ECU 794 has detected
that fuel pressure is lower
than commanded
pressure.
167 / 1 P167 / 1 Electrical Charging Sys- Warning lamp illumi- Check batter- D794 -
tem Voltage Low - Data nated until very low ies and
Valid but Below Normal battery voltage condi- alternator.
Operational Range - Most tion is corrected.
Severe Level. Very low
battery voltage detected
by the battery voltage
monitor feature.
167 / 16 P167 / 0 Electrical Charging Sys- Amber warning lamp Check fuses. D794 -
tem Voltage High - Data illuminated until high Check batter-
Valid but Above Normal battery voltage condi- ies and
Operational Range - tion is corrected. alternator.
Moderately Severe Level.
High battery voltage de-
tected by the battery volt-
age monitor feature.
167 / 18 P167 / 1 Electrical Charging Sys- Amber lamp will light Check batter- D794 -
tem Voltage Low - Data until low battery volt- ies and
Valid but Below Normal age condition is alternator.
Operational Range - corrected.
Moderately Severe Level.
Low battery voltage de-
tected by the battery volt-
age monitor feature.
168 / 16 P168 / 0 Battery 1 Voltage - Data Possible electrical Check fuses. D794 -
Valid but Above Normal damage to all electri- Check batter-
Operational Range - cal components. ies and
Moderately Severe Level. alternator.
ECU 794 supply voltage
is above the maximum
system voltage level.


and menu
components
Code J1587
168 / 18 S168 / 1 Battery 1 Voltage - Data Engine may stop run- Check fuses. D794 -
Valid but Below Normal ning or be difficult to Check batter-
Operational Range - start. ies and
Moderately Severe Level. alternator.
ECU 794 supply voltage
is below the minimum
system voltage level.
171 / 3 P171 / 3 Ambient temperature - D794 -
sensor, circuit fault- Ab-
normally high voltage or
short-circuit to higher
voltage.
171 / 4 P171 / 4 Ambient temperature - D794 -
sensor, circuit fault - Ab-
normally low voltage or
short-circuit to lower
voltage.
190 / 0 P190 / 0 Engine Crankshaft Fuel injection disa- Ease off the - -
Speed/Position - Data bled until engine throttle or se-
Valid but Above Normal speed fails below the lect higher
Operational Range - Most overspeed limit. gear.
Severe Level. Engine
speed signal indicates
engine speed above en-
gine protection limit.
190 / 2 P190 / 2 Engine Crankshaft Engine can exhibit Check cable D794 -
Speed/Position - Data Er- misfire as control harness be-
ratic, Intermittent, or In- switches from the pri- tween control
correct. Crankshaft mary to the backup unit and
engine speed sensor in- speed sensor. En- component.
termittent gine power is re- Check the
synchronisation. duced while the sensor.
engine operates on
the backup speed
sensor.
190 / 2 P190 / 2 Engine Crankshaft Engine can run Check cable D794 -
Speed/Position - Data Er- rough. Possibly poor harness be-
ratic, Intermittent, or In- starting capability. tween control
correct. Loss of signal Engine runs using unit and
from crankshaft sensor. backup speed sen- component.
sor. Engine power is Check the
reduced. sensor.


and menu
components
Code J1587
251 / 2 P251 / 2 Real-Time Clock Power None on perform- - - -
Interrupt - Data Erratic, ance. Data in the
Intermittent or Incorrect. ECU 794 will not
Real-time clock lost have accurate time
power. and date information.
441 / 3 P441 / 3 Auxiliary Temperature None on Check cable D794 -
Sensor Input 1 - Voltage performance. harness be-
Above Normal, or Short- tween control
ed to High Source. High unit and
signal voltage or open cir- component.
cuit detected at the OEM Check the
auxiliary temperature sensor.
circuit.
441 / 4 P441 / 4 Auxiliary Temperature None on Check cable D794 -
Sensor Input 1 Circuit - performance. harness be-
Voltage Below Normal, or tween control
Shorted to Low Source. unit and
Low signal voltage de- component.
tected at OEM auxiliary Check the
temperature circuit. sensor.
558 / 2 S230 / 2 Accelerator Pedal or Le- Engine only running Check cable D794 -
ver Idle Validation Circuit at idle. harness be-
- Data Erratic, Intermittent tween control
or Incorrect. Voltage de- unit and
tected simultaneously on component.
both idle validation and Check
off-idle validation component.
switches.
- Voltage Below Normal tween control
or Shorted to Low unit and
Source. No voltage de- component.
tected simultaneously on Check
both the idle validation component.
off-idle and on-idle
circuits.
- Out of Calibration. Volt- tween control
age at idle validation on- unit and
idle and off-idle circuit component.
does not match accelera- Check
tor pedal position. component.


and menu
components
Code J1587
611 / 2 P089 / 2 Auxiliary Intermediate Intermediate speed - D794 -
(PTO) Speed Switch Vali- control switch may
dation - Data Erratic, In- not operate correctly.
termittent, or Incorrect.
The position of the inter-
mediate speed control
switch 1 does not match
the position of the inter-
mediate speed control
validation switch.
611 / 3 S232 / 3 Sensor Supply Voltage 4 Engine only running - D794 -
Circuit - Voltage Above at idle.
Normal or Shorted to
High Source. High volt-
age detected at +5 volt
sensor supply circuit to
the accelerator pedal po-
sition sensor.
611 / 4 S232 / 4 Sensor Supply 3 Circuit - Possible hard starting - D794 -
Voltage Below Normal, or and rough running.
Shorted to Low Source.
Low voltage detected on
the +5 volt sensor supply
circuit to the engine
speed sensor.
611 / 4 S232 / 4 Sensor Supply Voltage 4 Engine will only die. - D794 -
Circuit - Voltage Below
Normal or Shorted to Low
Source. Low voltage de-
tected at +5 VDC sensor
supply circuit to the accel-
erator pedal position
sensor.
611 / 15 S151 / 0 Turbocharger compres- Fuel is limited in an - D794 -
sor outlet temperature - attempt to decrease
data above normal. High the calculated turbo-
turbocharger compres- charger compressor
sor outlet temperature outlet temperature.
has been calculated by
the ECU 794.


and menu
components
Code J1587
612 / 2 P190 / 2 Engine Magnetic Crank- Fuelling to the injec- - D794 -
shaft Speed/Position lost tors is disabled, and
both of two signals - Data the engine can not be
Erratic, Intermittent, or In- started.
correct. The ECU 794 has
detected that the primary
engine speed sensor and
the backup engine speed
sensor signals are
reversed.
627 / 2 S251 / 2 Power Lost without Igni- Possible no noticea- Check fuses. D794 -
tion Off - Data Erratic, In- ble performance ef- Check batter-
termittent or Incorrect. fects or engine dying ies and
Supply voltage to the or hard starting. Fault alternator.
ECU 794 fell below 6.2 information, trip infor-
volts momentarily, or the mation, and mainte-
ECU 794 was not allowed nance monitor data
to power down correctly can be inaccurate.
(retain battery voltage for
30 seconds after key
OFF).
627 / 2 S251 / 2 Power Supply Lost With Possible no noticea- Check fuses. D794 -
Ignition On - Data Erratic, ble performance ef- Check batter-
Intermittent or Incorrect. fects or engine dying ies and
Supply voltage to the or hard starting. Fault alternator.
ECU 794 fell below 6.2 information, trip infor-
VDC momentarily, or the mation, and mainte-
ECU 794 was not allowed nance monitor data
to power down correctly can be inaccurate.
(retain battery voltage for
30 seconds after key
OFF).
627 / 2 S254 / 12 Injector Power Supply - Possible smoke, low Check fuses. D794 -
Bad Intelligent Device or power, engine mis- Check batter-
Component. The fire, and/or engine ies and
ECU 794 measured in- will not start. alternator.
jector boost voltage is
low.
629 / 12 S254 / 12 Engine Control Module - Engine may not start. Check the D794 -
critical internal failure. Er- control unit
ror internal to the
ECU 794 related to mem-
ory hardware failures or
internal ECU 794 voltage
supply circuits.


and menu
components
Code J1587
629 / 12 S254 / 12 Engine Control Module No performance ef- Check the D794 -
Warning Internal Hard- fects or possible se- control unit
ware Failure - Bad Intelli- vere power derate.
gent Device or
Component.
630 / 2 S253 / 2 Engine Control Module Possible no noticea- Reprogram D794 -
Data Lost - Data Erratic, ble performance ef- the software in
Intermittent or Incorrect. fects or engine dying Control unit,
Severe loss of data from or hard starting. Fault engine
the ECU 794. information, trip infor- (D794).
mation, and mainte-
nance monitor data
can be inaccurate.
630 / 31 S240 / 11 Engine Control Module Possible no noticea- - D794 -
Calibration Program ble performance ef-
Memory (RAM) Corrup- fects or engine dying
tion - Condition Exists. or hard starting. Fault
Severe loss of data from information, trip infor-
the ECU 794. mation, and mainte-
nance monitor data
can be inaccurate.
633 / 31 S018 / 11 Fuelling Actuator Number Possible low power. - D794 -
1 Circuit Error Conditions
Exists. Fuel pump actua-
tor circuit resistance too
high or too low.
639 / 9 S231 / 9 SAE J1939 Multiplexing One or more multi- Use diagnos- - CAN/
PGN Timeout Error - Ab- plexed devices will tic menu to POWER,
normal Update Rate. The not operate properly. find incorrect menu 2
Cummins ECU 794 did One or more symp- segment.
not receive a multiplexed toms will occur.
message from an OEM
VECU within the time limit
or did not receive it at all.
639 / 13 S231 / 13 SAE J1939 Multiplexing At least one multi- Use diagnos- - CAN/
Configuration Error - Out plexed devices will tic menu to POWER,
of Calibration. The ECU not operate properly. find incorrect menu 2
794 expected information segment.
from a multiplexed device
but only received a por-
tion of the necessary
information.


and menu
components
Code J1587
641 / 3 S027 / 3 VGT actuator driver cir- Possible low power. - D794 -
cuit - voltage above nor- Power removed from
mal or shorted to high the turbocharger ac-
source. tuator motor.
641 / 4 S027 / 4 VGT actuator driver cir- Possible low power. - D794 -
cuit - voltage below nor- Power removed from
mal, or shorted to low the turbocharger ac-
source. tuator motor.
644 / 2 S030 / 2 External Speed Com- Primary or secondary Check cable - -
mand Input (Multiple Unit engines may be shut harness be-
Synchronisation) - Data down. tween control
Erratic, Intermittent, or In- unit and
correct. The throttle input component.
signal to the primary or Check
secondary engine for component.
multiple unit synchronisa-
tion is less than 3 percent
or more than 97 percent.
647 / 3 S033 / 3 Fan Control Circuit - Volt- The fan may stay on Check cable D794 -
age Above Normal or continuously or not harness be-
Shorted to High Source. run at all. tween control
Open circuit or high volt- unit and
age detected at the fan component.
control circuit. Check
component.
647 / 4 S033 / 4 Fan Control Circuit - Volt- The fan may stay on Check cable D794 -
age Below Normal or continuously or not harness be-
Shorted to Low Source. run at all. tween control
Low signal voltage de- unit and
tected at the fan control component.
circuit when commanded Check
on. component.
651 / 5 S001 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 1 Circuit - Cur- possibly run rough. harness be-
rent Below Normal, or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 1 injector Check the
DRIVER or RETURN pin. injector.


and menu
components
Code J1587
651 / 7 S001 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 1 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
number 1. injector.
driver or return pin. injector.
number 2. injector.
ed at Number 3 injector or Check the
return pin. injector.
number 3. injector.
rent Below Normal or tween control


and menu
components
Code J1587
number 4. injector.
DRIVER or RETURN pin. injector.
Number 5. injector.
Number 6. injector.
677 / 3 S39 / 3 Starter Relay Circuit - Either the engine will Check cable D794 ENGINE,
Voltage Above Normal or not start or the engine harness be- menu 5
Shorted to High Source. will not have starter tween control
Open circuit or high volt- lockout protection. unit and
age detected at starter component.
lockout circuit. Check the
relay.


and menu
components
Code J1587
677 / 4 S39 / 4 Starter Relay Circuit - The engine will not Check cable D794 ENGINE,
Voltage Below Normal or have starter lockout harness be- menu 5
Shorted to Low Source. protection. tween control
Low voltage detected at unit and
starter lockout circuit. component.
Check the
relay.
697 / 3 S057 / 3 Auxiliary PWM Driver #1 - Can not control - D794 -
Voltage Above Normal or transmission.
Shorted to High Source.
High signal voltage de-
tected at the analogue
torque circuit.
697 / 4 S057 / 4 Auxiliary PWM Driver #1 - Can not control - D794 -
Voltage Below Normal or transmission.
Low signal voltage de-
tected at the analogue
torque circuit.
703 / 11 S051 /11 Auxiliary Equipment Sen- Possible engine pow- Check cable D794 -
sor Input #3 (OEM er derate. harness be-
Switch) - Root Cause Not tween control
Known. unit and
component.
Check the
component.
723 / 2 S064 / 2 Backup Engine Speed/ Possible low power. Check cable D794 -
Position Sensor Number harness be-
2 - Data Erratic, Intermit- tween control
tent, or Incorrect. Cam- unit and
shaft engine speed component.
sensor intermittent Check the
synchronisation. sensor.
723 / 2 S064 / 2 Engine Speed Sensor Possible poor start- Check cable D794 -
(Camshaft) Error - Data ing. Engine power harness be-
Erratic, Intermittent, or In- derate. tween control
correct. The ECU 794 has unit and
detected an error in the component.
camshaft position sensor Check the
signal. sensor.


and menu
components
Code J1587
723 / 7 S064 / 7 Engine Speed Sensor/ Engine will run derat- Check cable D794 -
Position Camshaft and ed. Excessive harness be-
Crankshaft Misalignment smoke, hard start, tween control
- Mechanical System Not and rough idle unit and
Responding Properly or possible. component.
Out of Adjustment. Me- Check the
chanical misalignment sensor.
between the crankshaft
and camshaft engine
speed sensors.
729 / 3 S070 / 3 Intake Air Heater #1 Cir- The intake air heaters Check cable D794 -
cuit - Voltage Above Nor- may be ON or OFF all harness be-
mal or Shorted to High the time. tween control
Source. High voltage de- unit and
tected at the intake air component.
heater signal circuit. Check
component.
729 / 4 S070 / 4 Intake Air Heater #1 Cir- The intake air heaters Check cable D794 -
cuit - Voltage Below Nor- may be ON or OFF all harness be-
mal or Shorted to Low the time. tween control
Source. Low voltage de- unit and
tected at the intake air component.
heater signal circuit. Check
component.
974 / 3 P974 / 3 Remote Accelerator Ped- Remote accelerator Check cable D794 -
al or Lever Position Sen- will not operate. Re- harness be-
sor 1 Circuit - Voltage mote accelerator po- tween control
Above Normal, or shorted sition will be set to unit and
to High Source. High volt- zero percent. component.
age detected at remote Check
accelerator pedal position component.
circuit.
974 / 4 P974 / 4 Remote Accelerator Ped- Remote accelerator Check cable D794 -
al or Lever Position Sen- will not operate. Re- harness be-
sor 1 Circuit - Voltage mote accelerator po- tween control
Below Normal, or Shorted sition will be set to unit and
to Low Source. Low volt- zero percent. component.
age detected at remote Check
accelerator pedal position component.
signal.


and menu
components
Code J1587
974 / 19 P29 SAE J1939 Multiplexing The engine will not Use diagnos- - CAN/
Remote Accelerator Ped- respond to the re- tic menu to POWER,
al or Lever Data Error - mote throttle. Engine find incorrect menu 2
Received Network Data may only idle. The segment.
Error. The OEM machine primary or cab accel-
electronic control unit erator may be able to
(VECU) detected a fault be used.
with the remote
accelerator.
ver Position Sensor Sup- at idle. harness be-
ply Voltage Circuit - tween control
Voltage Above Normal or unit and
Shorted to High Source. component.
High voltage detected at Check
sensor supply circuit for component.
the accelerator pedal or
lever position sensor.
1043 / 4 S221 / 4 Accelerator Pedal or Le- Engine will only die. Check cable D794 -
ver Position Sensor Sup- harness be-
ply Voltage Circuit - tween control
Voltage Below Normal or unit and
Shorted to Low Source. component.
Low voltage detected at Check
sensor supply circuit to component.
the accelerator pedal or
lever position sensor.
1043 / 4 S221 / 4 Engine Speed/Position Possible hard starting Check cable D794 -
Sensor (Crankshaft) Sup- and rough running. harness be-
ply Voltage Circuit - Volt- tween control
age Below Normal or unit and
Shorted to Low Source. component.
Low voltage detected on Check
the ECU 794 voltage sup- component.
ply line to engine speed
sensor.
1072 / 3 S028 / 3 Engine Brake Actuator Engine brake on cyl- Check cable D794 -
Circuit #1 - Voltage inders 1, 2, and 3 can harness be-
Above Normal or Shorted not be activated or tween control
to High Source. Open cir- exhaust brake will not unit and
cuit or high voltage de- operate. component.
tected at the engine brake Check
solenoid number 1 signal component.
circuit.


and menu
components
Code J1587
Circuit #1 - Voltage Below inders 1, 2, and 3 can harness be-
Normal or Shorted to Low not be activated or tween control
Source. Low voltage de- exhaust brake will not unit and
tected at the engine brake operate. component.
solenoid number 1 signal Check
circuit. component.
Circuit #2 - Voltage inders 4, 5, and 6 can harness be-
Above Normal or Shorted not be activated. tween control
to High Source. Open cir- unit and
cuit or high voltage de- component.
tected at the engine brake Check
solenoid number 2 signal component.
circuit.
Circuit #2 - Voltage Below inders 4, 5, and 6 can harness be-
Normal or Shorted to Low not be activated. tween control
Source. Low voltage de- unit and
tected at the engine brake component.
solenoid number 2 signal Check
circuit. component.
1075 / 3 S126 / 3 Electric Lift Pump for En- Engine can be diffi- - D794 -
gine Fuel Supply Circuit - cult to start.
Voltage Above Normal, or
High voltage or open de-
tected at the fuel lift pump
signal circuit.
1075 / 4 S126 / 4 Electric Lift Pump for En- Engine can be diffi- - D794 -
gine Fuel Supply Circuit - cult to start.
Voltage Below Normal, or
tected at the fuel lift pump
circuit.
1079 / 3 S212 / 3 Sensor Supply Voltage Engine power derate. Check cable D794 -
number 1 Circuit - Volt- harness be-
age Above Normal or tween control
Shorted to High Source. unit and
High voltage detected at component.
sensor supply number 1 Check the
circuit. sensor.


and menu
components
Code J1587
Number 1 Circuit - Volt- harness be-
age Below Normal or tween control
sensor supply number 1 Check the
circuit. sensor.
1080 / 3 S232 / 3 Sensor Supply 2 Circuit - Engine power derate. Check cable D794 -
Voltage Above Normal or harness be-
Shorted to High Source. tween control
High voltage detected at unit and
sensor supply number 2 component.
circuit. Check the
sensor.
Number 2 Circuit - Volt- harness be-
age Below Normal, or tween control
the sensor supply Check the
number 2 circuit. sensor.
1137 / 2 S114 / 2 Multiple Unit Synchroni- Multiple Unit Syn- - D794 -
sation Switch - Data Er- chronisation feature
ratic, Intermittent, or is disabled.
Incorrect. Multi-unit syn-
chronous ON/OFF switch
and multi-unit synchro-
nous complimentary ON/
OFF switch have different
values in the ECU 794.
1172 / 3 /3 Turbocharger Number 1 Engine power derate. - D794 -
Compressor Inlet Tem-
perature Sensor Circuit -
Voltage Above Normal or
tected at the turbocharger
compressor inlet air tem-
perature circuit.


and menu
components
Code J1587
1172 / 4 /4 Turbocharger Number 1 Engine power derate. - D794 -
Compressor Inlet Tem-
perature Sensor Circuit -
Voltage Below Normal or
tected at the turbocharger
compressor inlet air tem-
perature sensor circuit.
1347 / 3 S126 / 3 High Fuel Pressure Sole- Engine will run poorly - D794 -
noid Valve Circuit - Volt- but will be severely
age Above Normal or derated. Rail pres-
Shorted to High Source. sure will be higher
Electronic fuel control ac- than commanded.
tuator shorted high.
1347 / 4 S126 / 4 High Fuel Pressure Sole- Engine will run poorly - D794 -
noid Valve Circuit - Volt- at idle. Engine will
age Below Normal or have low power. Fuel
Shorted to Low Source. pressure will be high-
Electronic fuel control ac- er than commanded.
tuator shorted low.
1347 / 7 S126 / 7 Fuel Pump Pressurising Engine will not run or - D794 -
Assembly 1 - Mechanical possible low power.
System Not Responding
Properly or Out of Adjust-
ment. A pumping imbal-
ance between the front
and rear pumping plung-
ers has been detected.
1347 / 7 S126 / 7 Fuel Pumping Element Engine will not run or - D794 -
Number 1 (Front) - Me- possible low power.
chanical System Not Re-
sponding Properly or Out
of Adjustment.
1378 / 31 S153 / 11 Change Lubricating Oil None on perform- - D794 -
and Filter - Condition Ex- ance; maintenance
ists. Change engine oil reminder only.
and filter.
1388 / 3 P223 / 3 Auxiliary Pressure Sen- None on - D794 -
sor Input 1 Circuit - Volt- performance.
age Above Normal, or
tected at the OEM pres-
sure circuit.


and menu
components
Code J1587
1388 / 4 P223 / 4 Auxiliary Pressure Sen- None on - D794 -
sor Input 1 Circuit - Volt- performance.
age Below Normal, or
Low signal voltage or
open circuit detected at
the OEM pressure circuit.
2789 / 15 / 0 Exhaust gas temperature Derate in power out- - D794 -
- data above normal. High put of the engine in
exhaust temperature has attempt to decrease
been calculated by the the calculated ex-
electronic control system. haust gas tempera-
ture value.

Error codes engine (engine

–
alternative Volvo TAD760VE)

and menu
components
Code Flash J1587

94/1 3.8 PID94/1 Low fuel pres- No limitation. Change the fuel filter. - -
sure (feed). Change the fuel
prefilter.
Check whether pres-
sure can be built up with
the hand pump.
94/3 3.6 PID94/3 Sensor fuel No limitation. Check the cable har- D794/B:16 -
pressure, ness between control
short-circuited unit and component.
to voltage. Check the sensor.
94/5 3.6 PID94/5 Sensor fuel No limitation. Check the cable har- D794/B:16 -
pressure, ness between control
to ground or Check the sensor.
open circuit.
94/7 3.8 PID94/7 Sensor fuel No limitation. Change the fuel filter. D794/B:16 -
pressure, Change the fuel
short-circuited prefilter.
to voltage,
Check whether pres-
ground or open
sure can be built up with
circuit.
the hand pump.
97/0 2.1 PID97/0 Water in fuel. No limitation. Drain water separator. - -

Clean metal filter in the
fuel feed’s hose con-
nection on the engine.
Check fuel filter and fuel
pre-filter.
97/4 2.9 PID97/4 Sensor water No limitation. Check the cable har- D794/B:8 -
in fuel short- ness between control
circuited to unit and component.
ground or open Check the sensor.
circuit.


and menu
components
Code Flash J1587

100/0 6.6 PID100/0 Low engine oil The engine is Check the oil level. - ENGINE,
pressure. switched off. Change oil filter. menu 6
Check the system pres-

sure valves and the
safety valve in the lubri-
cation system.
Check the sensor.
100/3 3.1 PID100/3 Sensor oil No limitation. Check the cable har- D794/B:11 ENGINE,
pressure, ness between control menu 6
100/5 3.1 PID100/5 Sensor oil No limitation. Check the cable har- D794/B:11 ENGINE,
pressure, open ness between control menu 6
circuit. unit and component.
Check the sensor.
105/0 6.2 PID105/0 High The engine is Check that charge-air - ENGINE,
charge-air switched off. cooler is clean. menu 7
temperature. Check the sensor.
105/4 3.2 PID105/4 Sensor charge No limitation. Check the cable har- D794/A:47 ENGINE,
air tempera- ness between control menu 7
ture, cable unit and component.
short-circuited Check the sensor.
to ground.
105/5 3.3 PID105/5 Sensor charge No limitation. Check the cable har- D794/A:47 ENGINE,
air tempera- ness between control menu 7
ture, cable unit and component.
open circuit. Check the sensor.
106/0 3.5 PID106/0 High booster Reduced en- Check turbocharger. - ENGINE,
pressure. gine power. Check the sensor. menu 6
Check fuel quality and

injectors.
106/3 3.4 PID106/3 Sensor, boost Reduced en- Check the cable har- D794/A:22 ENGINE,
pressure, ca- gine power. ness between control menu 7
ble short- unit and component.
circuited to Check the sensor.
voltage.


and menu
components
Code Flash J1587

106/5 3.4 PID106/5 Sensor boost Reduced en- Check the cable har- D794/A:22 ENGINE,
pressure, ca- gine power. ness between control menu 7
ble open unit and component.
circuit. Check the sensor.
108/2 - PID108/2 Incorrect sig- No limitation. Check the cable har- - ENGINE,
nal from Sen- ness between control menu 6
sor, boost unit and component.
pressure. Check the sensor.
108/3 - PID108/3 Sensor, boost No limitation. Check the cable har- D794/A:29 ENGINE,
108/4 - PID108/4 Sensor boost No limitation. Check the cable har- D794/A:29 ENGINE,
to frame Check the sensor.
ground or open
circuit.
110/0 6.1 PID110/0 High coolant No limitation. Check the coolant level. - ENGINE,
temperature. Check that radiator is menu 7
clean.
Check the thermostat.
Check the cap on the
expansion tank.
Check if there is air in
coolant system.
Check the sensor.
110/4 3.3 PID110/4 Sensor coolant Preheating is Check the cable har- D794/B:27 ENGINE,
temperature, activated even ness between control menu 7
short-circuited if engine is unit and component.
to ground. warm. Check the sensor.
110/5 3.3 PID110/5 Sensor coolant Preheating is Check the cable har- D794/B:27 ENGINE,
temperature, activated even ness between control menu 7
cable open if engine is unit and component.
circuit. warm. Check the sensor.
111/1 2.2 PID111/1 Low coolant No limitation. Check the coolant level; - -
level. fill if necessary.
Check the sensor.


and menu
components
Code Flash J1587

158/1 3.9 PID158/1 Low battery The engine Check and charge the D794/B:57, -
voltage. may be diffi- batteries. B:60
cult to start. Check alternator.
Check the battery
cables.
164/0 - PID164/0 High fuel No limitation. Check the fuel pump. - -

164/2 - PID164/2 Incorrect sig- Engine speed Check the cable har- D794/B:16 -
nal from Sen- limited to ness between control
sor, fuel 1100 rpm. unit and component.
164/4 - PID164/4 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, limited to ness between control
short-circuited 1100 rpm. unit and component.
to ground. Check the sensor.
164/5 - PID164/5 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, open limited to ness between control
circuit. 1100 rpm. unit and component.
Check the sensor.
190/0 2.6 PID190/0 Engine speed No limitation. Ease off throttle or se- - -
too high. lect higher gear.
626/3 5.4 PID45/3 Preheating re- Preheating Check the cable har- D794/B:25 ENGINE,
lay, short- cannot be ness between control menu 5
circuited to activated. unit and component.
voltage. White smoke Check the relay.
with cold-start.
Starting prob-
lems in cold
weather.
626/4 5.4 PID45/4 Preheating re- Preheating re- Check the cable har- D794/B:25 ENGINE,
lay, short- lay is activated ness between control menu 5
circuited to constantly. unit and component.
ground. Fuse for pre- Check the relay.
heating may
blow.


and menu
components
Code Flash J1587

626/5 5.4 PID45/5 Preheating re- Preheating Check the cable har- D794/B:25 ENGINE,
lay, open cir- cannot be ness between control menu 5
cuit or activated. unit and component.
defective White smoke Check the relay.
component. with cold-start.
Starting prob-
lems in cold
weather.
629/3 9.9 SID254/3 Engine control The engine Change the control unit. - -
unit (D794), in- does not start.
ternal error.
ternal error.
ternal error.
636/2 9.9 SID21/3 Incorrect sig- Engine takes Check the cable har- D794/A:45, -
nal from Sen- longer time to ness between control A:46
sor, camshaft start than nor- unit and component.
speed. mal. Engine Check the sensor.
runs normally
when it has
started.
636/3 2.5 SID21/3 Sensor rota- Engine takes Check the cable har- D794/A:45, -
tion speed longer time to ness between control A:46
camshaft, no start than nor- unit and component.
signal. mal. Engine Check the sensor.
runs normally
when it has
started.
636/8 2.5 SID21/8 Sensor engine Engine takes Check the cable har- D794/A:45, -
speed, cam- longer time to ness between control A:46
shaft, abnor- start than nor- unit and component.
mal frequency. mal. Engine Check the sensor.
runs normally
when it has
started.


and menu
components
Code Flash J1587

637/2 2.4 SID22/2 Faulty signal Engine is diffi- Check the cable har- D794/A:37, ENGINE,
from Sensor cult to start ness between control A:38 menu 2
engine speed, and runs unit and component.
flywheel. rough, if it Check the sensor.
starts.
637/3 2.4 SID22/3 Sensor engine Engine is diffi- Check the cable har- D794/A:37, ENGINE,
speed, fly- cult to start ness between control A:38 menu 2
wheel, abnor- and runs unit and component.
mal frequency. rough, if it Check the sensor.
starts.
637/8 2.4 SID22/8 Sensor engine Engine is diffi- Check the cable har- D794/A:37, ENGINE,
speed, fly- cult to start ness between control A:38 menu 2
wheel, abnor- and runs unit and component.
mal frequency. rough, if it Check that the sensor is
starts. connected correctly.
639/2 6.5 SID231/2 Communica- Engine Use diagnostic menu to D794/B:51, CAN/POW-
tion error with switched off: find incorrect segment. B:55 ER, menu 3
Control unit, engine cannot Check the cable har-
engine (D794), be started. ness between control
configuration Engine on: en- unit and component.
error. gine goes to Check the control unit.
idle and can
only be
stopped by us-
ing the emer-
gency stop.
639/2 9.9 SID240/2 Communica- It may not be Reprogram the control - -

tion error with possible to unit.
Control unit, start the
engine (D794), engine.
configuration
error.

configuration
error.


and menu
components
Code Flash J1587

639/9 6.4 PSID201/ Communica- Instruments Use diagnostic menu to - -
1675/9 9 tion error with and controls find incorrect segment.
Control unit, do not work. Check the cable har-
engine (D794), ness between control
configuration unit and component.
error.
Check the control unit.

configuration
error.

configuration
error.
651/3 7.1 SID1/3 Electric fail- Engine only Check the cable har- D794/A:24 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
reduced
power.
reduced
power.


and menu
components
Code Flash J1587

651/7 7.1 SID1/7 Incorrect com- Runs rough at Check the fuel D794/A:24 -
pression or de- low rpm and pressure.
fective injector low load. Check valve clearance.
cylinder 1.
Check the cable har-
ness between control
unit and component.
Check the injector.
Perform compression
test and check
cylinder 1.
reduced
power.
reduced
power.
reduced
power.
reduced
power.


and menu
components
Code Flash J1587

cylinder 2.
unit and component.
Check the injector.
Perform compression
test and check
cylinder 2.
reduced
power.
reduced
power.
reduced
power.
reduced
power.


and menu
components
Code Flash J1587

cylinder 3.
unit and component.
Check the injector.
Perform compression
test and check
cylinder 3.
reduced
power.
reduced
power.
reduced
power.
reduced
power.


and menu
components
Code Flash J1587

cylinder 4.
unit and component.
Check the injector.
Perform compression
test and check
cylinder 4.
reduced
power.
reduced
power.
reduced
power.
reduced
power.


and menu
components
Code Flash J1587

655/7 7.5 SID5/7 Incorrect com- Engine only Check that cabling to D794/A:48 -
pression or de- runs on 5 cyl- the injectors is not
fective injector inders, sounds damaged.
cylinder 5. rough and has Check the cable har-
reduced ness between control
power. unit and component.
Check the injector.
Perform compression
test and check
cylinder 5.
reduced
power.
reduced
power.
reduced
power.
reduced
power.


and menu
components
Code Flash J1587

cylinder 6.
unit and component.
Check the injector.
Perform compression
test and check
cylinder 6.
656/12 7.6 SID6/12 Electric fail- Engine only Check the cable har- D794/A:36, -
ure, injector runs on 5 cyl- ness between control A:40
reduced
power.
677/3 6.3 SID39/3 Starter motor The engine Check the cable har- D794/B:29 ENGINE,
1675/3 relay, short- does not start. ness between control menu 5
circuited to Engine starts unit and component.
voltage. immediately Check the relay.
when ignition
is turned on.
1675/4 relay, short- does not start. ness between control menu 5
ground Check the relay.
1675/5 relay, open does not start. ness between control menu 5
circuit. unit and component.
Check the relay.
679/0 - PSID97/0 Incorrect sig- Engine speed Check the cable har- - -
nal from con- limited to ness between control
trol Pressure 1100 rpm. unit and component.
relief valve. Reduced en- Check the component.
gine power.
679/3 - SID42/3 Pressure relief Engine speed Check the cable har- - -
valve, short- limited to ness between control
circuited to 1100 rpm. unit and component.
voltage. Check the component.


and menu
components
Code Flash J1587

valve, short- limited to ness between control
circuited to 1100 rpm. unit and component.
ground. Check the component.
valve, open limited to ness between control
circuit. 1100 rpm. unit and component.
Check the component.
679/7 - PSID97/7 Pressure relief Engine speed Check the cable har- - -
valve, me- limited to ness between control
chanical 1100 rpm. unit and component.
defect. Reduced en- Check the component.
gine power.
679/11 - PSID97/ Pressure relief Engine speed Check the cable har- - -
11 valve, uniden- limited to ness between control
tified problem. 1100 rpm. unit and component.
Reduced en- Check the component.
gine power.
679/14 - PSID97/ Pressure relief Engine speed Check the cable har- - -
14 valve, defec- limited to ness between control
tive 1100 rpm. unit and component.
component. Reduced en- Check the component.
gine power.
729/3 - SID70/3 Sensor pre- Fuse blows. Check the cable har- D794/B:31 -
heating, short- ness between control
voltage. Check the component.
729/4 - SID70/4 Sensor pre- Engine difficult Check the cable har- D794/B:31 -
heating, short- to start in cold ness between control
circuited to weather. unit and component.
ground. Check the component.
729/5 - SID70/5 Sensor pre- Engine difficult Check the cable har- D794/B:31 -
heating, open to start in cold ness between control
circuit. weather. unit and component.


and menu
components
Code Flash J1587

1079/3 9.3 SID 232/3 Reference No limitation. Check the cable har- D794/B:17 -
voltage 5 V no. ness between control
1 to sensor, unit and component.
to voltage.
1079/4 9.3 SID 232/4 Reference No limitation. Check the cable har- D794/B:17 -
to ground.
1080/3 - SID 211/3 Reference No limitation. Check the cable har- D794/A:7 -
to voltage.
1080/4 - SID 211/4 Reference No limitation. Check the cable har- D794/A:7 -
to ground.
1239/0 - PSID 96/0 Fuel pressure Engine speed Check fuel feed. - -
too high. limited to
1100 rpm.
High engine
power. (Pow-
erful engine)
1239/1 - PSID 96/1 Fuel pressure Engine speed Check fuel filter, - -
too low limited to change if necessary.
1100 rpm. Check fuel feed.
Reduced en-
gine power.
1239/4 - PSID 96/4 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, limited to ness between control
short-circuited 1100 rpm. unit and component.
to ground. Reduced en- Check the sensor.
gine power.
Engine start-
ing difficulty.


and menu
components
Code Flash J1587

1239/7 - PSID 96/7 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, me- limited to ness between control
chanical 1100 rpm. unit and component.
defect. Reduced en- Check the sensor.
gine power.
Engine start-
ing difficulty.
1239/ - PSID 96/ Sensor fuel Engine speed Check the sensor. - -
12 12 pressure, de- limited to
fective 1100 rpm.
component. Reduced en-
gine power.
Engine start-
ing difficulty.
2791/3 - PPID19/3 Internal EGR, Internal EGR Check the cable har- D794/B:30 -
short-circuited not working. ness between control
to voltage. unit and component.
short-circuited not working. ness between control
to ground. unit and component.
open circuit. not working. ness between control
unit and component.
2791/7 - PPID19/7 Internal EGR, Internal EGR Check, Sensor boost D794/B:30 -
mechanical not working. pressure.
defect. Check the component.
(IEGR)
Contact Volvo Penta
workshop for more
information.
520192 6.8 PPID6/5 Sensor piston No limitation. Check the cable har- D794/B:14 -
/5 cooling pres- ness between control
sure, short- unit and component.
circuited to Check the sensor.
voltage,
ground or open
circuit.


and menu
components
Code Flash J1587

- - PPID 435/ High fuel Engine speed Check fuel feed. - -
0 pressure. limited to
1100 rpm.
High engine
power. (Pow-
erful engine)
- - PPID 435/ Low fuel pres- Engine speed Check fuel filter, - -
4 sure. limited to change if necessary.
1100 rpm. Check fuel feed.
Reduced en-
gine power.

D Error codes – 2 Transmission 53
2 Transmission
mm mm mm mm mm mm
Error codes transmission

page
–
Control unit transmission can generate two states with reduced func-
tionality to protect the transmission in the event of serious malfunc-
tions:
• "Limp-home", indicated in display with "LH".
In this mode only 1-2 gear in both directions can be used. If the
malfunction occurs in a higher gear then downshifting has to be
performed manually to 1st gear or 2nd.
• "Shutdown", indicated in display with "Sd".
In this mode the transmission is permanently in neutral as there is
no oil pressure to enable gear selection.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
00/50 Memory error in con- Transmission locked in - - -
trol unit transmission. neutral (shutdown).
20/60 Sensor oil pressure Transmission locked in Check the cable harness D793/A:2 - TRANSM,
(B253) indicates low neutral (shutdown). between control unit and B253 menu 10
oil pressure when component.
there should be Check the solenoid
pressure. valve.
20/61 The oil pressure sen- Transmission locked in Check the cable harness D793/A:2 - TRANSM,
sor (B253) indicates neutral (shutdown). between control unit and B253 menu 10
oil pressure when component.
there should not be Check the solenoid
pressure. valve.
21/02 Solenoid valves VFS Transmission locked in Check cabling between D793/D1 - TRANSM,
short-circuiting to volt- neutral (shutdown). the control unit and the Y6069, D793/ menu 7
age, ground, or open component with diag- F2 - Y6075
circuit. nostic menu.
Check the solenoid
valve.

54 D Error codes – 2 Transmission
Connections
Diagnostic
menu
components
Code
30/04 Low battery voltage. Control unit saves stored Check the cable harness - CAN/
information to flash mem- to the control unit. POWER,
ory and restarts to clear Check alternator, battery menu 12
memory. and cable harness be-
tween battery and
alternator.
30/05 High battery voltage. Control unit receives re- Check voltage feed. - CAN/
duced proportional control If auxiliary start equip- POWER,
precision depending on ment is connected, dis- menu 12
reduced PWM work cycle. connect it.
31/00 Reference voltage Control unit receives re- Check the voltage feed. - CAN/
sensor 8 V, too low. duced sensor signals. Check the control unit. POWER,
menu 12
31/01 Reference voltage Control unit receives re- Check the voltage feed. - CAN/
sensor 8 V, too high. duced sensor signals. Check the control unit. POWER,
menu 12
40/06 Incorrect direction Control unit locks trans- Check cabling to gear - TRANSM,
from gear selector. mission in neutral. selector with regards to menu 2
forward and reverse
signal.
41/06 Incorrect gear selec- Control unit doesn’t allow Check cabling to gear - TRANSM,
tion from gear change of range, howev- selector with regards to menu 2
selector. er, operation of machine signal range.
is possible.
42/04 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
low. one or several clutches purpose to understand if menu 6
are slipping. and, if that is the case,
which clutch is slipping.
Check the set gear ratio
for the control unit.
42/05 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
high. one or several clutches purpose to understand if menu 6
are slipping. and, if that is the case,
which clutch is slipping.
Check the set gear ratio
for the control unit.
43/03 Signal from Sensor Control unit indicates the Check the cable harness D793/H3 - TRANSM,
engine rpm and oil error. between control unit and B758/766 menu 10
temperature transmis- component.
sion (B758/766) out- Check the sensor.
side valid interval.

Connections
Diagnostic
menu
components
Code
43/07 Torque converter tem- Control unit indicates the Check the transmission D793/H3 - TRANSM,
perature exceeds error to make operator oil cooler, clean if B758/766 menu 10
100 C. aware of the warning’s necessary.
level. Check the thermostat in
the transmission oil
cooler.
43/08 Torque converter tem- The control unit protects Check the transmission D793/H3 - TRANSM,
perature exceeds the transmission and does oil cooler, clean if B758/766 menu 10
125 C. not allow the temperature necessary.
in the torque converter to Check the thermostat in
exceed the limit value. the transmission oil
The control unit locks the cooler.
transmission in neutral
position, the engine is re-
stricted to 50% of max.
rpm.
44/10 Faulty signal for accel- - Use diagnostic menu to - CAN/
erator pedal position find incorrect segment. POWER,
from engine control menu 4
unit (D794)
46/05 Max. torque for inch- - - - -
ing has been
exceeded.
50/00 Sensor oil pressure Transmission in Check the cable harness D793/A:2 - TRANSM,
(B253), short-circuited limp-home. between control unit and B253 menu 10
to ground. component.
Check the sensor.
50/01 Sensor oil pressure Transmission in Check the cable harness D793/A:2 - TRANSM,
(B253), not connected limp-home. between control unit and B253 menu 10
or open circuit. component.
Check the sensor.
51/00 Sensor engine rpm The control unit limits the Check the cable harness D793/H3 - TRANSM,
and oil temperature transmission’s tempera- between control unit and B758/766 menu 10
transmission (B758/ ture measurement to the component.
766) short-circuited to lowest value in its set- Check the sensor.
ground. tings, which results in
poor temperature
compensation.

Connections
Diagnostic
menu
components
Code
51/01 Sensor engine rpm The control unit limits the Check the cable harness D793/H3 - TRANSM,
and oil temperature transmission’s tempera- between control unit and B758/766 menu 10
transmission (B758/ ture measurement to the component.
766) not connected or highest value in its set- Check the sensor.
open circuit. tings, which results in
poor temperature
compensation.
52/00 Sensor oil tempera- The control unit limits the Check the cable harness D793/J3 - S221 TRANSM,
ture (S221) short- transmission’s tempera- between control unit and menu 10
circuited to ground. ture measurement to the component.
highest value in its set- Check the sensor.
tings, which results in
poor temperature
compensation.
52/01 Sensor oil tempera- The control unit limits the Check the cable harness D793/J3 - S221 TRANSM,
ture (S221) open transmission’s tempera- between control unit and menu 10
circuit. ture measurement to the component.
highest value in its set- Check the sensor.
tings, which results in
poor temperature
compensation.
54/00 Reference voltage - Check the cable harness - CAN/
sensor 5 V short- between control unit and POWER,
circuiting to frame component. menu 12
ground. Check the sensor.
54/01 Reference voltage - Check the cable harness - CAN/
sensor 5 V open between control unit and POWER,
circuit. component. menu 12
Check the sensor.
60/00 Sensor rpm drum When only one rpm signal Check cable between D793/C3 - TRANSM,
(B752) short-circuited that is not the engine rpm control unit and B752 menu 6
to ground. signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.

Connections
Diagnostic
menu
components
Code
60/01 Sensor rpm drum When only one rpm signal Check cable between D793/C3 - TRANSM,
(B752) not connected. that is not the engine rpm control unit and B752 menu 6
signal is incorrect, the component.
missing rpm.
61/00 Sensor rpm output When only one rpm signal Check cable between D793/D3 - TRANSM,
shaft (B758) short- that is not the engine rpm control unit and B758 menu 6
circuited to ground. signal is incorrect, the component.
missing rpm.
61/01 Sensor rpm output When only one rpm signal Check cable between D793/D3 - TRANSM,
shaft (B758) not that is not the engine rpm control unit and B758 menu 6
connected. signal is incorrect, the component.
missing rpm.
62/00 Sensor engine rpm When only one rpm signal Check cable between D793/F3 - TRANSM,
(B758/766), short- that is not the engine rpm control unit and B758/766 menu 6
circuited to ground. signal is incorrect, the component.
missing rpm.

Connections
Diagnostic
menu
components
Code
62/01 Sensor engine rpm When only one rpm signal Check cable between D793/F3 - TRANSM,
(B758/766), not con- that is not the engine rpm control unit and B758/766 menu 6
nected or has open signal is incorrect, the component.
circuit. control unit calculates the Check component.
missing rpm.
63/00 Sensor rpm turbine When only one rpm signal Check cable between D793/R2 - TRANSM,
(B751) short-circuited that is not the engine rpm control unit and B751 menu 6
to ground. signal is incorrect, the component.
missing rpm.
63/01 Sensor rpm turbine When only one rpm signal Check cable between D793/R2 - TRANSM,
(B751) not connected. that is not the engine rpm control unit and B751 menu 6
signal is incorrect, the component.
missing rpm.
70/00 Solenoid valve VFS Transmission in Check the cable harness D793/B1 - TRANSM,
front (Y630), short- limp-home. between control unit and Y630, C1 - menu 8
circuited to each oth- component. Y630
er, signal cable short- Check the solenoid
circuited to voltage, or valve.
plus-cable short-
circuited to frame
ground.
forward (Y630) open limp-home. between control unit and Y630, C1 - menu 8
circuit or short- component. Y630
circuited voltage. Check the solenoid
valve.

Connections
Diagnostic
menu
components
Code
forward (Y630), con- limp-home. between control unit and Y630, C1 - menu 9
trol current higher than component. Y630
1400 mA. Check the solenoid
valve.
forward (Y630), con- limp-home. between control unit and Y630, C1 - menu 9
trol current outside ap- component. Y630
proved interval. Check the solenoid
Incorrect impedance. valve.
71/00 Solenoid valve VFS Transmission in Check the cable harness D793/D1 - TRANSM,
2/4 (Y6069), short- limp-home. between control unit and Y6069, E1 - menu 8
circuited to each oth- component. Y6069
er, signal cable short- Check the solenoid
circuited to voltage, or valve.
plus-cable short-
circuited to frame
ground.
2/4 (Y6069) open cir- limp-home. between control unit and Y6069, E1 - menu 8
cuit or short-circuited component. Y6069
voltage. Check the solenoid
valve.
2/4 (Y6069), control limp-home. between control unit and Y6069, E1 - menu 9
current higher than component. Y6069
valve.
2/4 (Y6069), control limp-home. between control unit and Y6069, E1 - menu 9
current outside ap- component. Y6069
proved interval (incor- Check the solenoid
rect impedance). valve.
72/00 Solenoid valve VFS Transmission in Check the cable harness D793/F1 - TRANSM,
reverse (Y631), ca- limp-home. between control unit and Y631, G1 - menu 8
bles short-circuited to component. Y631
each other, signal ca- Check the solenoid
ble short-circuited to valve.
voltage, or plus-cable
short-circuited to
frame ground.

Connections
Diagnostic
menu
components
Code
reverse (Y631) open limp-home. between control unit and Y631, G1 - menu 8
circuit or short- component. Y631
circuited voltage. Check the solenoid
valve.
reverse (Y631), con- limp-home. between control unit and Y631, G1 - menu 9
trol current higher than component. Y631
valve.
reverse (Y631), con- limp-home. between control unit and Y631, G1 - menu 9
trol current outside ap- component. Y631
proved interval Check the solenoid
(incorrect impedance). valve.
73/00 Solenoid valve VFS Transmission in Check the cable harness D793/H1 - TRANSM,
1/3 (Y6067), cables limp-home. between control unit and Y6067, J1 - menu 8
short-circuited to each component. Y6067
other, signal cable Check the solenoid
short-circuited to volt- valve.
age, or plus-cable
short-circuited to
frame ground.
1/3 (Y6067) open cir- limp-home. between control unit and Y6067, J1 - menu 8
cuit or short-circuited component. Y6067
voltage. Check the solenoid
valve.
1/3 (Y6067), control limp-home. between control unit and Y6067, J1 - menu 9
current higher than component. Y6067
valve.
1/3 (Y6067), control limp-home. between control unit and Y6067, J1 - menu 9
current outside ap- component. Y6067
proved interval (incor- Check the solenoid
rect impedance). valve.
77/02 All gear packs Transmission locked in - - -
disengaged. neutral (shutdown).

Connections
Diagnostic
menu
components
Code
80/00 Solenoid valve RSP Transmission locked in Check the cable harness D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). between control unit and Y6066 menu 7
short-circuited to component.
frame ground. Check the solenoid
valve.
80/01 Solenoid valve RSP Transmission locked in Check the cable harness D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). between control unit and Y6066 menu 7
is not connected or component.
short-circuited to Check the solenoid
voltage. valve.
81/00 Solenoid valve VFS Transmission in Check the cable harness D793/E2 - TRANSM,
2/4 (Y6074), cable limp-home. between control unit and Y6074 menu 7
valve.
81/01 Solenoid valve VSF Transmission in Check the cable harness D793/E2 - TRANSM,
2/4 (Y6074), cable is limp-home. between control unit and Y6074 menu 7
not connected or component.
short-circuited to volt- Check the solenoid
age. valve.
1/3 (Y6075), cable limp-home. between control unit and Y6075 menu 7
valve.
82/01 Solenoid valve VSF Transmission in Check the cable harness D793/F2 - TRANSM,
1/3 (Y6075), cable is limp-home. between control unit and Y6075 menu 7
not connected or component.
short-circuited to volt- Check the solenoid
age. valve.
83/00 Solenoid valve RSP Transmission locked in Check cabling to sole- D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). noid valve drive. Y6066 menu 7
short-circuited to Check solenoid valve
frame ground. drive.
83/01 Solenoid valve RSP Transmission locked in Check cabling to sole- D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). noid valve drive Y6066 menu 7
is not connected or Check solenoid valve
short-circuited to drive.
voltage.
90/xx - System error. Transmission locked in - D793/A:20 -
99/xx neutral (shutdown).

Connections
Diagnostic
menu
components
Code
95/71 Control unit cannot in- - -
terpret input data.
99/90 Incorrect software in - -
control unit
transmission.

D Error codes – 8 Control system 63
8 Control system
mm mm mm mm mm mm
Error codes machine

page
–
Code Description Limitation Action Connections Diagnostic Group

and menu
components
1 Communication er- – Use diagnostic menu to D797-1 CAN/POWER, 11.6.2 Redun-
ror with frame con- find incorrect segment. menu 1-3 dant CAN bus
trol unit (D797-1)
ror with frame con- find incorrect segment. menu 1-3 dant CAN bus
trol unit (D797-2).
ror with Control find incorrect segment. menu 1-3 dant CAN bus
unit, attachment
(D791-1).
8 Communication er- – Use diagnostic menu to D795 CAN/POWER, 11.6.2 Redun-
ror with Control unit find incorrect segment. menu 1-3 dant CAN bus
KID (D795).
11 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/POWER, 11.6.2 Redun-
network, find incorrect segment. ing on machine menu 1-3 dant CAN bus
segment 1. configuration.
network, find incorrect segment. ing on machine menu 2 and 3 dant CAN bus
19 Accelerator pedal 2 Accelerator Calibrate the accelera- D790-1/K6:12 – CALIBRA- 1. Engine
VBFS not pedal for tor pedal. See R690-2 TION: DRIVE-
calibrated rearward op- section 8 Control sys- TRAIN, menu 5
eration not tem, group 8.5.2.3 Cali- and 6
working. En- brate DRIVE-TRAIN.
gine speed
limited to
idling speed.

64 D Error codes – 8 Control system

and menu
components
20 Accelerator pedal Accelerator Calibrate the accelera- D790-1/K6:11 – CALIBRA- 1. Engine
not calibrated pedal for for- tor pedal. See R690-1 TION: DRIVE-
ward opera- section 8 Control sys- TRAIN, menu 1
tion not tem, group 8.5.2.3 Cali- and 2
working. En- brate DRIVE-TRAIN.
gine speed
limited to
idling speed.
21 Communication er- Gear selec- Use diagnostic menu to D790-1/K13:1 – CAN/POWER, 11.6.3 CAN bus
ror with transmis- tion not check communication. D793/M2 menu 4 drive-train
sion control unit working. Check the cable har- D790-1/K13:2 –
(D793) ness between Control D793/L2
unit, cab (D790-1) and
Control unit, transmis-
sion (D793).
22 Communication er- Engine does Use diagnostic menu to Volvo: D790-1/ CAN/POWER, 11.6.3 CAN bus
ror with Control not respond check communication. K13:1, K13:2 – menu 4 drive-train
unit, engine to commands Check the cable har- D794/2, 1
(D794). from the cab. ness between Control Cummins:
unit, cab (D790-1) and D790-1/K13:1,
Control unit, engine K13:2 – D794/
(D794). 46, 37
23 The set-up file can- No controls in Contact Cargotec. D790-1 – 11.5.3.1 Con-
not be read in Con- the cab are trol unit, cab
trol unit, cab working.
(D790-1).
24 Power supply to Cab fan not Check fuse F58-5/3 D790-1/K2:8 – – 9.4.3 Cabin fan
cab fan below working. 58-5/3:2
18 V.
25 Interference dur- Error code Switch the ignition off D794 ENGINE, 11.5.3.10 En-
ing software down- stored in and on. menu 8 gine control unit
26
load. Buffer for Control unit, Repeat software
27 error codes from engine download.
28 Control unit, en- (D794).
gine (D794), active
29
error code when
30 downloading.
31 Incorrect power Controls in Check fuse F58-5/1. D790-1/K1:2, CAN/POWER, 11.5.1.3 Igni-
supply to cab con- cab not Check cabling between K1:3, K1:4 – menu 7 tion voltage
trol unit (D790-1). working. the control unit and the F58-5/1:1, 1:2 (15)
Voltage under 18 V component with diag-
or over 32 V. nostic menu.
Check the control unit.


and menu
components
32 Incorrect 5 V refer- Analogue Check the wiring be- D790-1/K4:5, K CAN/POWER, 11.5.3.1 Con-
ence voltage to an- controls in tween the control unit 5:11, K5:13, menu 7 trol unit, cab
alogue cab cab not work- and component with the K7:2, K 9:7
controls. Voltage ing (mini- diagnostic menu.
under 4.9 V or over wheel/steer- Check component.
5.1 V. ing lever and
controls for
air
conditioning).
33 No feedback signal The emer- Check fuse F58-3/8. D790-1/K11:13 CAN/POWER, 11.5.1.4 Emer-
for emergency stop gency stop Check cabling between – K3009-1/87 menu 5 gency stop
switch voltage from switch cannot the control unit and the switch voltage
Relay, emergency be disen- component with diag- (15E)
stop switch voltage gaged. All hy- nostic menu.
(K3009-1). draulic
functions are
blocked.
34 Incorrect signal Parking Check cabling between D791-1/K8:5 – HYD, menu 5 4.5 Parking
from Switch, park- brake cannot the control unit and the S107/7 brake
ing brake (S107), be released. component with diag- D791-1/K8:13 –
indicates released nostic menu. S107/1
and applied at Check the switch.
same time or noth-
ing at all.
35 Interference dur- Error code Switch the ignition off D793 TRANSM, 11.5.3.9 Trans-
ing software down- stored in and on. menu 13 mission control
36
load. Buffer for Control unit, Repeat software unit
37 error codes from transmission download.
38 Control unit, trans- (D793).
mission (D793),
39
active error code
40 when downloading.
41 Transistor has Wiper rear Check cabling between D790-1/K2:4 – CAB, menu 3 9.5.7 Wiper
been triggered due not working. the control unit and the M650-2/53 motor rear
to short circuit or component with diag-
open circuit in cir- nostic menu.
cuit for rear wiper Check the motor.
motor (M650-2).
42 Transistor has Revolving Check cabling between D790-1/K2:5 – LIGHTS, 9.6.8 Revolving
been triggered due beacon not the control unit and the H428 menu 6 beacon
to short circuit or working. component with diag-
cuit for rotating Check the component.
beacon (H428).


and menu
components
43 Transistor has Left cab re- Check bulb. D790-1/K2:6 – LIGHTS, 9.6.5 Back-up
been triggered due versing light Check cabling between E405L menu 8 lights
to short circuit or not working. the control unit and the
open circuit in cir- component with diag-
cuit for left revers- nostic menu.
ing light (E405L).
44 Transistor has Right cab re- Check bulb. D790-1/K2:7 – LIGHTS, 9.6.5 Back-up
been triggered due versing light Check cabling between E405R menu 8 lights
to short circuit or not working. the control unit and the
cuit for right revers- nostic menu.
ing light (E405R).
45 Transistor has Wiper front Check cabling between D790-1/K2:1 – CAB, menu 2 9.5.5 Wiper
been triggered due not working. the control unit and the M650-1/53 motor front
cuit for front wiper Check the component.
motor (M650-1).
46 Transistor has Cab fan not Check cabling between D790-1/K2:2 – CLIMATE, 9.4.3 Cabin fan
been triggered due working. the control unit and the M657/2 menu 6
cuit for fan motor Check the motor.
(M657).
47 Transistor has Recirculation Check cabling between D790-1/K2:3 – CLIMATE, 9.4.2 Fresh air
been triggered due damper to the control unit and the M612/3 menu 6 filter and recir-
to short circuit or ventilation component with diag- culation
open circuit in cir- not working. nostic menu. damper
cuit for recircula- Check the motor.
tion actuating
motor (M612).
48 Transistor has Heat in cab Check cabling between D790-1/K4:1 – CLIMATE, 9.4.5 Water
been triggered due cannot be the control unit and the Y673/5 menu 7 valve
to short circuit or adjusted. component with diag-
cuit for water valve Check the motor.
(Y673).
49 Transistor has Heat in cab Check cabling between D790-1/K4:2 – CLIMATE, 9.4.5 Water
been triggered due cannot be the control unit and the Y673/6 menu 7 valve
to short circuit or adjusted. component with diag-
cuit for water valve Check the motor.
(Y673).


and menu
components
50 Transistor has Air distribu- Check cabling between D790-1/K4:3 – CLIMATE, 9.4.14 Air
been triggered due tion in cab the control unit and the Y672/5 menu 8 distributor
to short circuit or cannot be component with diag-
open circuit in cir- adjusted. nostic menu.
cuit for actuating Check the motor.
motor (Y672).
51 Transistor has Air distribu- Check cabling between D790-1/K4:4 – CLIMATE, 9.4.14 Air
been triggered due tion in cab the control unit and the Y672/6 menu 8 distributor
to short circuit or cannot be component with diag-
open circuit in cir- adjusted. nostic menu.
cuit for actuating Check the motor.
motor (Y672).
52 Transistor has Bypass of ex- Check component. D790-1/K5:3 – - -
been triggered due ternal top lift Check the wiring.
to short circuit or attachment
open circuit in cir- not working.
cuit for bypass of
external top lift at-
tachment.
53 Transistor has Windscreen Check cabling between D790-1/K5:4 – CAB, menu 1 9.5.4 Washer
been triggered due washer rear the control unit and the M651-2 motor and
to short circuit or and roof not component with diag- reservoir
open circuit in cir- working. nostic menu.
cuit for roof and Check the motor.
rear washer motor
(M651-2).
54 Transistor has Flashing haz- Check cabling between D790-1/K5:5 – LIGHTS, 9.6.7 Flashing
been triggered due ard lights not the control unit and the S109/ menu 7 hazard lights
cuit for flashing Check the switch.
hazard light switch
(S109).
55 Transistor has Reduced or Check bulbs for back- D7901/K6:1, K LIGHTS, 9.1 Controls
been triggered due no background lighting, replace 8:15, K 9:2, all menu 14 and
to short circuit or ground light- if necessary. inputs of type A instruments
open circuit in cir- ing in Check the cable har- Digital in
cuit for background instruments ness for background
lighting in switches and controls. lighting.
and instruments.
56 Transistor has Work lights Check cabling between D790-1/ K7:8 – LIGHTS, 9.6.10 Working
been triggered due 20’ not the control unit and the R3017-2/86 menu 12 lights, cab
cuit for relay for 20’ Check the component.
working lights.


and menu
components
57 Transistor has Indicator light Check cabling between D790-1/ K7:9 – - 7.1.1 Control
been triggered due for levelling the control unit and the S815/7 levers/Joystick
to short circuit or lock in joy- component with diag-
open circuit in cir- stick not nostic menu.
cuit for indicator working. Check the component.
light for levelling
lock in joystick
(S815).
58 Transistor has Twistlock on Check cabling between D790-1/ K7:10 – EXT-ATTACH, 7.9.2
been triggered due external top the control unit and the K3005/86 menu 6 Twist-locks
to short circuit or lift attach- component with diag-
open circuit in cir- ment does nostic menu.
cuit for relay for not work. Check the component.
twistlock on exter-
nal top lift attach-
ment (K3005).
59 Transistor has Spreading on Check cabling between D790-1/ K7:11 – EXT-ATTACH, 7.10.5.1
been triggered due external top the control unit and the K3006/86 menu 6 Spreading
to short circuit or lift attach- component with diag-
open circuit in cir- ment does nostic menu.
cuit for relay for not work. Check the component.
spreading on exter-
nal top lift attach-
ment (K3006).
60 Transistor has Seat heating Check cabling between D790-1/ K10:7 – CAB, menu 8 9.3.3 Heating
been triggered due does not the control unit and the K383/86 coil
to short circuit or work. component with diag-
cuit for relay for Check the component.
heating element in
driver’s seat
(K383).
61 Transistor has Work lights Check cabling between D790-1/ K10:8 – LIGHTS, 9.6.10 Working
been triggered due 40’ not the control unit and the K3017-1/86 menu 12 lights, cab
cuit for relay for 40’ Check the component.
working lights
(K3017-1).
63 Transistor has No ignition Check cabling between D790-1/K10:10 CAN/POWER, 11.5.1.3 Igni-
been triggered due voltage to the the control unit and the – K315-1/86 menu 5 tion voltage
to short circuit or machine’s component with diag- (15)
open circuit in cir- Control units. nostic menu.
cuit for relay for ig- Check the component.
nition voltage
(K315-1).


and menu
components
64 The transistor has No emergen- Check cabling between D790-1/K10:11 CAN/POWER, 11.5.1.4 Emer-
been triggered due cy stop the control unit and the – K3009-1/86 menu 6 gency stop
to short circuit or switch volt- component with diag- switch voltage
open circuit in cir- age to the nostic menu.
cuit for Relay, machine’s Check the component.
emergency stop Control units.
switch voltage
(K3009-1).
65 The transistor has No emergen- Check cabling between D790-1/K10:12 CAN/POWER, 11.5.1.4 Emer-
been triggered due cy stop the control unit and the – K3009-2/86 menu 6 gency stop
to short circuit or switch volt- component with diag- switch voltage
open circuit in cir- age to the nostic menu.
cuit for Relay, machine’s Check the component.
emergency stop Control units.
switch voltage
(K3009-2).
66 Transistor has Windshield Check cabling between D790-1/K10:13 CAB, menu 1 9.5.4 Washer
been triggered due washer not the control unit and the – M651-1, motor and
to short circuit or working. component with diag- M651-2 reservoir
cuit for windscreen Check the component.
washer motor
(M651-1, M651-2).
67 Transistor has Wiper roof Check cabling between D790-1/K10:14 CAB, menu 4 9.5.6 Wiper
been triggered due not working. the control unit and the – M650-3 motor roof
cuit for roof wiper Check the motor.
motor (M650-3).
68 Transistor has Pause heater Check cabling between D790-1/K10:15 - 9.4 Heating,
been triggered due not working. the control unit and the – M667 ventilation and
to short circuit or component with diag- air conditioning
cuit for circulation Check the motor.
pump, pause heat-
er (M667).
69 Transistor has No voltage Check cabling between D790-1/K10:16 - 11.5.1.3 Igni-
been triggered due feed to en- the control unit and the – K315-2/86 tion voltage
to short circuit or gine and component with diag- (15)
open circuit in cir- transmission. nostic menu.
cuit for relay for Check the component.
drivetrain ignition
voltage (K315-2).


and menu
components
71 Transistor has Interior light- Check bulb. D790-1/K11:6 – LIGHTS, 9.6.11 Interior
been triggered due ing in cab not Check cabling between E434-1 menu 9 lighting cab
to short circuit or working. the control unit and the
cuit for cab interior nostic menu.
lighting (E434-1).
75 Relay ignition volt- The cab con- Check cabling between - CAN/POWER, 11.5.1.3 Igni-
age (K315-1) has trol unit the control unit and the menu 5 tion voltage
jammed in position (D790-1) still component with diag-
on. has a power nostic menu.
supply and is Check the component.
thereby
active.
80 No signal from Air condition- Check the drive belt for D797-1/K1:40 – CLIMATE, 9.4.10 Pres-
Pressure switch, ing not the compressor for air S246 menu 3 sure switch
air conditioning working. conditioning.
(S246), despite the Check that compressor
AC compressor be- for air conditioning is
ing activated. activated.
Check cabling between
the control unit and the
component with diag-
nostic menu.
81 Faulty signal from Air distribu- Check cabling between D790-1/K4:7 – CLIMATE, 9.4.6 Fresh air
actuating motor tion cannot the control unit and the Y672/9 menu 4 and recircula-
(Y672). Signal volt- be adjusted. component with diag- tion damper
age under 0.2 V or nostic menu.
over 4.8 V. Check the motor.
85 Faulty signal from Accelerator Check cabling between D790-1/K6:11 – ENGINE, 1 Engine
accelerator pedal pedal for for- the control unit and the B690-1/2 menu 1
(B690-1). Signal ward opera- component with diag-
voltage under 0.2 V tion not nostic menu.
or over 4.8 V. working. En- Check the component.
gine speed
limited to
idling speed.
86 Faulty signal from Accelerator Check the wiring be- D790-1/K6:12 – VBFS, menu 4 1 Engine
auxiliary accelera- pedal for tween the control unit B690-2/2
tor pedal (B690-2). rearward op- and component with the
Signal voltage un- eration not diagnostic menu.
der 0.2 V or over working. En- Check component.
4.8 V. gine speed
limited to
idling speed.


and menu
components
87 Faulty signal from Lift and lower Check cabling between D790-1/K7:3 – ELSERV, 7.1.1 Control
lifting/lower control not working. the control unit and the R8071/3 menu 1 (P1) lever
lever (R8071). Sig- component with diag-
nal voltage under nostic menu.
0.2 V or over 4.8 V. Check the lever.
88 Faulty signal from Tilt not Check cabling between D790-1/K7:4 – ELSERV, 7.1.1 Control
tilt control lever working. the control unit and the R8072/3 menu 1 (P2) lever
(R8072). Signal component with diag-
voltage under 0.2 V nostic menu.
or over 4.8 V. Check the lever.
89 Faulty signal from Side shift not Check cabling between D790-1/K7:5 – ELSERV, 7.1.1 Control
side shift control le- working. the control unit and the R8073/3 menu 1 (P3) lever
ver (R8073). Signal component with diag-
voltage under 0.2 V nostic menu.
or over 4.8 V. Check the lever.
90 DCF370-500/ Spreading Check cabling between D790-1/K7:6 – ELSERV, 7.1.1 Control
DCF80-100 not working. the control unit and the R8074/3 menu 2 (P4) lever
Faulty signal from component with diag-
spreading control nostic menu.
lever (R8074). Sig- Check the lever.
nal voltage under
0.2 V or over 4.8 V.
DCF360-450CSG Extension left
Faulty signal from not working.
control lever for ex-
tension left
(R8074). Signal
voltage under 0.2 V
or over 4.8 V.
91 DCF370-500/ Extra load Check the wiring be- D790-1/K7:7 – ELSERV, 7.1.1 Control
DCF80-100 handling tween the control unit R8075-1/3 menu 2 (P5) lever
Faulty signal from function not and component with the
auxiliary function working. diagnostic menu.
control lever Check component.
(R8075-1). Signal
voltage under 0.2 V
or over 4.8 V.
DCF360-450CSG Levelling not
Faulty signal from working.
levelling control le-
ver (R8075-1). Sig-
nal voltage under
0.2 V or over 4.8 V.


and menu
components
92 Faulty signal from Joystick con- Check cabling between D790-1/K9:8 – EL-STEER- 5.1.2 Mini-
steering lever trol or mini- the control unit and the R825-1/H1 ING, menu 1 wheel
(R825-1) or mini- wheel not component with diag- 5.1.3 Joystick
wheel (R825-1). working. nostic menu.
Signal voltage un- Check the switch.
der 0.2 V or over
4.8 V.
93 Faulty signal from Joystick con- Check cabling between D790-1/K9:9 – EL-STEER- 5.1.2 Mini-
mini-wheel trol or mini- the control unit and the R825-2/H2 ING, menu 1 wheel
(R825-2). Signal wheel not component with diag-
voltage under 0.2 V working. nostic menu.
or over 4.8 V. Check the switch.
94 Faulty signal from Cab heat Check cabling between D790-1/K10:4 – CLIMATE, 9.4.5 Water
cab heater water cannot be the control unit and the Y673/9 menu 4 valve
valve (Y673). Sig- adjusted. component with diag-
nal voltage under nostic menu.
0.2 V or over 4.8 V. Check the motor.
95 DCF370-500/ Extra load Check cabling between D790-1/K9:9 – ELSERV, 7.1.1 Control
DCF80-100 handling the control unit and the R8075-2/3 menu 2 (P7) lever
Faulty signal from function not component with diag-
auxiliary function working. nostic menu.
control lever Check the lever.
(R8075-2). Signal
voltage under 0.2 V
or over 4.8 V.
DCF360-450CSG Extension
Faulty signal from right not
control lever for ex- working.
tension right
(R8075-2). Signal
voltage under 0.2 V
or over 4.8 V.
96 Faulty signal from Air condition- Check cabling between D790-1/K4:8 – CLIMATE, 9.4.17 Sensor
cab temperature ing not the control unit and the B775-1/2 menu 1 cab
sensor (B775-1) working. component with diag- temperature
Sensor indicates nostic menu.
temperature under Check the sensor.
-43 C or over
105 C.
97 Faulty signal from Air condition- Check cabling between D790-1/K4:9 – CLIMATE, 9.4.18 Sensor,
outdoor tempera- ing not the control unit and the B774/2 menu 2 ambient
ture sensor (B774). working. component with diag- temperature
Temperature sig- nostic menu.
nal over 105 C. Check the sensor.


and menu
components
98 Faulty signal from Air condition- Check cabling between D790-1/K4:10 – CLIMATE, 9.4.16 Sensor,
outlet fan tempera- ing not the control unit and the B775-2/2 menu 2 temperature
ture sensor working. component with diag- outlet fan
(B775-2) Sensor nostic menu.
indicates tempera- Check the sensor.
ture under -43 C
or over 105 C.
99 Faulty signal from Air condition- Check cabling between D790-1/K4:11 – CLIMATE, 9.4.12 Sensor
refrigerant temper- ing not the control unit and the B775-3/2 menu 2 temperature
ature sensor working. component with diag- refrigerant
(B775-3) Sensor nostic menu.
indicates tempera- Check the sensor.
ture under -43 C
or over 105 C.
101 Redundant volt- – Check cabling between D797-1/K2:7 CAN/POWER, 11.5.1.2 Re-
age feed left to the control unit and the menu 10 dundant volt-
frame control unit component with diag- age feed of
(D797-1) does not nostic menu. control units
reach destination. Check the control unit.
age feed right to the control unit and the menu 10 dundant volt-
(D797-1) does not nostic menu. control units
103 Incorrect power No electric Check fuse F58-2/1, re- D797-1/K2:1, CAN/POWER, 11.5.1.3 Igni-
supply to frame power feed to place if necessary. K2:9, K2:10 – menu 10 tion voltage
control unit components. Check cabling between F58-2/1:1, 1:2 (15)
(D797-1). Voltage the control unit and the
under 18 V or over component with diag-
32 V. nostic menu.
104 Incorrect emergen- Functions Check fuse F58-2:1 and D797-1/K2:11 – CAN/POWER, 11.5.1.4 Emer-
cy stop switch volt- normally sup- replace if necessary. F58-2/1:1 menu 10 gency stop
age to frame plied emer- Check the wiring be- switch voltage
control unit gency stop tween the control unit
(D797-1) switch volt- and component with the
age have no diagnostic menu.
feed. All hy-
Check component.
draulic func-
tions
blocked.
105 Incorrect 5 V refer- Incorrect Check cabling between D797-1/K1:8 – CAN/POWER, 8.2.1 Overload
ence voltage to function, lift the control unit and the B768-1/1, menu 11 protection
pressure sensor. and tilt component with diag- B768-2/1
Voltage under sensor nostic menu.
4.9 V or over 5.1 V. Check the sensor.


and menu
components
106 Transistor has Cooling fan Check cabling between D797-1/K1:14 – HYD, menu 1 10.6.3 Cooling
been triggered due hydraulic oil the control unit and the M668/1 fan
to short circuit or not working. component with diag-
cuit for hydraulic oil Check the motor.
cooling fan (M668).
107 Transistor has Mast work Check bulb. D797-1/K1:1 – LIGHTS, 9.6.9 Working
been triggered due lights not Check the bulb holder. E404L-1, menu 10 lights mast
to short circuit or working. E404R-1
open circuit in cir-
cuit for mast work
lights (E404R-1,
nostic menu.
E404L-1).
108 Transistor has High beam Check bulb. D797-1/K1:15 – LIGHTS, 9.6.1
been triggered due not working. Check the bulb holder. E402L-1, menu 3 Head-lights
to short circuit or E402R-1
open circuit in cir- Check cabling between
cuit for high beam
(E402R-1,
E402L-1). nostic menu.
109 Transistor has Low beams Check bulb. D797-1/K1:28 – LIGHTS, 9.6.1
been triggered due not working. Check the bulb holder. E400L, E400R menu 3 Head-lights
to short circuit or
cuit for low beam
(E400L, E400R).
nostic menu.
111 Transistor has Running Check bulb. D797-1/K1:2 – LIGHTS, 9.6.2 Running
been triggered due lights not Check the bulb holder. H416-1, menu 2 lights
to short circuit or working. H416-2,
open circuit in cir- H417-1, H417-2
cuit for running
lights (H416-1,
nostic menu.
H416-2, H417-1,
H417-2).
112 Transistor has Cooling fan Check cabling between D797-1/K1:3 – HYD, menu 2 4.8.9 Cooling
been triggered due brake oil not the control unit and the M674/1 fan
cuit for brake oil Check the motor.
cooling fan (M674).


and menu
components
113 Electric servo Lift and lower Check cabling between D797-1/K1:4 – ELSERV, DCF370-500:
Transistor has not working. the control unit and the Y6004/1, menu 3 and 4 7.2.6 Control
been triggered due component with diag- Y6005/1 valve, load
to short circuit or nostic menu. handling
open circuit in cir- Check the solenoid DCF360-
cuit for solenoid valves. 450CSG:
valve, lift mast 7.2.5 Control
(Y6005) and sole- valve, lift and tilt
noid valve, lower
mast (Y6004)
Hydraulic servo, Mast lifting/ Check cabling between D797-1/K1:4 – FREELIFT, 7.2.5 Shuttle
freelift lowering not the control unit and the Y6004-1/1 menu 2 valve, freelift
Transistor has working. component with diag- Y6005-1/1
been triggered due nostic menu.
to short circuit or Check the solenoid
open circuit in cir- valves.
cuit for solenoid
valve, lift mast
(Y6005-1) and so-
lenoid valve, lower
mast (Y6004-1).
Hydraulic servo Mast lifting/ Check cabling between D797-1/K1:4 – OLS, menu 5 7.10.5 Sepa-
Transistor has lowering not the control unit and the Y6045/1, and 6 rate top lift mast
been triggered due working. component with diag- Y6076/1
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valves.
valve, stop mast lift
(Y6045) and sole-
noid, stop mast
lower (Y6076).


and menu
components
114 Electric servo Tilt not Check cabling between D797-1/K1:5 – ELSERV, DCF370-500:
Transistor has working. the control unit and the Y6010/1, menu 5 and 6 7.7.5 Control
been triggered due component with diag- Y6011/1 valve, load
to short circuit or nostic menu. handling
open circuit in cir- Check the solenoid DCF360-
cuit for solenoid valve. 450CSG:
valve, tilt in 7.7.5 Control
(Y6011) and sole- valve, lift and tilt
noid valve, tilt out
(Y6010)
Hydraulic servo Carriage Check cabling between D797-1/K1:5 – FREELIFT, 7.2.5 Shuttle
Transistor has freelift not the control unit and the Y6004-2/1 menu 2 valve, freelift
been triggered due working. component with diag- Y6005-2/1
cuit for solenoid valve.
valve, lift carriage
(Y6005-2) and so-
lenoid valve, lower
carriage
(Y6004-2).
115 Transistor has Left direction Check bulb. D797-1/K1:30 – LIGHTS, 9.6.6 Direction
been triggered due indicator not Check the bulb holder. H422/1, H426/1 menu 4 indicators
to short circuit or working.
cuit for left direction
indicator (H422,
nostic menu.
H426).
116 Transistor has Right direc- Check bulb. D797-1/K1:31 – LIGHTS, 9.6.6 Direction
been triggered due tion indicator Check the bulb holder. H423/1, H427/1 menu 4 indicators
to short circuit or not working.
cuit for right direc- the control unit and the
tion indicator component with diag-
(H423, H427). nostic menu.
117 Transistor has Starter motor Check cabling between D797-1/K1:32 – ENGINE, 1.11 Start and
been triggered due not working. the control unit and the K315/85 menu 5 stop
cuit for start relay Check the component.
(K315) for starter
motor.


and menu
components
118 Transistor has Tail lights not Check bulb. D797-1/K1:33 – LIGHTS, 9.6.3 Tail lights
been triggered due working. Check the bulb holder. H412L/1, menu 2
to short circuit or H412R/1
cuit for tail light
(H412L, H412R).
nostic menu.
119 Transistor has Brake light Check bulb. D797-1/K1:7 – LIGHTS, 9.6.4 Brake
been triggered due left not Check the bulb holder. H411L/1 menu 8 light
cuit for left brake
light (H411L).
nostic menu.
120 Transistor has Brake light Check bulb. D797-1/K1:9 – LIGHTS, 9.6.4 Brake
been triggered due right not Check the bulb holder. H411R/1 menu 8 light
cuit for right brake the control unit and the
light (H411R). component with diag-
nostic menu.
121 The transistor has Back-up Check cabling between D797-1/K1:10 – LIGHTS, 9.7.5 Back-up
been triggered due alarm not the control unit and the H965/1 menu 8 alarm
cuit for Back-up Check the component.
warning device
(H965).
122 Transistor has Air condition- Check cabling between D797-1/K1:25 – CLIMATE, 9.4.7
been triggered due ing not the control unit and the M645/1 menu 6 Compressor
123 to short circuit or working. component with diag- D797-1/K1:29 –
open circuit in cir- nostic menu. M645/1
cuit for electromag- Check the component.
netic clutch of AC
compressor
(M645).
NOTE! Error code
122 and 123 apply
to the same user.
124 Transistor has Disconnec- Check cabling between D797-1/K1:34 – HYD, menu 6 10.4.3 Vane
been triggered due tion of the control unit and the Y6062/1 pump with fixed
to short circuit or pump 2 not component with diag- displacement
cuit for solenoid Check the solenoid
valve, hydraulic valve.
pump disengage-
ment (Y6062).


and menu
components
125 Transistor has Regenera- Check cabling between D797-1/K1:11 – ELSERV, 7.2.6 Valve
been triggered due tion not the control unit and the Y6051/1 menu 15 block lift
to short circuit or working. component with diag- cylinder
cuit for solenoid Check component.
valve regeneration,
lift, right (Y6051).
126 Transistor has Regenera- Check cabling between D797-1/K1:12 – ELSERV, 7.2.6 Valve
been triggered due tion not the control unit and the Y6052/1 menu 15 block lift
to short circuit or working. component with diag- cylinder
cuit for solenoid Check component.
valve regeneration,
lift, left (Y6052).
132 Vehicle Data file Some func- - - - -
missing. tions in ma-
chine not
working.
133 Faulty signal from Scales, re- Check the sensor. D797-1/K1:21 – HYD, menu 3 7.2.8 Sensor
hydraulic pressure generation Check cabling between B768-1/3 OLS, menu 1 hydraulic pres-
sensor for lift cylin- and slack the control unit and the sure lift cylinder
der (B768-1). chain logic, component with diag-
not working. nostic menu.
Overload
system not
working. Er-
ror code 150
activated.
134 Faulty signal from Overload Check the sensor. D797-1/K1:22 – HYD, menu 3 7.7.8 Hydraulic
hydraulic pressure system not Check cabling between B768-2/3 OLS, menu 1 pressure sen-
sensor for tilt cylin- working. Er- the control unit and the sor, tilt cylinder
der (B768-2). ror code 150 component with diag-
activated. nostic menu.
135 No feedback signal - Check that cooling fan is D797-1/K2:6 – HYD, menu 2 4.8.9 Cooling
from brake oil cool- working. M674/2 fan
ing fan (M674). Check cabling between
nostic menu.


and menu
components
137 Electric servo Lift mast not Check cabling between D797-1/K1:16 – ELSERV, DCF370-500:
Faulty signal from working. the control unit and the Y6005/2 menu 3 7.7.5 Control
solenoid valve for component with diag- valve, load
lift mast (Y6005). nostic menu. handling
Return current Check the solenoid DCF360-
does not match valve. 450CSG: 7.7.5
control current. Control valve,
lift and tilt
Hydraulic servo, Lift mast not Check cabling between D797-1/K1:16 – FREELIFT, 7.2.5 Shuttle
freelift working. the control unit and the Y6005-1/2 menu 2 valve, freelift
solenoid valve for nostic menu.
lift mast (Y6005-1). Check the solenoid
Return current valve.
does not match
control current.
Hydraulic servo Lift mast not Check cabling between D797-1/K1:16 – OLS, menu 5 7.10.5 Sepa-
Faulty signal from working. the control unit and the Y6045/2 rate top lift
solenoid valve for component with diag- attachment
interrupt mast lift nostic menu.
(Y6045). Return Check the solenoid
current does not valve.
match control
current.


and menu
components
138 Electric servo Lower mast Check cabling between D797-1/K1:17 – ELSERV, DCF370-500:
Faulty signal from not working. the control unit and the Y6004/2 menu 4 7.7.5 Control
lower mast nostic menu. handling
(Y6004). Return Check the solenoid DCF360-
current does not valve. 450CSG:
match control 7.7.5 Control
current. valve, lift and tilt
Hydraulic servo, Lower mast Check cabling between D797-1/K1:17 – FREELIFT, 7.2.5 Shuttle
freelift not working. the control unit and the Y6004-1/2 menu 2 valve, freelift
solenoid valve for nostic menu.
lower mast Check the solenoid
(Y6004-1). Return valve.
current does not
match control
current.
Hydraulic servo Lower mast Check cabling between D797-1/K1:17 – OLS, menu 6 7.10.5 Sepa-
Faulty signal from not working. the control unit and the Y6076/2 rate top lift
solenoid valve for component with diag- attachment
interrupt mast low- nostic menu.
ering (Y6076). Re- Check the solenoid
turn current does valve.
not match control
current.
139 Electric servo Tilt in not Check cabling between D797-1/K1:18 – ELSERV, DCF370-500:
tilt in (Y6011). Re- nostic menu. handling
turn current does Check the solenoid DCF360-
not match control valve. 450CSG:
current. 7.7.5 Control
valve, lift and tilt
Hydraulic servo Lift not Check cabling between D797-1/K1:18 – FREELIFT, 7.2.5 Shuttle
Faulty signal from working. the control unit and the Y6005-2/2 menu 2 valve, freelift
solenoid valve for component with diag-
lift carriage nostic menu.
(Y6005-2). Return Check the solenoid
match control
current.


and menu
components
140 Electric servo Tilt out not Check cabling between D797-1/K1:19 – ELSERV, DCF370-500:
tilt out (Y6010). Re- nostic menu. handling
turn current does Check the solenoid DCF360-
not match control valve. 450CSG:
current. 7.7.5 Control
valve, lift and tilt
Hydraulic servo Lower not Check cabling between D797-1/K1:19 – FREELIFT, 7.2.5 Shuttle
Faulty signal from working. the control unit and the Y6004-2/2 menu 2 valve, freelift
solenoid valve for component with diag-
lower carriage nostic menu.
(Y6004-2). Return Check the solenoid
match control
current.
141 Transistor has Parking Check cabling between D797-1/K1:34 – HYD, menu 5 4.5.3 Solenoid
been triggered due brake cannot the control unit and the Y642/1 valve parking
to short circuit or be released. component with diag- brake
cuit for parking Check the solenoid
brake solenoid valve.
valve (Y642).


and menu
components
142 DCF370-500 Tilt not Check cabling between D797-1/K1:35 – OLS, menu 7 7.10.5 Sepa-
Transistor has working. the control unit and the Y6012/1 rate top lift
been triggered due component with diag- attachment
valve, stop tilt
(Y6012)
DCF360-450CSG Disconnec- Check cabling between D797-1/K1:35 – HYD, menu 6 10.4.2 Axial
Transistor has tion of attach- the control unit and the Y6062/1 piston pump
been triggered due ment pump component with diag- with variable
to short circuit or not working. nostic menu. displacement
valve, hydraulic
pump disengage-
ment (Y6062).
DCF80-100 Quick-lift Check cabling between D797-1/K1:35 – HYD, menu 6 10.4.2 Axial
Transistor has pump en- the control unit and the Y6062/1 piston pump
been triggered due gagement component with diag- with variable
to short circuit or not working. nostic menu. displacement
valve, hydraulic
pump disengage-
ment (Y6062).
143 Transistor has Spreading Check cabling between D797-1/K1:36 – EXT-ATTACH, 7.10.5 Sepa-
been triggered due and twist- the control unit and the Y6039/6018/1 menu 5 rate top lift
to short circuit or locks on top component with diag- attachment
open circuit in cir- lift attach- nostic menu.
cuit for solenoid ment not Check the solenoid
valve, lock twist- working. valve.
locks/spreading
out (Y6039/6018).
144 Transistor has Spreading Check cabling between D797-1/K1:37 – EXT-ATTACH, 7.10.5 Sepa-
been triggered due and twist- the control unit and the Y6040/6019/1 menu 5 rate top lift
to short circuit or locks on top component with diag- attachment
open circuit in cir- lift attach- nostic menu.
cuit for solenoid ment not Check the solenoid
valve, open twist- working. valve.
locks/spreading in
(Y6040/6019).


and menu
components
145 High brake oil Reduced Check that cooling fan is D797-1/K2:6 – HYD, menu 2 4.8.10 Sensor
temperature. braking ca- working. B772/1 brake oil
pacity. If the Check that the radiator temperature
temperature is not clogged.
continues to
Check the brake oil
rise, speed is
limited to level.
5 km/h. Check the sensor.
146 Faulty signal from Speed limited Check the sensor. D797-1/K2:6 – HYD, menu 2 4.8.10 Sensor
brake oil tempera- to 5 km/h. Check cabling between B772/1 brake oil
ture sensor (B772). the control unit and the temperature
Signal voltage un- component with diag-
der 0.2 V or over nostic menu.
4.8 V.
147 High temperature No limitation. Check that cooling fan is D797-1/K2:13 – HYD, menu 1 10.6.4 Sensor
hydraulic oil. working. B776/1 hydraulic oil
Check that the radiator temperature
is not clogged.
Check the sensor.
148 Faulty signal from Incorrect Check the sensor. D797-1/K2:13 – HYD, menu 1 10.6.4 Sensor
hydraulic oil tem- temperature Check cabling between B776/1 hydraulic oil
perature sensor display. the control unit and the temperature
(B776). component with diag-
nostic menu.
149 Faulty signal from Incorrect dis- Check the sensor. D797-1/K2:15 – CAB, menu 7 1.2.2 Sensor
fuel level sensor play of fuel Check cabling between B757/1 fuel level
(B757). Resistance volume the control unit and the
over 180 . (empty or component with diag-
full). nostic menu.
150 Defective overload Overload Check if there are error – OLS, menu 8.2.1 Overload
protection. system not codes for sensors in the 1-7 protection
This error code working. All overload system.
cannot be removed lift functions
with Reset. operate at re-
duced speed.
option (D797-2) nostic menu. Control units
does not reach Check the control unit.
destination.


and menu
components
option (D797-2) nostic menu. Control units
does not reach Check the control unit.
destination.
153 Incorrect power No electric Check fuse F58-2/3, D797-2/K2: CAN/POWER, 11.5.1.3 Igni-
supply to frame power feed to change if needed. 1/9/10 menu 13 tion voltage
control unit option components. Check cabling between D797-2/K2:1, (15)
(D797-2). Voltage the control unit and the K2:9, K2:10 –
under 18 V or over component with diag- F58-2/3:1, 3:2
32 V. nostic menu.
154 Incorrect control Functions Check fuse F58-3/5; re- D797-F/K2:11 – CAN/POWER, 11.5.1.4 Emer-
switch voltage to normally sup- place if needed. F58-3/5:1 menu 13 gency stop
frame control unit, plied emer- Check cabling between switch voltage
option (D797-2). gency stop the control unit and the
switch volt- component with diag-
age have no nostic menu.
feed. All hy-
draulic func-
tions
blocked.
155 Incorrect 5 V refer- – Check cabling between D797-2/K1:8 CAN/POWER, 11.5.1 Power
ence voltage to the control unit and the menu 14 supply
pressure sensor. component with diag-
Voltage under nostic menu.
157 Transistor has Rear high Check bulb. D797-2/K1:1 – VBFS, menu 6 9.6.1
been triggered due beam not Check the bulb holder. E402R-2/1, Head-lights
to short circuit or working. E402L-2/1
cuit for rear high
beam (E402R-2,
nostic menu.
E402L-2).
158 Transistor has Rear low Check bulb. D797-2/K1:15 – VBFS, menu 6 9.6.1
been triggered due beam not Check the bulb holder. E401R/1, Head-lights
to short circuit or working. E401L/1
cuit for rear low
beam (E401R,
nostic menu.
E401L).


and menu
components
160 Transistor has Auxiliary Check the lights. Check D797-2/K1:42 – LIGHTS, 9.6.9 Working
been triggered due work lights, the wiring between the E404R-2/1, menu 11 lights mast
to short circuit or frame front, control unit and compo- E404L-2/1 9.6.10 Working
open circuit in cir- not working. nent with the diagnostic lights, cab
cuit for auxiliary menu.
9.6.12 Work
work lights Check component.
(E404R-2, lights,
attachment
E404L-2).
161 Transistor has Joystick con- Check cabling between D797-2/K1:2 – EL-STEER- 5.2.10 Control
been triggered due trol or mini- the control unit and the Y636-3/1 ING, menu 5 valve joystick
to short circuit or wheel not component with diag- steering/
open circuit in cir- working. nostic menu. mini-wheel
valve, steering valve.
right (Y636-3).
162 Transistor has Joystick con- Check cabling between D797-2/K1:3 – EL-STEER- 5.2.10 Control
been triggered due trol or mini- the control unit and the Y636-4 /1 ING, menu 4 valve joystick
to short circuit or wheel not component with diag- steering/
open circuit in cir- working. nostic menu. mini-wheel
valve, steering valve.
right (Y636-4).
163 Transistor has Lift carriage Check cabling between D797-2/K1:4 – ELSERV, 7.2.6 Control
been triggered due not working. the control unit and the Y6022/1 menu 11 valve load
to short circuit or component with diag- handling
valve, lift carriage valve.
(Y6022).
164 Transistor has Lower car- Check cabling between D797-2/K1:5 – ELSERV, 7.2.6 Control
been triggered due riage not the control unit and the Y6023/1 menu 12 valve load
to short circuit or working. component with diag- handling
valve, lower car- valve.
riage (Y6023).
165 Transistor has Side shift Check cabling between D797-2/K1:30 – ELSERV, 7.4.5 Control
been triggered due right not the control unit and the Y6021/1 menu 8 valve load
valve, side shift valve.
right (Y6021).


and menu
components
166 Transistor has Side shift left Check cabling between D797-2/K1:31 – ELSERV, 7.4.5 Control
valve, side shift left valve.
(Y6020).
167 Transistor has Spreading in Check cabling between D797-2/K1:32 – ELSERV, 7.5.5 Control
valve, spreading in valve.
(Y6019).
168 Transistor has Spreading Check cabling between D797-2/K1:33 – ELSERV, 7.5.5 Control
been triggered due out not the control unit and the Y6018/1 menu 10 valve load
valve, spreading valve.
out (Y6018).
169 Reversible opera- Driver’s seat Check cabling between D797-2/K1:7 – CAN/POWER, 9.3.9.2 Sensor
tor's seat position indi- the control unit and the S720-F/1, menu 14 turnable driv-
Transistor has cator not component with diag- S720-R/1 er’s seat
been triggered due working. nostic menu.
to short circuit or Check the sensor.
cuit for reversible
driver’s seat sen-
sor (S720-F,
S720-R).
Tiltable cab Cab position Check cabling between D797-2/K1:7 – CAN/POWER, 9.10.4.7 Sen-
Transistor has indicator not the control unit and the B769-1/A, menu 14 sor, cab up/cab
been triggered due working. component with diag- B769-2/A down
open circuit in cir- Check the sensor.
cuit for sensor for
cab tilt (B769-1,
B769-2).
170 Transistor has Change of Check cabling between D797-2/K1:9 – VBFS, menu 5 5.2.15 Direc-
been triggered due steering an- the control unit and the Y636-1/1 tional control
to short circuit or gle for re- component with diag- valve, turnable
open circuit in cir- versible nostic menu. driver’s seat
cuit for solenoid driver’s seat Check the solenoid
valve, steering for- not working. valve.
ward (Y636–1).


and menu
components
171 Transistor has Change of Check cabling between D797-2/K1:10 – VBFS, menu 5 5.2.15 Direc-
been triggered due steering an- the control unit and the Y636-2/1 tional control
to short circuit or gle for re- component with diag- valve, turnable
open circuit in cir- versible nostic menu. driver’s seat
cuit for solenoid driver’s seat Check the solenoid
valve, steering not working. valve.
rearward (Y636-2).
172 Reversible opera- Tail light front Check bulb. D797-2/K1:25 – VBFS, menu 7 9.6.3 Tail lights
tor's seat not working. Check the bulb holder. H413R/1,
Transistor has H413L/1
been triggered due the control unit and the
cuit for tail light for-
ward (H413R,
H413L).
Cab sliding Cab sliding Check cabling between D797-2/K1:25 – - 9.10.4 Hydrau-
Transistor has not working. the control unit and the Y6080/1 lic sliding cab
been triggered due component with diag-
valve cab sliding
(Y6080).
173 Reversible opera- Rotation of Check cabling between D797-2/K1:29 – VBFS, menu 2 9.3.10.1 Con-
tor's seat driver’s seat the control unit and the Y646-1/1 trol valve, re-
Transistor has not working component with diag- versible
been triggered due nostic menu. operator’s seat
to short circuit or Check the solenoid
open circuit in cir- valve.
cuit for turnable op-
erator’s station
clockwise
(Y646-1).
Tiltable cab Cab tilt up not Check cabling between D797-2/K1:29 – MOVING-CAB, 9.10.4.5 Con-
Transistor has working. the control unit and the Y6047/1 menu 4 trol valve,
been triggered due component with diag- cab tilt
valve, cab tilt up
(Y6047).


and menu
components
174 Reversible opera- Rotation of Check the wiring be- D797-2/K1:39 – VBFS, menu 2 9.3.10.1 Con-
tor's seat driver’s seat tween the control unit Y646-2/1 trol valve, re-
Transistor has not working and component with the versible
been triggered due diagnostic menu. operator’s seat
to short circuit or Check component.
cuit for turnable op-
erator’s station
anticlockwise
(Y646-2).
Tiltable cab Cab tilt down Check the wiring be- D797-2/K1:39 – MOVING-CAB, 9.10.4.5 Con-
Transistor has not working. tween the control unit Y6048/1 menu 4 trol valve, cab
been triggered due and component with the tilt
to short circuit or diagnostic menu.
open circuit in cir- Check component.
cuit for solenoid
valve, cab tilt down
(Y6048).
187 Faulty signal from Joystick con- Check cabling between D797-2/K1:16 – AUXILIARY / 5.2.10 Control
steering solenoid trol or mini- the control unit and the Y636-3/2, EL-STEER- valve joystick
valve (Y636-3, wheel not component with diag- Y636-4/2 ING, menu 4 steering/
Y636-4). Return working. nostic menu. and 5 mini-wheel
current does not Check the solenoid
match control valve.
current.
188 Faulty signal from Carriage lift- Check cabling between D797-2/K1:17 – ELSERV, 5.2.10 Control
solenoid valve, lift ing/lowering the control unit and the Y6022/2, menu 11 valve joystick
carriage (Y6022) not working. component with diag- Y6023/2 and 12 steering/
and solenoid valve, nostic menu. mini-wheel
lower carriage Check the solenoid
(Y6023). Return valve.
current does not
match control
current.
189 Faulty signal from Side shift not Check cabling between D797-2/K1:18 – ELSERV, 7.4.5 Control
solenoid valve, working. the control unit and the Y6020/2, menu 7 and 8 valve load
side shift left component with diag- Y6021/2 handling
(Y6020) and sole- nostic menu.
noid valve, side Check the solenoid
shift right (Y6021). valve.
Return current
does not match
control current.


and menu
components
190 Faulty signal from Spreading Check cabling between D797-2/K1:19 – ELSERV, 7.5.5 Control
solenoid valve, not working. the control unit and the Y6018/2, menu 9 and 10 valve load
spreading out component with diag- Y6019/2 handling
noid valve, spread- Check the solenoid
ing in (Y6019). valve.
Return current
does not match
control current.
193 Transistor has Right front Check bulb. D797-1/K1:36 – VBFS, menu 8 9.6.4 Brake
been triggered due brake light Check the bulb holder. H410R/1 light
cuit for right front
brake light
(H410R). nostic menu.
194 Transistor has Left front Check bulb. D797-1/K1:37 – VBFS, menu 8 9.6.4 Brake
been triggered due brake light Check the bulb holder. H410L/1 light
cuit for left front the control unit and the
brake light
nostic menu.
(H410L).
251 Redundant volt- - Check cabling between D791-1/K2:7 CAN/POWER, 11.5.1.2 Re-
age feed left to at- the control unit and the menu 15 dundant volt-
tachment control component with diag- age feed of
unit (D791-1) does nostic menu. Control units
not reach Check the control unit.
destination.
252 Redundant volt- - Check cabling between D791-1/K2:8 CAN/POWER, 11.5.1.2 Re-
(D791-1) does not nostic menu. Control units
253 Incorrect power Functions Check fuse F58-3/1, re- D791-1/K2:1, CAN/POWER, 11.5.1.4 Emer-
supply to attach- normally sup- place if necessary. K2:9, K2:10 – menu 15 gency stop
ment control unit plied emer- Check cabling between F58-3/1:1 switch voltage
(D791-1). Voltage gency stop the control unit and the
under 18 V or over switch volt- component with diag-
32 V. age have no nostic menu.
feed. No at-
tachment
functions
operational.


and menu
components
254 Incorrect emergen- Functions Check fuse F58-3/1, re- D791-1/K2:11 – CAN/POWER, 11.5.1.4 Emer-
cy stop switch volt- normally sup- place if necessary. F58-3/1:1 menu 15 gency stop
age to Control unit, plied emer- Check cabling between switch voltage
attachment gency stop the control unit and the
(D791-1). switch volt- component with diag-
age have no nostic menu.
feed. No at-
tachment
functions op-
erational.
255 Incorrect 5 V refer- – Check cabling between D791-1/K1:8 CAN/POWER, 11.5.1 Power
ence voltage to the control unit and the menu 16 supply
pressure sensor. component with diag-
Voltage under nostic menu.
256 Transistor has Central lubri- Check cabling between D791-1/K1:14 – OPT, menu 2 9.14.1 Pump
been triggered due cation attach- the control unit and the M693-2/1 unit
to short circuit or ment not component with diag-
cuit for central unit Check the component.
for central lubrica-
tion (M693-2).
257 Transistor has Work light at- Check bulb. D791-1/K1:1 – LIGHTS, 9.6.12 Work
been triggered due tachment left Check the bulb holder. E404L, menu 13 light
to short circuit or not working. E404UL, attachment
open circuit in cir- E404LL-3/1
cuit for attachment
work lights, left
nostic menu.
(E404L-3).
258 Transistor has Work light at- Check bulb. D791-1/K1:15 – LIGHTS, 9.6.12 Work
been triggered due tachment Check the bulb holder. E404R, menu 13 light
to short circuit or right not E404UR, attachment
open circuit in cir- working. E404LR-3/1
cuit for attachment
work lights, right
nostic menu.
(E404R-3).


and menu
components
259 DCF360-450CSG Extra work Check bulb. D791-1/K1:28 – LIGHTS, 9.6.12 Work
Transistor has light attach- Check the bulb holder. E404-4L/1, menu 13 light
been triggered due ment not E404-4-R/1 attachment
to short-circuit or working.
cuit for auxiliary at- nostic menu.
tachment work
lights (E404-4L,
E404-4-R).
DCF80-100 Warning sig- Check the buzzer. D791-1/K1:28 – ATTACH, 7.5.7 Buzzer,
Transistor has nal for auto- Check cabling between H9003/1 menu 21 automatic
been triggered due matic the control unit and the spreading
to short circuit or spreading not component with diag- 20’-40’
cuit for warning sig-
nal, automatic
spreading (H9003).
260 Transistor has Levelling of Check cabling between D791-1/K1:42 – ATTACH, 7.8.4 Valve
been triggered due attachment the control unit and the Y637-1/1, menu 15 block, levelling
to short circuit or not working. component with diag- Y637-2/1 cylinders
cuit for control Check the solenoid
valve for levelling valve.
clockwise (Y637-1,
Y637-2).
261 DCF360-450CSG Extension left Check cabling between D791-1/K1:2 – ATTACH, 7.3.2 Control
Transistor has in of attach- the control unit and the Y6046-1/1 menu 18 valve
been triggered due ment not component with diag- attachment
to short circuit or working. nostic menu.
valve, extension
left in (Y6046-1).
DCF80-100 Spreading Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Transistor has left in of at- the control unit and the Y6019L/2 menu 18 valve
been triggered due tachment not component with diag- attachment
valve, spreading
left in (Y6019L).


and menu
components
Transistor has out of attach- the control unit and the Y6046-2/1 menu 17 valve
been triggered due ment not component with diag- attachment
to short circuit or functioning. nostic menu.
valve, extension
left out (Y6046-2).
Transistor has left out of at- the control unit and the Y6018L/2 menu 17 valve
valve, spreading
left out (Y6018L).
263 DCF360-450CSG Extension Check cabling between D791-1/K1:4 – ATTACH, 7.3.2 Control
Transistor has right in of at- the control unit and the Y6046-3/1 menu 20 valve
valve, extension
right in (Y6046-3).
Transistor has right in of at- the control unit and the Y6019R/2 menu 20 valve
valve, spreading
right in (Y6019R).


and menu
components
Transistor has right out of at- the control unit and the Y6046-4/1 menu 19 valve
valve, extension
right out (Y6046-4).
Transistor has right out of at- the control unit and the Y6018R/2 menu 19 valve
valve, spreading
right out (Y6018R).
265 DCF360-450CSG Clockwise Check cabling between D791-1/K1:30 – ATTACH, 7.8.2 Control
Transistor has levelling of the control unit and the Y6036/1 menu 16 valve
been triggered due attachment component with diag- attachment
to short-circuit or not working. nostic menu.
cuit for control valve.
valve, levelling
clockwise (Y6036).
DCF80-100 Levelling left Check cabling between D791-1/K1:19 – ATTACH, 7.8.2 Control
Transistor has of attachment the control unit and the Y6036/2 menu 13 valve
been triggered due not working. component with diag- attachment
cuit for levelling, valve.
left (Y6036).


and menu
components
266 DCF360-450CSG Anticlock- Check cabling between D791-1/K1:31 – ATTACH, 7.8.2 Control
Transistor has wise level- the control unit and the Y6035/1 menu 16 valve
been triggered due ling of component with diag- attachment
to short circuit or attachment nostic menu.
open circuit in cir- not Check the solenoid
cuit for control functioning. valve.
valve, levelling an-
ticlockwise
(Y6035).
DCF80-100 Levelling Check cabling between D791-1/K1:19 – ATTACH, 7.8.2 Control
Transistor has right of at- the control unit and the Y6036/2 menu 14 valve
valve, levelling
right (Y6035).
267 Transistor has Side shift left Check cabling between DCF360- ATTACH, 7.4.2 Control
been triggered due of attachment the control unit and the 450CSG menu 11 valve
to short circuit or not working. component with diag- D791-1/K1:32 – attachment
open circuit in cir- nostic menu. Y6020/1
cuit for solenoid Check the solenoid DCF80-100
valve, side shift left valve.
(Y6020). D791-1/K1:18 –
Y6020/2
268 Transistor has Side shift Check cabling between DCF360- ATTACH, 7.4.2 Control
been triggered due right of at- the control unit and the 450CSG menu 12 valve
to short circuit or tachment not component with diag- D791-1/K1:33 – attachment
open circuit in cir- working. nostic menu. Y6021/1
cuit for solenoid Check the solenoid DCF80-100
valve, side shift valve.
right (Y6021). D791-1/K1:18 –
Y6021/2
269 Transistor has Twistlock/ Check cabling between D791-1/K1:7 – ATTACH, 7.9.1.2 Control
been triggered due lock tongue the control unit and the Y6040/1 menu 9 valve
to short circuit or not working. component with diag- attachment
valve, lock twist- valve.
lock/lock tongue
(Y6040).


and menu
components
270 Transistor has Twistlock/ Check cabling between D791-1/K1:9 – ATTACH, 7.9.1.2 Control
been triggered due lock tongue the control unit and the Y6039/1 menu 9 valve
valve, open twist- valve.
lock/lock tongue
(Y6039).
271 The transistor has Twistlocks Check cabling between D791-1/K1:10 – CAN/POWER, 7.9.1.2 Control
been triggered due and spread- the control unit and the B769-1/A, menu 16 valve
to short circuit or ing not component with diag- B777-1/A, attachment
open circuit in cir- working. nostic menu. B7202L/A,
cuit for Voltage Check the sensor. B7202R/A,
feed, position sen- B7203L/A,
sor attachment. B7203R/A,
B7204L/A,
B7204R/A,
B7205L/A,
B7205R/A,
Transistor has Sensor on at- Check cabling between D791-1/K1:10 – CAN/POWER, 7.9.1.2 Control
been triggered due tachment not the control unit and the B769-L/A, menu 16 valve
to short circuit or working. component with diag- B769-R/A, attachment
open circuit in cir- nostic menu. B777-L/A,
cuit for voltage Check the sensor. B777-R/A,
feed to attachment B7203L/A,
sensor. B7203LL/A,
B7203LU/A,
B7203LU-2/A,
B7203R/A,
B7203RL/A,
B7203RU/A,
B7203RU-2/A,
B7204L/A,
B7204R/A,
B7205LL/A,
B7205LU/A,
B7205RL/A,
B7205RU/A
272 Transistor has Indicator Check bulb. D791-1/K1:25 – ATTACH, 7.9.1
been triggered due light, open Check the bulb holder. H562/1 menu 10 Twistlocks
to short circuit or twistlock/lock
tongue not
cuit for indicator the control unit and the
working.
light, twistlock/lock component with diag-
tongue open nostic menu.
(H562).


and menu
components
273 DCF360-450CSG Indicator Check bulb. D791-1/K1:29 – ATTACH, 7.9.1
The transistor has light, align- Check the bulb holder. H563/1 menu 10 Twistlocks
been triggered due ment twist-
to short circuit or lock not
open circuit in cir- working.
cuit for Indicator nostic menu.
light, alignment
(H564).
DCF80-100 Indicator Check bulb. D791-1/K1:29 – ATTACH, 7.9.1
Transistor has light, locked Check the bulb holder. H563/1 menu 10 Twistlocks
been triggered due twistlock/lock
to short circuit or tongues not
cuit for indicator nostic menu.
light, locked twist-
lock/lock tongues
(H563).
274 The transistor has Indicator Check bulb. D791-1/K1:39 – ATTACH, 7.9.1
been triggered due light, attach- Check the bulb holder. H564/1 menu 10 Twistlocks
to short circuit or ment align-
ment not
cuit for Indicator the control unit and the
working.
light, alignment component with diag-
(H564). nostic menu.
Faulty signal from of attachment the control unit and the Y6046-1/2, menu 17 and valve
solenoid, extension not working. component with diag- Y6046-2/2 18 attachment
left in (Y6046-1) nostic menu.
and solenoid valve, Check the solenoid
extension left out valve.
(Y6046-2). Return
current does not
match control
current.
Faulty signal from left not the control unit and the Y6019L/2, menu 17 and valve
solenoid, spread- working. component with diag- Y6019R/2 18 attachment
ing left in (Y6019L) nostic menu.
spreading left out valve.
(Y6018L). Return
current does not
match control
current.


and menu
components
Faulty signal from right of at- the control unit and the Y6046-3/2, menu 19 valve
solenoid, extension tachment not component with diag- Y6046-4/2 and 20 attachment
right in (Y6046-3) working. nostic menu.
extension right out valve.
(Y6046-4). Return
current does not
match control
current.
Faulty signal from right not the control unit and the Y6019R/2, menu 19 valve
solenoid, spread- working. component with diag- Y6018R/2 and 20 attachment
ing right in nostic menu.
(Y6019R) and so- Check the solenoid
lenoid valve, valve.
spreading right out
(Y6018R). Return
current does not
match control
current.
289 Faulty signal from Side shift of Check cabling between D791-1/K1:18 – ATTACH, 7.4.2 Control
solenoid valve, attachment the control unit and the Y6020/2, menu 11 valve
side shift left not working. component with diag- Y6021/2 and 12 attachment
noid valve, side Check the solenoid
shift right (Y6021). valve.
Return current
does not match
control current.


and menu
components
290 Faulty signal from Attachment Check cabling between D791-1/K1:19 – ATTACH, 7.5.2 Control
solenoid, spread- spreading not the control unit and the Y6018/2, menu 13 valve
ing out (Y6018) working. component with diag- Y6019/2 and 14 attachment
and solenoid valve, nostic menu.
spreading in Check the solenoid
current does not
match control
current.
Faulty signal from Levelling of Check cabling between D791-1/K1:19 – ATTACH, 7.5.2 Control
solenoid valve, lev- attachment the control unit and the Y6035/2, menu 13 valve
elling right (Y6036) not working. component with diag- Y6036/2 and 14 attachment
and solenoid valve, nostic menu.
levelling left Check the solenoid
current does not
match control
current.
291 Transistor has Spreading Check cabling between D791-1/K1:34 – ATTACH, 7.5.2 Control
been triggered due out of attach- the control unit and the Y6018/1 menu 13 valve
to short circuit or ment not component with diag- attachment
valve, spreading valve.
out (Y6018).
Transistor has Indicator light Check bulb. D791-1/K1:34 – ATTACH, 7.5.2 Control
been triggered due for upper Check the bulb holder. H564UL/1 menu 23 valve
to short circuit or alignment not attachment
cuit for indicator
light, upper align-
nostic menu.
ment (H564UL).
292 Transistor has Spreading in Check cabling between D791-1/K1:35 – ATTACH, 7.5.2 Control
been triggered due of attachment the control unit and the Y6019/1 menu 14 valve
valve, spreading in valve.
(Y6019).
298 Sensor, twistlock Lift and Check that Sensors, D791-1/K2:13 ATTACH, 7.9.1.7 Sensor
indicates that left spreading not twistlock, are clean and menu 8 twistlocks
twistlock is be- working. correctly adjusted.
tween open and Check cabling between
locked position. the control unit and the
nostic menu.


and menu
components
299 Sensor, twistlock Lift and Check that Sensors, D791-1/K2:15 ATTACH, 7.9.1.7 Sensor
indicates that right spreading not twistlock, are clean and menu 8 twistlocks
twistlock is be- working. correctly adjusted.
tween open and Check cabling between
locked position. the control unit and the
nostic menu.
300 Sensor, alignment, Twistlock not Check that Sensors, - ATTACH, 7.9.1.6 Sensor
indicates unrea- working. alignment, are clean menu 7 alignment
sonable distance. and correctly adjusted.
Check that the contact
pin runs smoothly.
nostic menu.
451 Redundant volt- - Check cabling between D795/K1:7 CAN/POWER, 11.5.1.2 Re-
Control unit KID component with diag- age feed of
(D795) does not nostic menu. control units
reach destination.
452 Redundant volt- - Check cabling between D795/K1:8 CAN/POWER, 11.5.1.2 Re-
Control unit KID component with diag- age feed of
(D795) does not nostic menu. control units
reach destination.
460 No messages re- Incorrect val- Use diagnostic menu to D795/K1:10, CAN/POWER, 11.6.2 Redun-
ceived on CAN ues in operat- check the CAN bus K1:11, K1:12, menu 1, 2, 17 dant CAN bus
buffer 1. ing menus. K1:13
461 No messages re- Error codes Use diagnostic menu to D795/K1:5, CAN/POWER, 11.6.2 Redun-
ceived on CAN from other check the CAN bus K1:6 menu 1, 2, 17 dant CAN bus
buffer 2. Control units
cannot be
shown.
500 Time for service. - Check that servicing has - - C Preventive
been performed. If serv- maintenance
icing has been per-
formed following the
Cargotec service sched-
ule, reset the service in-
dicator; see section 8
Control system, group
8.2.4 Service indicator.


E Schematics 1
E Schematics
Table of Contents E Diagrams

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram DCF 80-100, electric servo ....................................................... 4
11 Common electrics .......................................................................................... 6
Circuit diagram, description ................................................................................... 6
Component designations ........................................................................................ 7
Circuit diagrams, compilation ................................................................................. 8

2 E Schematics

E Schematics – 10 Common hydraulics 3
mm mm mm mm mm mm
Hydraulic diagrams, compilation

page
–
Designation Drawing number

Hydraulic diagram DCF 80-100, electric servo page 4 A47749.0100

4 E Schematics – 10 Common hydraulics
Hydraulic diagram DCF 80-100,

page
–
electric servo
26
25
25
29
24
23
17
28
20 22
21
16
19
37
6
36
27
43
18
35
34
33
4e
15
42
4d
41
14
4c
5
44
40
4b
4a
32
39
4
9
7
13
2
014796 (A57035.0100 ver 02)

38
8
12
3
11
1
30
31
10

E Schematics – 10 Common hydraulics 5
1. Side shift cylinder 17. Brake valve

2. Cylinder, twistlock/lock tongue 18. NC switch, low brake pressure (S204)
3. Overcentre valve 19. Solenoid valve parking brake (Y642)
4. Control valve attachment 20. Switch (NO), parking brake (S200)
4a. Solenoid valve, side shift left (Y6020) and side shift right 21. NO switch, declutch (S220)
(Y6021) 22. NO switch, brake lights (S216)
4b. Solenoid valve, open twistlock/lock tongue (Y6039) and 23. Parking brake caliper
lock twistlock/lock tongue (Y6040)
24. Brake cylinder
4c. Solenoid valve, spreading out left (Y6018L) and spread-
25. Wheel brake
ing in left (Y6019L)
26. Drive axle block
4d. Solenoid valve, spreading out right (Y6018R) and
spreading in right (Y6019R) 27. Accumulator charge valve
4e. Solenoid valve, levelling right (Y6035) and levelling left 28. Oil cooler
(Y6036) 29. Fine filter
5. Spreading cylinder 30. Pressure limiting valve
6. Levelling cylinder 31. Solenoid valve, quick-lift (Y6062)
7. Lift cylinder 32. Solenoid valve, main pump relief (Y6062-2)
8. Tilt cylinder 33. Return filter
9. Accumulator 34. Pressure filter
10. Pressure reducing valve 35. Steering cylinder
11. Accumulator 36. Steering valve
12. Servo filter 37. Control valve for lever steering/mini-wheel, solenoid valve
13. Control valve for lift and tilt, control valve for lift mast for steering right (Y636-3) and steering left (Y636-4)
(Y6005) and lower mast (Y6004), tilt in (Y6011) and tilt out 38. Quick-lift pump
(Y6010)
39. Hydraulic oil pump
14. Cab tilt cylinder
40. Hydraulic oil pump
15. Control valve for cab tilt, control valve for cab tilt up
41. Hydraulic oil pump, brakes
(Y6047) and cab tilt down (Y6048)
42. Priority valve
16. Accumulator
43. Breather filter
44. Tank

6 E Schematics – 11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Circuit diagram, description

page
–
A circuit diagram is divided into circuit names (drawing numbers) and

consists of a set of numbered pages.
The following is an explanation of symbols in circuit diagrams:
• X is connection terminal (followed by number)
• Designation 353-2
353 is component designation (see Component designations
page 7 for description of each component). 2 indicates that it is the
second component of this type in the specific diagram.
• Sensors etc. are drawn in resting position on circuit, that is, with-
out voltage.
• Colour cables:
White cable = ground signal
Grey cable = other cables
• Fuse box, for example F58, means fuse box with 8 fuses
• An arrow symbol indicates a reference to another circuit diagram
• 20015.0001 circuit drawings-post designations K-standard.
K-standard 1: norms, rules
K-standard 2: cables, general physical
K-standard 5: Designation and marking system, item designations
circuit drawings
• Ground connection:
1: X37-A is ground connection in the electrical distribution box. A
connection terminal for ground. Frame connection-connection ter-
minal to chassis.
2: Zero reference is found in control units.

E Schematics – 11 Common electrics 7
Component designations
page
–
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 pro-
vided as an appendix after the circuit diagrams.
Prefix Description
A Unit, sub-unit. Example: amplifier with separate components
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
D Binary element, delay unit, memory. Example: control unit.
E Lighting and heating unit.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: fuse.
H Signal device. Example indicator light.
K Relay, contactor.
L Inductance, reactance.
M Motor. Example: electric motor.
N Analogue element. Example: operation amplifier.
P Measuring instrument, test equipment. Example: operating hour gauge.
Q Electrical connector for power circuit. Example: circuit breaker.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
T Transformer.
U Modulator, converter or transformer. Example: frequency converter
V Conduit, semiconductor. Example: diode, transistor
W Transmission route, wave-guide, antenna. Example: cable, bus bar.
X Outlet/socket, connecting device Example: connection terminal.
Y Electrically controlled mechanical device: Example: solenoid valve, hydraulic valve.
Z Transformer, network, hybrid, filter, equaliser, limiter. Example: cable balancing network.

Circuit diagrams, compilation

page
–
Circuit diagrams are attached as an appendix in the following order.

The circuit diagram for the basic machine has drawing number
A49226.0100.
Sheet Designation
0.0-1 Cross-reference list
0.1-1 Truth table opt.
1.0-1 Circuit, drivetrain, engine
1.0-2A Circuit, Volvo TAD722 engine
1.0-2B1 Circuit, Cummins QSM11 engine
1.0-2B2 Circuit, Cummins QSM11 engine
1.0-2C Circuit, Volvo 950,1240,1250 engine
1.0-2D Circuit, Volvo TAD760 engine
1.0-2E1 Circuit, Cummins QSB6.7 engine
1.0-2E2 Circuit, Cummins QSB6.7 engine
2.0-1 Circuit, drivetrain gearbox
2.0-2A1 Circuit, TE32 gearbox
2.0-2B1 Circuit, TE17 gearbox
4.0-1 Circuit, brake system
4.8-1 Circuit, brake oil cooling
5.2-1 Circuit, lever/mini-wheel steering
5.2-2 Circuit, lever/mini-wheel steering
7.0-1 Circuit, electric servo levers
7.0-2 Circuit, electric servo joystick
7.0-4 Circuit, accessory attachment
7.0-5 Circuit, accessory attachment
7.0-7 Circuit, lifting height
7.2-1 Circuit, lift/lower electric servo

Sheet Designation
7.2-2 Circuit, freelift sensors
7.2-3 Circuit, freelift sensors
7.2-6 Circuit, mast valves
7.3-1 Circuit, gantry attachment
7.4-1 Circuit, side shift, electric servo
7.4-2 Circuit, side shift gantry
7.5-1 Circuit 20-40, 30-35 stop
7.5-2 Circuit, spreading gantry
7.5-3 Circuit, 20’-40’ opt.
7.7-1 Circuit, tilt electric servo
7.7-2 Circuit, tilt indication
7.8-1 Circuit, levelling gantry
7.9-1 Circuit, twistlock
7.9-2 Circuit, sensor gantry
7.9-3 Circuit, pliers Avesta
7.10-1 Circuit, 5th function electric servo
7.10-2 Circuit, option gantry
8.2-1 Circuit, bypassing
8.2-2 Circuit, overload system
8.2-3 Circuit, mast sensor OLS
8.2-4 Circuit RMI
9.0-1 Circuit, std. opt.
9.1-1 Circuit, optional equipment
9.1-2 Circuit, hour counter
9.3-1 Circuit, seat heating
9.3-2 Circuit, air suspension seat
9.3-3 Circuit, reversible driver’s seat
9.4-1 Circuit, climate system
9.4-2 Circuit, climate system
9.5-1 Circuit, wipers

Sheet Designation
9.6-1 Circuit, work lights 20’-40’
9.6-2 Circuit, work lights, carriage
9.6-3 Circuit, work lights, mast
9.6-4 Circuit lighting
9.6-7 Circuit, direction indicators & hazard
9.6-8 Circuit, interior lighting
9.6-9 Circuit, work lights, option
9.6-10 Circuit, work lights, option
9.6-11 Circuit, entry lighting
9.6-12 Circuit, aux. lights, attachment
9.6-13 Circuit, work lights, option, hood lamp
9.6-14 Circuit, work lights, option carriage
9.7-1 Circuit, alarm, audible signals
9.7-2 Circuit, back-up alarm
9.7-3 Circuit, compressor horn
9.7-4 Circuit for horn, servo panel
9.8-1 Circuit, radio
9.8-2 Circuit, printer
9.9-1 Circuit, rearview mirror heating
9.10-1 Circuit, cab tilt/sliding cab
9.14–1 Circuit, central lubrication
10.4-1 Circuit, hydr. pump disengagement
10.6-1 Circuit, hydraulic oil cooling
11.5-1 Circuit, current
11.5-6 Circuit, emergency stop switch current
11.5-7 Circuit 24/12V
11.5-8 Circuit 24V socket
11.5-9 Circuit, option, ground power

Sheet Designation
11.5-10 Circuit, option, ground
11.5-11 Circuit, option, ground
11.6-1 Circuit CAN bus ground
11.6-2A Circuit, CAN bus KDU opt.
11.6-2B Circuit, CAN bus KDU opt.
11.6-2C Circuit, CAN bus KDU opt.
Circuit diagrams are attached as an appendix in the following order.

The circuit diagram for the side lift attachment has drawing number
A50400.0100.
Sheet Designation
0.0_1 Cross-reference list
7.4_1 Circuit, side shift
7.5_1 Circuit, spreading
7.5_2 Circuit, spreading buzzer
7.5_3 Circuit, spreading sensors
7.8_1 Circuit, levelling
7.9_1 Circuit, open/lock
7.9_2 Circuit, open/lock sensors
7.9_3A Circuit, indicator lights
7.9_3B Circuit, indicator lights
7.9_4 Circuit, alignment sensors
7.9_5A Circuit, alignment sensors
7.9_5B Circuit, alignment sensors
9.6_1 Circuit, work lights, carriage/attachment
9.14_1 Circuit, central lubrication
11.5_1 Circuit, current
11.5_2 Circuit, current
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1 2 3 4 5 6 7 8
BU BU
BU BU
A A
-K1 -K3 -K4 -K5 -K6 -K7
85 85 86 86 85 85 86 86 85 85 86 86 85 85 86 86 85 85 86 86 85 85 86 86
BU
BU
BU
30 30 87 87 30 30 87 87 30 30 87 87 30 30 87 30 30 87 87 30 30 87 87
87A 87A 87A 87A 87a 87A 87A
ALIGNMENT TWISLOCKS OPEN TWISTLOCKS LOCKED END POSITION DAMPING LENGTH ADJUSTMENT 20 - 40 TWISTLOCK VALVE
10
10
B B
5 9
1
BU 13
14
7
8
11
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BU 20
22
23
CHASSIS BU
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1 -XK8 -XK8-30
14 30 1
C C
GY
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19 87a 1
-X100 1 1 2 2 5 7 8 9 10 11 12 13 14 17 19 20 22 23
RD +24V
-X200 1 1 /4.E2
TWISTLOCK YE TW._LOCKED
2 2 /4.E2
20' - 40' GY TW._OPEN
3 3 /4.E2
GND BK ALIGNMENT
D 4 4 /4.E2 D
24V
written permission and the contents thereof must

This document must not be copied without our
secuted.
not be imparted to a third party nor be used for any

unauthorized purpose. Contravention will be pro-
5 5
ALIGNMENT YE./.GN CHASSIS
/2.D2
6 6
TWISTLOCKS OPEN 1 DAMPING
7 7 /2.D2
TWISTLOCKS LOCKED
8 8 2 +24V
30' - 35' /2.D2
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/5.D7
2 CHASSIS
/2.D2
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4 ALIGNMENT
/2.E2
SPREADING YE
/3.B2
1 +24V
stöd av gällande lag.

hörigen användas. Överträdelse härav beivras med
Denna ritning får ej utan vårt medgivande kopieras.

Den får ej heller delgivas annan eller annars obe-
/2.E2
DAMPING GY
/3.C2
F 2 CHASSIS F
/2.F2
Ref. Benämning Produkt/Product Blad/Sheet

Nr Ändring Ändring nr Datum Sign. Datum/Date
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn CJS 021206 1 5
+ATTACHMENT Krets aggregat topplyft 20-40 DCD370-
R
H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
KONTAKT ECONOSEAL, SERIE E KONTAKT ECONOSEAL, SERIE E

CONTACT ECONOSEAL, SERIE E CONTACT ECONOSEAL, SERIE E
-X7202Rf -X7202Rm
3 2 2 BN
-X7202Lm -X7202Lf -B7202R
BN 2 2 3 4 1 1 BK
A -B7202L A
BK 1 1 4 BU 3 3 ALIGNMENT RIGHT FRONT
3 3 BU BU
ALIGNMENT LEFT FRONT
BU
-X7203Rf -X7203Rm
9 2 2 BN
-X7203Lm -X7203Lf -B7203R
BN 2 2 1 7 1 1 BK
-B7203L
BK 1 1 9 BU 3 3 ALIGNMENT RIGHT REAR
3 3 BU BU
ALIGNMENT LEFT REAR
BU
-X7204Rf -X7204Rm
BK 2 2 BN
-X7204Lm -X7204Lf -B7204R
BN 2 2 5 5 1 1 BK
B -B7204L B
BK 1 1 6 BU 3 3 UNLOCKED TWISTLOCK RIGHT
3 3 BU BU
UNLOCKED TWISTLOCK LEFT
BU
-X7205Rf -X7205Rm
BK 2 2 BN
-X7205Lm -X7205Lf -B7205R
BN 2 2 7 6 1 1 BK
-B7205L
BK 1 1 8 BU 3 3 LOCKED TWISTLOCK RIGHT
3 3 BU BU
LOCKED TWISTLOCK LEFT
BU
-XSP4
C C
-X769m -X769f
BN 2 2
-B769
BK 1 1
END POSITION DAMPING 3 3
BU
-XSP2
-XSP3
CHASSIS YE./.GN
/1.D7
D DAMPING 1
/1.D7 D

secuted.

+24V 2
/1.E7
-X100 3 4 6 15 16
CHASSIS 2
/1.E7
TW._LOCKED 8
/1.E7
TW._OPEN 6
/1.E7
+24V 1
E /1.E7 E
ALIGNMENT 4
/1.F7
+24V 1
/1.F7
CHASSIS 2
/1.F7


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-Y6044
TW. RD 1 1 2 2 BU
/1.E2
SOLENOID VALVE TWISTLOCK
-Y6046
B B
SPREADING YE 1 1 2 2 BU
/1.F2
SOLENOID VALVE SPREADING
CHASSIS
/1.E2
-XSP5
-Y6046-2
C C
DAMPING GY 1 1 2 2 BU
/1.F2
SOLENOID VALVE SPREADING DAMPING
-Y6046-3
D D
30-35_Stop BK 1 1 2 2 BU
/5.D7

secuted.

SOLENOID VALVE 30-35 STOP
OPTION
E E


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E563 -E564 -E562

B B
1 1 2 1 1 1 2 1 1 1 2 1
TWISTLOCKS LOCKED ALIGNMENT TWISTLOCKS OPEN
RD
C C
RD RD
-XSP1
D D

secuted.

+24V RD
/1.D7
TW._LOCKED YE
E /1.D7 E
TW._OPEN GY
/1.D7
ALIGNMENT BK
/1.D7


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Option 30-35' stop
BU CHASSIS
/1.C2
-K8
85 85 86 86
B B
30 87 87
87A
Bygel mellan 30 - 87a ersatt

av relä vid 30-35' stopp.
24
18
Jumper between 30 - 87a replaced
by relay at 30-35' stop.
C C
-X100 18 21 24
BK BK 30-35_Stop
/3.D2
-X777-1m -X777-1f
BN 2 2 RD RD 8 +24V_VIA_KNAPP
-B777-1 /1.E2
BK 1 1 -XSP6
D 3 3 BU
30-35 STOP D
BU

secuted.

-X777-2m -X777-2f
BN 2 2 RD
-B777-2
BK 1 1
3 3 BU BU CHASSIS
30-35 STOP DAMPING /1.E2
BU -XSP7
E E
GY DAMPING
/1.E2


F F

Ruta Sign.
Sq.
R
E³ DRAWING
1 2 3 4 5 6 7 8
E Schema - Komponentförteckning / E Schematics - List of Components
NUMBER CATEG SVENSKA ENGLISH

30 G Batteri Battery
32 A Kretskort elcentral Printed circuit board, Junction box
37 X Terminal stomanslutning Earthing terminal on chassis
39 X Terminal minusanslutning Terminal, negative terminal
51 F Säkringshållare 1-polig Fuse holder, 1-pole
62 F Batterihandske 2-polig Battery connector, 2-pole
64 F Batterihandske 4-polig Battery connector, 4-pole
72 X Stickuttag 2-polig Outlet, 2-pole
77 X Stickuttag 7-polig Outlet, 7-pole
78 X Stickuttag extra 7-polig Outlet, extra, 7-pole
100 S Strömställare ljus Switch, light
101 S Strömställare omk hel/halvljus Switch, main/dipped beam
102 S Strömställare dimljus Switch, fog light
103 S Strömställare fjärrljus Switch, distance light
104 S Strömställare lastljus Switch, mast lights
105 S Strömställare arbetsljus Switch, working lights
106 S Strömställare containerljus Switch, container light
107 S Strömställare park broms Switch, parking brake
108 S Strömställare centr smörjning Switch, central lubricator
109 S Strömställare varningsljus Switch, hazard lights
110 S Strömställare rot varningsljus Switch, rotating hazard beacon
111 S Strömställare fönsterhiss Switch, window regulator
112 S Strömställare kylanläggning (AC) Switch, air conditioner (AC)
113 S Strömställare styrning alt Switch, alternative steering
114 S Strömställare läsbelysning Switch, reading light
115 S Strömställare instr belysning Switch, instrument illumination
116 S Strömställare innerbelysning Switch, interior lighting
117 S Strömställare värme Switch, heating
118 S Strömställare fläktm värme Switch, heater fan
119 S Strömställare vindrutetorkare Switch, wiper
120 S Strömställare spolare Switch, washer
121 S Strömställare blackout Switch, blackout
122 S Strömställare nöd hydraulpump Switch, emergency hydraulic pump
123 S Strömställare backspegel Switch, observation mirror
124 S Strömställare kallstart Switch, cold start
125 S Strömställare avgasbroms Switch, exhaust brake
126 S Strömställare diff spärr/broms Switch, diff. Block
127 S Strömställare värmesystem diesel Switch, heating system diesel
128 S Strömställare kraftuttag sida Switch, power take off side
129 S Strömställare kraftuttag bak Switch, power take off rear
130 S Strömställare hög/lågväxel Switch, high/low gear
131 S Strömställare färdväljare fram Switch, gear selector forward
132 S Strömställare färdväljare bak Switch, gear selector rear
135 S Strömställare växelväljare Switch, gear shift
136 S Strömställare framhjuls styrning Switch, forward wheel steering
137 S Strömställare 4-hjuls styrning Switch, 4-wheel steering
138 S Strömställare crab styrning Switch, crab steering
139 S Strömställare defroster Switch, defroster
141 S Strömställare Stegbelysning Switch, Steplight
142 S Strömställare fot Switch, foot
143 S Strömställare sitsvärme Switch, seat heater
144 Q Batterifrånskiljare Battery disconnecting switch
145 S Strömställare AT-regulator Switch, AT-regulator
147 S Strömställare körvisare Switch, direction indicators
149 S Strömställare signalhorn Switch, horn
150 S Strömställare startlås/ellas Switch, main key switch
152 S Strömställare intervalltorkare Switch, intermittent wiper
156 S Strömställare kupevärmare Switch, cab heating

157 S Strömställare stoltilt Switch, seat tilt
158 S Strömställare dimbakljus Switch, rear fog light
159 S Strömställare extra fram/back väljare Switch, extra direction selector
160 S Strömställare komb fram/back Switch, combi-forward/reverse
161 S Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped beam, washer,
spol,torkare m intervall körvisare wiper (intermittent), direction indicator
162 S Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped beam, washer,
spol, torkare m 2 int, fram/bacK wiper w 2int., forward/revers
163 S Strömställare start på 2-an Switch, start 2nd gear
165 S Strömställare stolvärme Switch, seat heater
166 S Strömställare låsning vändskiva Switch, interlocking of turntable
167 S Strömställare luftfjädring Switch, pneumatic springing
168 S Strömställare låsn stol Switch, interlocking of seat
169 S Strömställare stolsvändning Switch, reversible seat
170 S Strömställare förångare (LPG) Switch, evaporator (LPG)
171 S Strömställare v-skiva upp/ner Switch, fifth wheel up/down
172 S Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
173 S Strömställare v-skiva skevning Switch, fifth wheel, levelling
174 S Strömställare,utskjut Switch, projecting
175 S Strömställare hyttlyft upp Switch, cab hoist up
176 S Strömställare hyttlyft ner Switch, cab hoist down
177 S Strömställare hyttskjutning Switch, cab movement
178 S Strömställare nollställning Switch, reset
179 S Strömställare Aut/man växling Switch Aut/man gearshifting
180 S Strömställare fyrhjulsdrift Switch, 4-WD
190 S Strömställare klimatanläggning Switch, air conditioner
191 S Strömställare recirkulation Switch, re-circulation
192 S Strömställare vattenavskiljare
195 S Strömställare joy-stick X Switch, joy-stick X
196 S Strömställare joy-stick X+Y Switch, joy-stick X+Y
197 S Strömställare längs/tvärskörning Switch, length/sideways driwing
198 S Strömställare flytläge skevning Switch, equalizing fifth wheel
199 S Strömställare option Switch, option
200 S Brytkontakt lampa park broms Contact, breaking,warning lamp,parking brake
201 S Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
202 S Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil pressure engine
204 S Brytkontakt tryck ackumulator Contact, breaking, pressure accumulatortank
205 S Brytkontakt innerbelysning Contact, breaking, interior lighting
206 S Brytkontakt handskfack belysning Contact, breaking, glove
207 S Slutkontakt diff spärr Contact, making, diff. interlock
208 S Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp temperature brake
bromsar
214 S Slutkontakt överväxel Contact, making, over drive
215 S Slutkontakt temp motor Contact, making, temperature engine
216 S Slutkontakt bromsljus Contact, making, brake lights
217 S Slutkontakt backljus Contact, making, reversing light
218 S Slutkontakt AT-regulator Contact, making, AT-control
219 S Slutkontakt lampa luftfilter Contact, making, indicating light air filter
220 S Brytkontakt drivning Contact, breaking, drive cut off
221 S Slutkontakt temp växellåda Contact, making, temperature gear box
222 S Slutkontakt lampa temp moment - Contact, making, warning lamp temperature torque
förstärkare amplifier.
223 S Släpkontakt signal Contact, brush, horn
224 S Slutkontakt insprutningspump Contact, making, injection pump
225 S Brytkontakt säkerhetsbälte Contact, breaking, seat belt
228 S Slutkontakt hyttlåsning Contact, making, cab locking
229 S Slutkontakt stolslåsning Contact, making, seat locking
230 S Brytkontakt stol Contact, breaking, seat
231 S Slutkontakt fotkontroll stolvändning Contact, making, seat rotation, foot switch
232 S Brytkontakt lampa luftanslutning släp Contact, breaking, warning lamp air connection
233 S Slutkontakt lampa låsning vändskiva Contact, warning, interlocking of turntable

235 S Slutkontakt sidoskjutning stol Contact, making, side shifting of seat
236 S Slutkontakt vattennivå Contact, water level
239 S Brytkontakt termisk Contact, breaking, thermic
240 S Slutkontakt termisk Contact, making, thermic
241 S Brytkontakt lampa luftmatning släp Contact, breaking, warning lamp air supply to trailer
242 S Slutkontakt lampa oljetryck v-låda Contact, making, warning lamp, oil pressure gear box
243 S Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air condition)
244 S Slutkontakt hydraulik aktiverad Contact, making, hydraulics
245 S Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
246 S Slutkontakt tryck kylmedia Contact, pressure refrigerant
250 S Manöverbrytare Operating Switch
251 S Slutkontakt vändbar förarstol Contact, making, VBFS
260 S Slutkontakt lyft steg 1 Contact, making, hoist step 1
261 S Slutkontakt lyft steg 2 Contact, making, hoist step 2
262 S Slutkontakt tilt Contact, making, tilting
263 S Slutkontakt gaffelspridning Contact, making, fork positioning
264 S Slutkontakt sidoföring Contact, making, sideshift
265 S Slutkontakt stativ in/ut Contact, making, lifting mast in-out
266 S Brytkontakt hyttdörr Contact, breaking cab door
267 S Slutkontakt bromstryck Contact, making, brake pressure
268 S Slutkontakt kompressor Contact, making, Compressor
269 S Slutkontakt sax inne Contact, making extender in
270 S Slutkontakt överlastskydd Contact, making, overload protection
271 S Slutkontakt, filter växellåda Contact, making, filter gearbox
299 S Slut/brytkontakt option Contact, making/braking option
300 K Relä hel/halvljus Relay, main/dipped beam
301 K Relä dimljus Relay, fog light
302 K Relä fjärrljus Relay, distance light
303 K Relä lastljus Relay, mast light
304 K Relä arbetsljus Relay, working light
305 K Relä backljus Relay, reversing light
306 K Relä helljus Relay, main beam
307 K Relä halvljus Relay, dipped beam
308 K Relä bromsljus Relay, brake light
309 K Relä parkeringsbroms Relay, parking light
310 K Relä körvisare vä Relay, direction indicator left
311 K Relä körvisare hö Relay, direction indicator right
312 K Relä startelement Relay,element preheater
313 K Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
314 K Relä parkeringsbroms Relay, parking brake
315 K Relä tändningslås Relay, ignition key
316 K Relä torkare Relay, wiper
317 K Relä strålkastartorkare Relay, roading lights wiper
318 K Relä AT-regulator Relay, AT-regulator
319 K Relä varningsblinkers Relay, hazard blinkers
320 K Relä elektrisk stopp Relay, electical stop
321 K Relä intervalltorkare Relay, intermittent wiper
322 K Relä kylvätskenivå Relay, coolant level
323 K Relä blinkers Relay, blinkers
324 K Relä rangespärr Relay, range interlock
325 K Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
326 K Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
327 K Relä växel neutral Relay, gear neutral
328 K Relä växelskifte Relay, gear shift
329 K Relä växel hög/låg Relay, high/low gear
330 K Relä startspärr Relay, start interlock
331 K Relä drivning fram Relay, forward driving
332 K Relä drivning bak Relay, reversing driving
333 K Tidrelä förvärmning Time relay, automatically preheating
334 K Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
335 K Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear (diesel,LPG)

336 K Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear (diesel,LPG)
337 K Relä drivriktning motor Relay, motor drive direction
338 K Relä kylfläkt drivmotor Relay, cooling fan drive motor
339 K Relä kylfläkt elskåp Relay, cooling fan electrical box
340 K Tidrelä fördröjt tillslag Time relay, start delay
341 K Tidrelä fördröjt frånslag Time relay, stop delay
342 K Relä drivning 2/4 hjul Relay, switching 2/4 WD
343 K Relä dimbakljus Relay, fog light rear
344 K Relä momentförstärkare Relay, torque amplifier
345 K Relä låsning vändskiva Relay, interlocking of turntable
346 K Relä frikoppling stollåsning Relay, releasing of seat interlocking
347 K Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light signal
348 K Relä fläktmotor värmare Relay, fan heating
349 K Relä fartreglage Relay, speed control
350 K Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
351 K Relä hyttlyft upp Relay, cab hoist up
352 K Relä hyttlyft ner Relay, cab hoist down
353 K Relä säkerhetsslinga Relay, safety loop
354 K Relä styrsystem Relay, signal control system
355 K Relä sensorstyrning Relay, sensor control
356 K Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
357 K Relä roterande varningsljus Relay, hazard beacon
358 K Relä komressor luft Relay, compressor air
359 K Relä Hydrauloljekylare Relay hydraulic oil cooler
360 K Relä startsolenoid Relay, starting solenoid
361 K Relä kompressor AC Relay, compressor air conditione
362 K Relä vattenventil AC Relay, water valve air conditioner
363 K Relä kondensor AC Relay, condenser air conditione
364 K Relä stolsbrytare Relay seat switch
365 K Relä fönsterhiss upp Relay, electrical screen elevator up
366 K Relä fönsterhiss ner Relay, electrical screen elevator down
367 K Relä styrning Relay, steerin
368 K Relä lågt bromstryck Relay, low brake pressure
369 K Relä centralsmörjning Relay, central lubrication
370 K Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
371 K Relä lyfthöjd Relay, liftheight
372 K Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter
373 K Relä bakljus Relay light
375 K Huvudkontaktor reglersystem Main contactor, operating control
376 K Kontaktor fram reglersystem Contactor, forward operating control
377 K Kontaktor bak reglersystem Contactor, reversing operating control
378 K Kontaktor by-pass Contactor, ¿by-pass¿ operating control/ Field
reglersystem/Fältförsvagning weakening
379 K Kontaktor pumpmotor Contactor, pump motor
380 K Kontaktor Contactor
381 K Kontaktor återladdning Contactor, recharging
382 K Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
383 K Relä, Stolsvärme Relay, heated seat
384 K Relä vattenseparator Relay, waterseparator
385 K Relä bränslepump insprutning Relay, fuel injection pump
386 K Relä, hög motortemperatur. Relay, high motor temperature
387 K Relä alternativ gaspedal Relay alternative throttle pedal
388 K Relä, Extra färdriktningsväljare Relay, Extra direction selector
389 K Relä, Pausvärme Relay, Paus heat
399 K Relä option Relay, option
400 E G-lampa vä fram Light bulb, roading light left hand front
400 E G-lampa hö fram Light bulb, roading light right hand rear
401 E G-lampa vä bak Light bulb, roading light left hand front
401 E G-lampa hö bak Light bulb, roading light right hand rear
402 E G-lampa fjärrljus Light bulb, distance light
403 E G-lampa lastljus Light bulb, mast light
404 E G-lampa arbetsljus Light bulb, working light

405 E G-lampa backljus Light bulb, rear light
406 E G-lampa cont belysning vänster Container light left-hand
406 E G-lampa cont belysning höger Container light right-hand
408 E G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
408 E G-lampa park ljus hö fram Light bulb, parking light, right-hand forward
410 H G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
410 H G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
411 H G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
411 H G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
412 H G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
412 H G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
413 H G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward (VBFS)
413 H G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward (VBFS)
416 H G-lampa sidomarkering vä fram Light bulb, side position light, left-hand forward
416 H G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear
417 H G-lampa sidomarkering hö fram Light bulb, side position light, right -hand forward
417 H G-lampa sidomarkering hö bak Light bulb, side position light, right-hand rear
420 H G-lampa positionsljus vänster Light bulb, position light, left-hand
421 H G-lampa positionsljus höger Light bulb, position light, right-hand
422 H G-lampa körvisare vä fram Light bulb, direction indicator left-hand forward
423 H G-lampa körvisare hö fram Light bulb, direction indicator right-hand forwrd
426 H G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
427 H G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear
428 H G-lampa roterande varningsljus Light bulb, flashing beacon lamp
429 E G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination
431 E G-lampa instrument belysning Light bulb, instrument illumination
432 E G-lampa handsfack belysning Light bulb, glove pocket light
433 E G-lampa instegs belysning Light bulb, step-in lighting
434 E G-lampa innerbelysning Light bulb, interior lighting
435 E G-lampa låsbelysning Light bulb, reading lighting
436 E G-lampa identifikationsljus Light bulb, identification light
437 E G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
438 E G-lampa motorrumsbelysning Light bulb, engine compartment light
439 E Nummerskyltsbelysning Light license plate
440 E G-lampa värmereglage belysning Light bulb, heating control light
445 H G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
446 H G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
451 H G-lampa dimbakljus vänster Light bulb, fog light rear left
452 H G-lampa dimbakljus höger Light bulb, fog light rear right
453 H G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand
453 H G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-hand
454 H G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
454 H G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
456 E G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
456 E G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
457 H G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand
457 H G-lampa positionsljus blackout höger Light bulb, position light blackout right-hand
458 E G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
458 E G-lampa fram blackout höger Light bulb, roading light blackout right-hand
459 E G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-hand
459 E G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-hand
460 E G-lampa arb.belysning hytt blackout IR Light bulb, working light cab blackout IR left
vä
460 E G-lampa arb.belysning hytt blackout IR Light bulb, working light cab blackout IR right
hö
461 E G-lampa arb.bel. bom 20' blackout IR Light bulb, working light boom20' b.out IR left
vä
461 E G-lampa arb.bel. bom 20' blackout IR Light bulb, working light boom20' b.out IR right
hö
462 E G-lampa arb.bel. bom 40' blackout IR Light bulb, working light boom40' b.out IR left
vä

462 E G-lampa arb.bel. bom 40' blackout IR Light bulb, working light boom40' b.out IR right
hö
463 H G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
463 H G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear, blackout
464 E G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand
464 E G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
465 H G-lampa röd saxagregat ute Light-bulb, red extender exended
466 H G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
467 H G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
468 G-Lampa Röd Maxlast Light bulb,Red Overload
500 H Kont lampa körvisare Indicating lamp, direction indicator
501 H Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
503 H Varn lampa oljetryck motor Warning lamp, oil pressure engine
504 H Kont lampa helljus Indicating lamp, main beam
505 H Varn lampa laddning Warning lamp, loading
506 H Varn lampa laddning (extra) Warning lamp, loading extra
507 H Varn lampa färdbroms Warning lamp, brake
508 H Varn lampa parkerings broms Warning lamp, parking brake
509 H Varn lampa nivå kylvatten Warning lamp, coolant level
510 H Kont lampa diff spärr Indicating lamp, diff. interlock
512 H Varn lampa temp momentförst Warning lamp, temperature converter
514 H Kont lampa överväxel Indicating lamp, overdrive clutch
519 H Kont lampa halvljus Indicating lamp, dipped lights
524 H Kont lampa luftfilter Indicating lamp, air filter
525 H Kont lampa UNIKAT Indicating lamp, UNIKAT
528 H Kont lampa förvärmning Indicating lamp, preheating
530 H Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
531 H Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
532 H Kont lampa crab styrning Indicating lamp, crab steering
533 H Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
547 H Varn lampa centralvarning Warning lamp, central warning
549 H Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
550 H Varn lampa hyttlåsning Warning lamp, cab lock
551 H Varn lampa temp v-låda Warning lamp, temperature gear box
552 H Varn lampa bromstryck Warning lamp, brake pressure
554 H Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system brakes
555 H Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
556 H Varn lampa låsning vändskiva Warning lamp, interlocking of turntable
560 H Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
561 H Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
562 H Varn lampa öppen twistlock Warning lamp, unlocked twist lock
563 H Varn lampa låst twistlock Warning lamp, locked twist lock
564 H Varn lampa anliggning Warning lamp, alignement
565 H Varn lampa temp motor el Warning lamp ,temperature motor
569 H Kont lampa elvärme Indicating lamp, electric heater
569 H Kont lampa elvärme Indicating lamp, electric heater
570 H Varn lampa överkoppling Warning lamp, by-pass safety system
säkerhetssystem
571 H Kont lampa bränslenivå Indicating lamp, fuel level
572 H Varningslampa lyfthöjd Warning lamp lifting height
573 H Kontroll lampa motor information Indicator lamp engine information
574 H Kontroll lampa stödben nere Indicator lamp support jacks down
575 H Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working pos
576 H Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
577 H Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
578 H Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
579 H Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
580 H Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
581 H Kontroll lampa främre ben nere Indicator lamp, front legs lower position
582 H Varningslampa överlast Warning lamp overload
583 H Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
584 H Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs

599 H Kont lampa option Indicating lamp, option
600 Y M-ventil avgasbroms Solenoid valve, exhaust brake
601 Y M-ventil diff spärr Solenoid valve, diff. interlock
602 Y M-ventil broms Solenoid valve, brake
603 Y M-ventil värme Solenoid valve, heater
604 Y M-ventil kraftuttag sida Solenoid valve, power take off, side
605 Y M-ventil kraftuttag bak Solenoid valve, power take off, rear
606 Y M-ventil 2/4 hjulsdrift Solenoid valve, 2/4WD
607 Y M-ventil hög/låg växel Solenoid valve, high/low gear
608 M Pumpaggregat hyttlyft Pump unit, cab hoist
609 M Ställmotor gaspådrag Regulating motor, throttle
610 Y M-ventil hydraulsystem allm Solenoid valve, hydraulics, general
611 Y M-ventil flödesbegränsning Solenoid valve, flow restriction
612 M Ställmotor recirkulation Regulating motor, re-circulation
613 Y M-ventil momentförstärkare Solenoid valve, torque amplifier
614 Y M-ventil rangespärr Solenoid valve, ranging interlock
615 Y M-ventil hjulvridning Solenoid valve, wheel turning
616 Y M-ventil kallstart Solenoid valve, cold start aid
617 Y M-ventil AT-regulator by-pass Solenoid valve, AT-regulator ¿by-pass¿
618 Y M-ventil vatten klimatanläggning Solenoid valve, water air conditioner
620 Y M-ventil vändskiva upp Solenoid valve, fifth wheel up
621 Y M-ventil vändskiva ner Solenoid valve, fifth wheel down
622 Y M-ventil vändskiva fram Solenoid valve, fifth wheel forward
623 Y M-ventil vändskiva bak Solenoid valve, fifth wheel rear
624 Y M-ventil skevning hö Solenoid valve, levelling right hand
625 Y M-ventil skevning vä Solenoid valve, levelling left hand
626 Y M-ventil AT-regulator Solenoid valve, AT-regulator
627 Y M-ventil vakuum Solenoid valve vacuum
628 Y M-ventil bränsleblandning Solenoid valve fuelmixture
630 Y M-ventil v-låda fram Solenoid valve, gear box, forward gear
631 Y M-ventil v-låda back Solenoid valve, gear box, rear gear
632 Y M-ventil v-låda spole 1 Solenoid valve, gear box, 1 gear
635 Y M-ventil klämtryck Solenoid valve, clamping pressure
636 Y M-ventil styrning Solenoid valve, steering
637 Y M-ventil flytläge skevning Solenoid valve, equalizing fifth wheel
638 Y M-ventil stopp insprut pump Solenoid valve, stop injection pump
639 Y M-ventil låsning orbitrol ls Solenoid valve, locking LS orbitrol
640 Y M-ventil gasol Solenoid valve, LPG
641 Y M-ventil förångare (LPG) Solenoid valve, evaporator (LPG)
642 Y M-ventil park broms Solenoid valve, parking brake
643 Y M-ventil låsning stol (VBFS) Solenoid valve, seat locking (VBFS)
644 Y M-ventil låsning vändskiva Solenoid valve, fifth wheel locking
645 Y Magnetkoppling komp AC Magnetic clutch, compressor AC
646 Y M-ventil stolsvändning Solenoid valve, seat rotation
647 Y M-ventil stolstilt Solenoid valve, seat tilt
648 Y M-ventil luftfjädring Solenoid valve, pneumatic springing
649 B Termostat klimatannläggning Thermostat, air condition
650 M Torkarmotor fram
651 M Vindrutespolarmotor Washer motor
652 M Strålkastarmotor Light motor
653 M Strålkastarspolarmotor Light washer motor
654 M Startmotor Starter motor
655 M Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
656 M Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
657 M Fläktmotor värme Heating fan
658 G Generator (extra) Alternator extra
659 G Generator utan laddregulator Alternator without loading regulator

660 G Generator med laddregulator Alternator with loading regulator
661 M Fönsterhissmotor Screenelevator motor
662 G Laddregulator Loading regulator
663 M Doseringspump klimatanläggning Dosage pump, air condition
664 M Cirk pump klimatanläggning Circulating pump, air condition
665 V Diod Diode
666 M Fläktmotor cirkulation Circulation fan
667 M Cirkulationspump värmesystem Circulation pump heating system
668 M Kylfläkt hydraulolja Cooling fan, hydraulic oil
669 E Värmare kupe/ motor diesel Heater compartment/engine diesel
670 M Kompressor Compressor
671 M Doseringspump diesel Dosage pump diesel
672 M Spjäll motor, ECC Draught valve motor, ECC
673 Y Vatten ventil motor, ECC Water valve motor, ECC
674 M Kylfläkt bromsolja Cooling fan, brake fluid
675 M Motor, Stolsvändning Motor, Seat rotation
676 Y M-ventil Broms stolsvändning Solenoid valve Brake seat turning
677 M Motor Låsning stolsvridning Motor Locking revolving seat
685 A Reglerenhet termostat AC Control unit, termostat AC
690 B Fartreglage (EC) Speed control (EC)
693 M Pump centralsmörjning Pump, central lubrication
694 M Styrmotor Steering motor
695 M Drivmotor (EC) Drive motor (EC)
696 M Pumpaggregate nödstyrning Pump, emergency steering
697 B Elbroms Electric brake
698 M Pumpmotor (EC) Pump motor (EC)
699 Y M-ventil option Solenoid valve, option
700 P Hastighetsmätare Speedometer
701 P Mätare oljetemp v-låda Gear box oil temperature gauge
702 P Klocka Clock
703 P Varvtalsmätare Engine rev meter
704 P Tryckluftsmätare Air pressure gauge
705 P Mätare oljetryck v-låda Gear box oil pressure gauge
706 P Termometer temp kylvätska motor Temperature gauge, engine coolant
707 P Bränslemätare Fuel gauge
708 P Timräknare Hour meter
709 P Kapacitetsmätare batteri Capacity gauge, battery
710 P Tidur motor/kupevärmare Timer, engine- and cab heater
711 P Räknare, impuls Counter, impulse
712 P Mätare oljetryck motor Motor oil pressure gauge
714 P Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
715 P Extra instrument allm Extra instrument, general
720 S Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS)
740 D FleetManager kontrollenhet FleetManager control unit
741 U FleetManager batterifilter FleetManager battery filter
742 D FleetManager kortläsare FleetManager card device
743 D FleetManager accelerations givare FleetManager acceleration sensor
744 D Galvaniskt isolerad CAN brygga Galvanic insulated CAN bridge
751 B Givare varvtal turbin Transmitter, speed turbin
752 B Givare varvtal inre växellåda Transmitter, speed internal gear chain
753 B Varvtalsgivare motor Transmitter, engine revolution
754 B Givare lufttryck Transmitter, air pressure
755 B Givare hydraulfilter indikering Transmitter, hydraulics filter indication
756 B Temperatur kylvätska motor Transmitter, engine coolant temperature
757 B Bränslenivågivare Transmitter, fuel level
758 B Varvtalsgivare v-låda Transmitter, gear box revolution
759 B Nivåindikator kylvätska Transmitter, coolant level
760 B Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic gear
change system (on gearbox output shaft)
761 B Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic gear
changing system (engine speed)
762 B Givare temp,spolkrets bromsar Transmitter, brake flushing circuit

763 B Givare nivå hydraulolja Transmitter, hydraulic fluid level
764 B Givare servotryck växellåda Transmitter, gear box servo pressure
765 B Givare oljetryck v-låda Transmitter, oil pressure gear box
766 B Givare oljetemp. v-låda Transmitter, oil temperature gear box
767 B Givare oljetryck motor Transmitter, oil pressure engine
768 B Givare oljetryck hydraulik Transmitter, hydraulic pressure
769 B Givare ändläge Transmitter, end position
770 B Givare rattutslag Transmitter, steering wheel angle
771 B Givare vinkel Transmitter, angle
772 B Givare temp bromsolja Transmitter, temperature brake fluid
773 B Givare närvaro Transmitter, presence
774 B Givare utomhustemp Transmitter, ambient temperature
775 B Givare temp klimatanläggning Transmitter, temperature air condition
776 B Givare temp hydraulolja Transmitter, hydraulic temperature
777 B Givare läge Transmitter, position
778 B Givare drivbrytning Transmitter, drive break
779 A Reglersystem återladdning (EC) Control system, recharging (EC)
780 D Reglersystem drivmotor Control system traction motor
781 D Reglersystem pumpmotor Control system pump motor
782 A Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
783 A Logik interface gaspådrag Logic (interface) throttle
784 A Logik interface bromsregl Logic (interface) brake control
785 A Logik interface styrsystem Logic (interface) control system
786 A Servoförstärkare styrsystem Servo amplifier steering system
789 B Givare allmän Transmitter, common
790 D Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
791 D Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
792 D Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
793 D Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
794 D Elektronisk kontrollenhet motor Electronic Control Unit, engine
795 P Display Display
796 D Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
797 D Elektronisk kontrollenhet, ram Electronic Control Unit, frame
798 D Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
799 A Logik allm (option) Logic, general (option)
800 S Startelement Start element
802 E Eluppvärmd backspegel Electrical heated observation mirror
803 E Eluppvärmd stol Electrical heated seat
804 E Cigarettändare Cigarett lighter
805 E Elvärme hytt Electrical heating cab
806 A Aggregat klimatanläggning Aggregate, air conditioner
807 R Potentiometer Potentiometer
808 E Eluppvärmd lufttorkare Electrical heater air dryer
810 A Kondensor AC, fläkt Condensor AC, fan
815 S Manöverspak Control lever
820 R Motstånd Resistor
821 C KONDENSATOR CAPACITOR
822 Z Signalfilter Signal filter
823 U Signalomvandlare höger Signal amplifier, right
824 U Signalomvandlare vänster Signal amplifier, left
825 R Reglage spakstyrning Controls, (steering with control levers).
826 Y Ventil spakstyrning Valve, (steering with control levers).
827 A Växellåda Gearbox
828 R Shuntmotstånd Shunt-resitor
830 L Tändspole Ignition coil
835 E Tändstift Ignition plug
840 S Strömfördelare Distributor
850 H Signalhorn Horn
853 H Summer Buzzer
888 E Lufttork, kompressor Air Dryer, Compressor
900 A Radio/bandspelare Radio/tape recorder
901 U Spänningsomvandlare Voltage converter

902 B Högtalare Loud speaker
903 W Antenn radio Aerial, radio
905 A Kommunikationsradio Communication radio
906 W Antenn kommunikationsradio Aerial, communication radio
907 A Monitor Monitor
908 A Kamera Camera
909 A Skrivare Printer
910 U Spänningsomvandlare 80V/24V Voltage converter 80 V / 24 V
911 A Dataterminal Dataterminal
912 A Alkolås Interlock device
940 A Logik batterivakt Logic switch , battery watch
941 U Laddningsutjämnare Even charger
950 A Logik transistortändning Logic transistor ignition
955 A Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
960 A Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic gear
changing
961 A Motor/kupevärmare Engine- and cab heater
962 E Logik slitageind kol elmotor Logic indication of wear, brush electrical motor
965 H Backvarnare Reversing alarm
1001 S Strömställare, TW Switch, TW
1002 S Strömställare, lossa TW Switch, unlocking of TW
1003 S Strömställare, låsa TW Switch, locking of TW
1004 S Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
1005 S Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
1006 S Strömställare, fällning främre ben Switch, front legs down
1007 S Strömställare, fällning bakre ben Switch, rear legs down
1008 S Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
1009 S Strömställare, Motor information Switch, Engine information
1010 S Srömställare, tilt av hytt Switch, tilt of cab
1011 S Strömställare IR ljus Switch IR light
1012 S Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
1013 S Strömställare stödben Switch, Support jacks
1014 S Strömställare förbikoppling Switch, over ride rotation stop
rotationstopp
1015 S Strömställare förbikoppling höjdbeg/tp- Switch, over ride height limit/tp-limit
beg
1016
1017 S Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
1018 S Strömställare diagnostik on/off Switch, diagnostics on/off
1019 S Strömställare rastvärme Switch, paus heat
1020 S Strömställare automatisk släpp/kläm Switch automatic release/clamp funktion
funktion
1021 S Strömställare sax Switch extender
1022 S Strömställare vertikalhållning Switch, vertical position
1023 S Strömställare låsning övre arm Switch, lock upper arm
1024 S Strömställare Korta Armen av/på Switch, Short Arm on/off
1025 S Strömställare pappersfunktioner av/på Switch, paper funktions on/off
1026 S Strömställare omkoppling Switch, switch papper/bale clamp
pappers/klämmagregat
1027 S Strömställare lyfthöjdsförval Switch, lift height selection
1028 S Strömställare lyfthöjdsförval öka Switch, lift height selection increase
1029 S Strömställare lyfthöjdsförval minska Switch, lift height selection decrease
1030 S Strömställare läraringång givare Switch, teaching ultrasonic sensor
ultraljud
1031 S Strömställare, Over Height Upp/Ned Switch, Over Height Up/Down
1032 S Brytare backljus Switch reverse light.
1033 S Flytta korta armen Move short arm
1034 S Strömställare förbikoppling startspärr Switch Override Start interlock
1035 S Strömställare Val av klämtryck Switch, Clamp pressure selection
1036 S Strömställare Korta Armen av/på Switch , Short Arm on/off
1037 S Strömställare låsning skevning Switch, lock levelling

1038 S Strömställare Övre armpar/Sidoföring Switch Upper arms/Sideshift
1039 S Strömställare Inching Switch, Inching
1040 S Switch stopp motor Switch, Stop engine
1041 S Strömställare motorrumsbelysning Switch, light engine compartment
1042 S Strömställare höjdjustering stol Switch, Seat height level
1043 S Strömställare längdjustering stol Switch, Seat for/aft adjustment
1044 S Strömställare Tankväljare Switch, Tankselector
1045 S Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
1046 S Strömställare eluppvärmd ruta Switch electrical heated shield
1047 S Henrik testar en brytare!
1048 S Strömställare fjärrstyrning Switch remote control
1049 S Strömställare styrning spegel Switch mirror control
1440 S Huvudströmbrytare
2000 D Elektronisk kontrollenhet, Electronic control unit, propotional valve
proportionalventil
3001 K Relä rotation Relay, rotation
3002 K Relä tilt Relay, tilt
3003 K Relä sidoföring Relay, side shifting
3004 K Relä längdinställning Relay, length adjustment
3005 K Relä twist lock Relay, twist lock
3006 K Relä spridning Relay, spreading
3007 K Relä lyft/sänk Relay, lifting/lowering
3008 K Relä hydraulfunktion extra Relay, extra hydraulic function
3009 K Relä manöverbrytare hydr Relay, operating switch
3010 K Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
3011 K Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
3012 K Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout
3013 K Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
3014 K Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
3015 K Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator left
3015 K Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator right
3016 K Relä signalhorn relay, horn
3017 K Relä containerbelysning Relay, Container light
3018 K Relä containerbelysning IR Relay, Container light IR
3305 K Relä VBFS, backljus Relay, rotating driver´s seat, reversing light
3306 K Relä VBFS, helljus Relay, rotating driver´s seat, main beam
3307 K Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
3308 K Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
3310 K Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction indicator left
3311 K Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction indicator right
3330 K Relä, säkerhetsbälte Relay, seat belt
3331 K Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving
3332 K Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing driving
3349 K Relä VBFS, fartreglage Relay, rotating driver´s seat, speed control
3404 K Relä VBFS, mastljus Relay, rotating driver´s seat, mast light
3405 K Relä,backalarm Relay,reversealarm
3412 K Relä bak ljus Relay, rotating driver´s seat, rear light
3500 A Head up display lasthantering Head up display load handling
3768 K Relä oljetryck hydraulik Relay, hydraulic pressure
3769 K Relä, blockering av hyttilt Relay, blocking of cab tilt
3770 K Relä anliggning Relay, alignment
3771 K Relä Krok Relay, Hook
3772 K Relä laddsignal (D+) Relay, charge signal (D+)
3773 K Relä 12V för minne radio Relay 12V for radio memory
3774 Relä kylfläkt olja Relay, cooling fan oil
3775
3776 K Relä värmare ruta Relay heated window
4370 E Sökljus Search light
5000 H Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
5001 H Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
6001 Y M-ventil blockering höger Solenoid valve, blocking right
6002 Y M-ventil blockering vänster Solenoid valve, blocking left

6003 Y M-ventil inkoppling av hydraulik till Solenoid valve, activation of toplift hydraulics
topplyft
6004 Y M-ventil sänk Solenoid valve, lower
6005 Y M-ventil lyft Solenoid valve, lift
6006 Y M-ventil bom ut Solenoid valve, boom out
6007 Y M-ventil bom in Solenoid valve, boom in
6008 Y M-ventil vridning medsols Solenoid valve, rotation clockwise
6009 Y M-ventil vridning motsols Solenoid valve, rotation counter-clockwise
6010 Y M-ventil tilt ut Solenoid valve, tilt out
6011 Y M-ventil tilt in Solenoid valve, tilt in
6012 Y M-ventil tilt Solenoid valve, tilt
6013 Y M-ventil fällning främre ben Solenoid valve, lowering front legs
6014 Y M-ventil fällning bakre ben Solenoid valve, lowering rear legs
6015 Y M-ventil klämma/lossa ben Solenoid valve, clamping/releasing legs
6016 Y M-ventil Hyttskjutning fram Solenoid valve, cab movement forward
6017 Y M-ventil Hyttskjutning bak Solenoid valve, cab movement reverse
6018 Y M-ventil spridning ut Solenoid valve, spreading out
6019 Y M-ventil spridning in Solenoid valve, spreading in
6020 Y M-ventil sidoföring vänster Solenoid valve, side shift left
6021 Y M-ventil sidoföring höger Solenoid valve, side shift right
6022 Y M-ventil extra hydraulfunktion ut Solenoid valve, extra hydraulic function out
6023 Y M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in
6024 Y M-ventil stativ ut Solenoid valve, mast out
6025 Y M-ventil stativ in Solenoid valve, mast in
6026 Y M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering left
6027 Y M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering right
6028 Y M-ventil vänster framhjul styrning Solenoid valve, left front wheel, steering left
vänster
6029 Y M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering right
6030 Y M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering left
6031 Y M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering right
6032 Y M-ventil vänster bakhjul styrning Solenoid valve, left rear wheel, steering left
vänster
6033 Y M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right
6034 Y M-ventil skevning Solenoid valve, levelling
6035 Y M-ventil skevning höger Solenoid valve, levelling right
6036 Y M-ventil skevning vänster Solenoid valve, levelling left
6037 Y M-ventil kylfläkt Solenoid valve, Cooling fan
6038 Y M-ventil frikoppling koppling Solenoid valve, lockup clutch
6039 Y M-ventil öppna twistlock Solenoid valve, unlocked twist lock
6040 Y M-ventil låsa twistlock Solenoid valve, locked twist lock
6041 Y M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
6042 Y M-ventil mellan bom Solenoid valve, middle boom
6043 Y Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
6044 Y M-ventil blockering twistlock Solenoid valve, blocking twistlock
6045 Y M-ventil blockering lyft Solenoid valve, blocking lift
6046 Y M-ventil utskjut Solenoid valve, projecting
6047 Y M-ventil, hyttilt upp Solenoid valve, cab tilt up
6048 Y M-ventil, hyttilt ner Solenoid valve, cab tilt down
6049 Y M-ventil, kylkrets broms Solenoid valve, cooling cicuit brake
6050 Y M-ventil blockering utskjut Solenoid valve, blocking projecting
6051 Y M-ventil, regenerering höger Solenoid valve, regeneration right
6052 Y M-ventil, regenerering vänster Solenoid valve, regeneration left
6053 Y M-ventil, körläge Solenoid valve, driving position
6054 Y M-ventil, klämma ihop Solenoid valve, clambing in
6055 Y M-ventil, klämma isär Solenoid valve, clambing out
6056 Y M-ventil, främre knä ut Solenoid valve, front knee out
6057 Y M-ventil, främre knä in Solenoid valve, front knee in
6058 Y M-ventil, bakre knä ut Solenoid valve, rear knee out
6059 Y M-ventil, bakre knä in Solenoid valve, rear knee in
6060 Y M-ventil, främre ben upp Solenoid valve, front legs up
6061 Y M-ventil, bakre ben upp Solenoid valve, rear legs up

6062 Y M-ventil, urkoppling hydraulpump Solenoid valve interruption hydraulic pump
6063 Y M-ventil, stödben upp Solenoid valve, brace up
6064 Y M-ventil, stödben ner Solenoid valve, brace down
6065 Y M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake
6066 Y M-ventil, v-låda, drivning Solenoid valve, gearbox, drive
6067 Y M-ventil, v-låda, oljetryck till 1:a/3:e Solenoid valve, gearbox,oilpressure to 1st/3rd gear
växeln
6068 Y M-ventil sax/rotation Solenoid valve externder/rotation
6069 Y M-ventil, v-låda, oljetryck till 2:a/4:e Solenoid valve, gearbox,oilpressure to 2nd/4th gear
växeln
6070 Y M-ventil Over Height upp Solenoid valve, Over Height up
6071 Y M-ventil Over Height ner Solenoid valve, Over Height down
6072 Y M-ventil klämtryck Solenoid valve clamp pressure
6073 Y Propertional ventil, Opti speed Proportional valve, Opti speed
6074 Y M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for 2nd/4th gear
växeln
6075 Y M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for 1st/3rd gear
växeln
6076 Y M-ventil blockering sänk Solenoid valve, blocking lower
6077 Y M-ventil Inching Solenoid valve, Inching
6078 Y M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
6079 Y M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
6080 Y M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
6081 Y M-ventil, ackumulatorladdning Solenoid valve, accumulator charge
6082 Y M-ventil tryckbegränsning Solenoid valve, pressure restriction
7200 S Givare, axeltryck höger Sensor, axle pressure right
7201 S Givare, axeltryck vänster Sensor, axle pressure left
7202 S Givare, anliggning vänster fram Sensor, alignment left front
7202 S Givare, anliggning höger fram Sensor, alignment right front
7203 S Givare, anliggning vänster bak Sensor, alignment left rear
7203 S Givare, anliggning höger bak Sensor, alignment right rear
7204 S Givare, öppen vänster twistlock Sensor, unlocked twistlock left
7204 S Givare, öppen höger twistlock Sensor, unlocked twistlock right
7205 S Givare, låst vänster twistlock Sensor, locked twistlock left
7205 S Givare, låst höger twistlock Sensor, locked twistlock right
7206 S Givare, gaffel aggregat Sensor, fork attachment
7207 S Givare, 2WD/4WD Sensor, 2WD/4WD
7208 S Givare, hytt i körläge Sensor, Cab in drive position
7209 S Givare, oljefilter indikering Sensor, Oil filter indication
7210 S Givare, hytt i transportläge Sensor, Cab in transportation position
7211 S Givare, lyfthöjd Sensor, lifting height
7212 S Givare, körläge Sensor, driving position
7213 S Givare, Anliggning främre ben Sensor, Alignment front legs
7214 S Givare, Anliggning bakre ben Sensor, Alignment rear legs
7215 S Givare, kläm främre ben Sensor, Clamp front legs
7216 S Givare, kläm bakre ben Sensor, Clamp rear legs
7217 S Givare, främnre knä Sensor, front knee
7218 S Givare, bakre knä Sensor, rear knee
7219 S Givare, främre ben Sensor, front legs
7220 S Givare, bakre ben Sensor, rear legs
7221 S Givare, styraxel Sensor, steering axle
7222 S Givare, stödben uppe Sensor, brace up
7223 S Givare, stödben nere Sensor, brace down
7224 B Givare, mätläge våg Sensor, measurepoint scale
7225 B Givare, rotationsstopp Sensor, rotation stop
7226 B Givare, tryck lyftcylinder Sensor, pressure lift cylinder
7227 B Givare, tryck klämma Sensor, pressure clamp
7228 B Givare lyfthöjd analog Sensor lift height analogue
7229 B Givare tiltvinkel analog Sensor tilt angle analogue
7230 B Givare ultraljud last position Sensor, ultrasonic load position
7231 B Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
7232 B Givare,IR Last position Givare,IR Load position

7233 B Givare lambda sond Sensor lambda sond
7234 B Givare vatten i bränsle Transmitter water in fuel
7235 B Givare temp avgaser Sensor exhaust temperature
7236 B Givare tryck avgaser Sensor exhaust pressure
7651 B Givare oljetryck v-låda 1:a/3e Transmitter oil pressure gearbox 1st/3rd
7652 B Givare oljetryck v-låda 1/3
7751 B Givare temperatur inne Sensor temp indoor
7753 B Sensor temperatur avisning Sensor temperatur deicing
7901 D d
8071 R Potentiometer lyft/sänk Potentiometer lift/lower
8072 R Potentiometer tilt Potentiometer tilt
8073 R Potentiometer sidoföring Potentiometer side shifting
8074 R Potentiometer spridning Potentiometer spreading
8075 R Potentiometer extra Potentiometer extra
8076 R Potentiometer mast in/ut Potentiometer reach in/out
8077 R Potentiometer höger framhjul Potentiometer right front wheel
8078 R Potentiometer vänster framhjul Potentiometer left front wheel
8079 R Potentiometer höger bakhjul Potentiometer right rear wheel
8080 R Potentiometer vänster bakhjul Potentiometer left rear wheel
8081 R Potentiometer tiltvinkel Potentiometer tilt angle
8082 R Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC
8083 R Potentiometer temperatur, ECC Potentiometer temperature, ECC
8084 R Potentiometer spjäll, ECC Potentiometer draught valve, ECC
8085 R Potentiometer rotation Potentiometer rotation
8086 R Potentiometer sax Potentiometer extender
8087 R Potentiometer klämma Potentiometer clamp
8088 R Potentiometer skevning Potentiometer levelling
8089 R Potentiometer kroklåsning Potentiometer flaps
8090 V Laser, pappersaggretgat Lase, Pulp an Paper
8091
8092 E Eluppvärmd ruta Electrical heated window
8093 W Genomföring, kablage Lead-through, harness
9000 M Motor höj/sänkbar stolspelare Motor rise/lower seat column
9001 D Åkerströms fjärrkontroll Åkerströms Remote Control
9002
9003 H Varningssignal aut. rörelse Warning alarm aut. movement
9888 A test
93774 K Relä hållkrets Relay, Holdcircuit
F Technical data 1
F Technical data
Table of Contents F Technical data

mm mm mm mm mm mm
Technical data ................................................................................................ 3

Specifications for data and volume ........................................................................ 3
Specifications oil, lubricants and fluids ................................................................... 5
Oils and lubricants, recommendation ..................................................................... 7
Tightening torques, recommendations ................................................................... 9
Tightening torque, ORFS connections ................................................................. 10
Tightening torque, connections for air conditioning .............................................. 12
Unit explanations .................................................................................................. 12
Conversion table, SI-units .................................................................................... 13
Conversion table, length ....................................................................................... 14
Conversion table, area ......................................................................................... 14
Conversion table, volume ..................................................................................... 14
Conversion table, weight ...................................................................................... 15
Conversion table, pressure .................................................................................. 15

2 F Technical data

F Technical data – Technical data 3
Technical data
mm mm mm mm mm mm
Specifications for data and volume

page
–
Data
1 Engine Volvo TAD760VE Cummins QSB6.7
Power acc. to ISO 3046 (net power) 180 kW at 2200 rpm 164 kW at 2200 rpm
Torque ISO 3046 1100 Nm at 1500 rpm 949 Nm at 1500 rpm
Number of cylinders 6 cylinders 6 cylinders
Alternator, output 1920 W (24 V / 80 Ah) 1680 W (24 V / 70 Ah)
Start battery, voltage – capacity 24 V (2x12 V – 140 Ah)
2 Transmission Dana-Spicer Off Highway TE17
No. of gears, forward - reverse 3-3
Drive axle, type Kessler D81
Kessler D91
4 Brakes
Parking brake Spring brake - Drive wheels
Service brake Wet Disc Brakes - Drive wheels
5 Steering Hydraulic servo
6 Suspension
Dimensions, front and rear 14.00x24
Tyre pressure (see also pressure 1.0 MPa

plate)
Tyre type, front and rear Air inflated. Spare and replacement tyres must be from a manufacturer approved
by Cargotec.
9. Cab Spirit Delta with Volvo TAD760VE Spirit Delta with Cummins QSB6.7
Equivalent sound pressure level in cab LpAZ 69 dB(A) LpAZ 65 dB(A)

according to EN12053 with measure-
ment uncertainty, R= 2.5 dB. Meas-
urement value with standard engine.

4 F Technical data – Technical data
Whole-body vibrations according to 0,4 - 0,7 m/s2

EN13059 with measurement uncer-
tainty k=0.3 x measured value.
9.6 Frame, body, cab and accessories, lighting system
Lamp Output (W) Socket

Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Tail lights, brake lights & LED direction - Replaced as a single unit.
indicators
Position lamps 5 W2.1x9.5d
- Replaced as a single unit

Position lamps LED
Headlights (high and low beams) 75/70 P43t-38(H4)
Back-up lights 70 PK22s(H3)
Working lights glow lights 70 PK22s(H3)
35 D1S Xenon tubes. The insert and

Working light Xenon ballast must be changed as a unit.
- Replaced as a single unit.

Work light LED
Revolving beacon 35 PK22s(H1)

Specifications oil, lubricants and

–
fluids
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system
Fuel tank, volume 450 l
Fuel quality Diesel, acc. to EN590
1.7 Engine, cooling system Volvo TAD760VE Cummins QSB6.7
Coolant volume 22 l 29 l
Coolant, filling point Volvo Penta Coolant VCS, ES Compleat, Premix

ready-mixed
WARNING!
Risk of engine damage, if different types of coolants are mixed.
When changing and topping up coolant, the same type of coolant must be
used as was used before. See Parts Catalogue for correct part number.
Oil type, quality See Oils and lubricants, recommendation page 7.
Oil volume 23 l 20 l
2.6 Transmission, lubrication TE17

system
Oil type See Oils and lubricants, recommendation page 7.
Oil volume 37 l
3.3 Power transmission, drive axle Kessler D81 - Kessler D91
Oil grade See Oils and lubricants, recommendation page 7.
Oil volume, differential 42 l - 54 l
Oil volume, hub reduction 2x4 l - 2x4 l
4.8 Brake system

7 Load handling

Refrigerant, air conditioning R134a
Refrigerant volume See air conditioning plate


Lubricant, air conditioning ZEXEL PAG oil ZXL100
Washer fluid, volume 5l
Hydraulic oil tank, volume 360 l
Hydraulic oil system, volume 450 l

Oils and lubricants,

page
–
recommendation
The service intervals indicated by Cargotec in the maintenance man-
ual only apply if oils are selected in accordance with the table below.
The table indicates recommended viscosity for different oil types and
grades depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
Oil type, quality C -40 -30 -20 -10 0 +10 +20 +30 +40
F -40 -22 -4 +14 +32 +50 +68 +86 +104
1.8 Engine, lubrication system

Volvo TAD760VE: VDS-3 *)
-15C SAE 15W40 (engine oil)
Cummins: API: CH-4 / ACEA: E5
SAE 5W30 (engine oil)
2.6 Transmission, lubrication system
ATF DEXRON III DEXRON III
3.3 Power transmission, drive axle
API GL-5 SAE 80W140
SAE 75W90
7 Load handling
Oil planetary gear hydraulic motor, hy- SAE 80W140

poid oil API GL-5
SAE 75W90
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32

WARNING
Change interval for engine oil requires that the sul-
phur content in the fuel does not exceed 0.5%.
A higher sulphur content in the fuel can damage the

engine and the aftertreatment system!
Only use fuel with a sulphur content that does not

exceed 0.5%
NOTE
Oil filters shall always be changed in connection with oil change.
*) The oil in the brake system must fulfil one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for
all lubrication points except slide plates, lifting equipment, and slide
plates.
For lifting 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
Contact grease
Use contact grease part no. 923836.0552.
Sealant silicone
Use silicone part no. 923107.0308.
Coolant
Use ready-mixed recommended coolant. Select the coolant mixture
that is adapted to the correct temperature.
CAUTION
Risk of engine damage, if different types of coolants

are mixed.


Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torque-tightening using a machine, for example, bolt runner, the
tightening torque should be reduced by approx. 5%.
For mild surfaces (hardness below 200 HB), washer shall be used un-
der both bolt head and nut. Alternatively, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication ac-
cording to the table below.
Condition Screw Nut Lubrication
1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9
Condition 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101.25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121.25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread

Quality 8.8 10.9 12.9
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm
3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, ORFS

page
–
connections
Pipe and hose fitting
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"

Pipe diameter Tightening torque

mm inch Nm
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Material fitting
UNF-UN Metric-ISO BSSP

Thread Tightening torque Thread Tightening torque Thread Tightening torque (Nm)
(inch) (Nm) (mm) (Nm) (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

Tightening torque, connections for

page
–
air conditioning
O-ring couplings cooling hoses
Hose diameter Thread Tightening torque
mm inch inch Nm
6 1/4" 7/16" 7-14 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-27 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-47 Nm
Pressure switch 3/8" 7-14 Nm
The above values should be considered guidelines and may vary de-
pending on installation.
Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion table, SI-units

page
–
SI-unit Recalculation factor Non-SI Recalculation factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm2 x 14.22 = psi x 0.070 = kp/cm2
N/mm2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 =W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 =J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l/min (dm3/min) x 0.264 = US gal/ min x 3.785 = litre/min

Conversion table, length

page
–
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm - 1 mm = 0.001 m
Conversion table, area

page
–
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1ha = 100a - 1mile2 = 259ha = 2.59km2
Conversion table, volume

page
–
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1gal (US) = 3785.41cm3 = 231in3 = 0.83267gal (UK)

Conversion table, weight

page
–
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table, pressure

page
–
Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56Torr (mmHg) = 0.96784atm


G Terminology and index 1
G Terminology and index
Table of Contents G Terminology and index

mm mm mm mm mm mm
Terminology and index.................................................................................. 3

Terminology ............................................................................................................ 3
Index ....................................................................................................................... 6

2 G Terminology and index

G Terminology and index – Terminology and index 3
Terminology and index

mm mm mm mm mm mm
Terminology
page
–
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grips the load when lifting.
Battery disconnector Cuts off power supply from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Control valve Valves that can be used to control something, for example, to release pressure and
thus lower a boom or a fork. See also control valve.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Display "Window" showing digital information on steering wheel panel in the cab.
Drive axle Driving axle that receives the torque from the drive-train.
Drive-train Parts in machine involved in power transmission; engine, torque converter, trans-
mission, propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied au-
tomatically during operation.
ECC Electric Climate Control. Air conditioning system with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heater system with thermostat heating control.
Electrolyte level Fluid level in battery cells.
End position As far out or away as the object can be moved, e.g. end position for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Coolant reservoir, with space for the fluid to change volume due to temperature
differences.
Fixed displacement Pump with fixed pump volume.
Frame member Structural members in the frame.
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drive-train.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Mechanical "sensor", for example, shows that a filter is clogged and needs to be
changed.
LC Load centre.
Levelling Attachment is tilted, for example if load stands on uneven ground.

4 G Terminology and index – Terminology and index
Term Description
Lift capacity Indicates machine’s maximal lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Lock hooks Two hooks that are slide down/in into holes in the container to lock the container in
place when lifting.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to
regulations.
Machine model Machine type. Indicated, for example: DCE 90-100. See also type designation.
Main fuse Located by battery. Cuts off current to all systems in machine.
Maintenance Periodic maintenance actions so that machine functions safely and for a long serv-
ice life.
Mast Carrier of trolley, attachment and load.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement (constant mesh).
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angle.
Proportional valve An electromagnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current’s amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, on the transmission valve housing.
Recirculation Circulate over and over again.
Refrigerant Fluid/gas in the climate control system. Must only be handled by authorised trained
personnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo Power amplifier. A small movement by the user generates great displacement, e.g.
power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Solenoid valve An electro magnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
Spreading (positioning) Widening of attachment.
Steering axle Wheel axle with steering.
Tilting The mast is tilted forwards or backwards.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for gearbox and torque converter. See specifications in operator’s manual.
Trolley Lifts the load, located on the mast.

Term Description
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Valve slide Movable part in valve. Determines oil’s path.
Wet brakes Brake discs in oil bath.
Wheelbase Distance between drive axle and steering axle.
Working hydraulics All load handling functions, that is, lift and lower, tilt, side shift, spreading (exten-
sion) and levelling.

Index
page
–
Designation Section Function group

A near accident is a warning! B Safety -
About machine version A Foreword -
About the documentation A Foreword -
About the Workshop Manual A Foreword -
Accelerator 1 Engine 1.1.2
Accumulator 4 Brakes 4.3.4
Accumulator 7 Load handling 7.7.2
Accumulator charging valve 4 Brakes 4.3.3
Accumulator charging valve 4 Brakes 4.8.4
Accumulator drain valve 10 Common hydraulics 10.2.1
Accumulator servo circuit 7 Load handling 7.2.4
Air cleaning system 1 Engine 1.6.1
Air distributor 9 Frame, body, cab and accessories 9.4.14
Air intake and exhaust outlet 1 Engine 1.6
Air pollution B Safety -
Air suspension 9 Frame, body, cab and accessories 9.3.5
Alternator 11 Common electrics 11.4
Alternator 11 Common electrics 11.4.1
Arm rest 9 Frame, body, cab and accessories 9.3.9
ATTACH, DCF 70 and DCF 80-100 with twistlock 8 Control system 8.4.9
attachment
ATTACH, DCF 80-100 with lifting hook attachment 8 Control system 8.4.9
ATTACH, DCF360-450CSG 8 Control system 8.4.9
Axial piston pump with variable displacement 10 Common hydraulics 10.4.2
Back rest cushion 9 Frame, body, cab and accessories 9.3.2
Back-up alarm 9 Frame, body, cab and accessories 9.7.5
Back-up lights 9 Frame, body, cab and accessories 9.6.5
Batteries 11 Common electrics 11.3
Battery disconnector 11 Common electrics 11.2.1
Body structure 9 Frame, body, cab and accessories 9.13
Brake lights 9 Frame, body, cab and accessories 9.6.4
Brake pedal 4 Brakes 4.1.1


Brake pressure NC switch 4 Brakes 4.3.7
Brake valve 4 Brakes 4.3.5
Brakes 4 Brakes 4
Break contact (opening switch) declutch 2 Transmission 2.8.2
Break contact (opening switch) parking brake 4 Brakes 4.5.5
Breather filter hydraulic oil tank 10 Common hydraulics 10.6.6
Breather filter hydraulic oil tank 4 Brakes 4.8.11
Bumper 9 Frame, body, cab and accessories 9.3.4
Buzzer, automatic spread 20’-40’ 7 Load handling 7.5.7
Bypass 8 Control system 8.2.2
Bypass valve, cooler 10 Common hydraulics 10.6.5
CAB 8 Control system 8.4.3
Cab frame 9 Frame, body, cab and accessories 9.10.1
Cab interior 9 Frame, body, cab and accessories 9.11
Cab structure and suspension 9 Frame, body, cab and accessories 9.10
Cab substructure 9 Frame, body, cab and accessories 9.10.3
Cabin fan 9 Frame, body, cab and accessories 9.4.3
Cable harness 11 Common electrics 11.5.5
Calibration 8 Control system 8.5.2
CAN bus 11 Common electrics 11.6.1
CAN bus drive-train 11 Common electrics 11.6.3
CAN/POWER 8 Control system 8.4.1
Central lubrication 9 Frame, body, cab and accessories 9.14
Chassis 9 Frame, body, cab and accessories 9.12
Circuit diagram, description 11 Common electrics -
Circuit diagrams, compilation 11 Common electrics -
CLIMATE 8 Control system 8.4.4
Clothing, etc. B Safety -
Collection block, unfiltered returns 10 Common hydraulics 10.5.5
Common electrics 11 Common electrics -
Common electrics 11 Common electrics 11
Common hydraulics 10 Common hydraulics 10
Common hydraulics 11 Common hydraulics -
Communication 11 Common electrics 11.6


Communication between PC and machine 11 Common electrics 11.6.4
Complete machine, description 0 Complete machine -
Component designations 11 Common electrics -
Compressed air-suspended seat 9 Frame, body, cab and accessories 9.3.6
Compressor 9 Frame, body, cab and accessories 9.4.7
Condenser 9 Frame, body, cab and accessories 9.4.8
Conditions A Foreword -
Container counter 7 Load handling 7.10.1
Control breaker 11 Common electrics 11.2.3
Control breaker 9 Frame, body, cab and accessories 9.2.1
Control levers 7 Load handling 7.1.1
Control system 8 Control system 8
Control system D Error codes -
Control system, engine 1 Engine 1.9
Control system, transmission 2 Transmission 2.8
Control units 11 Common electrics 11.5.3
Control valve, attachment 7 Load handling 7.4.2
Control valve, lift and tilt 7 Load handling 7.2.5
Control valve, lift and tilt 7 Load handling 7.7.5
Controls and instruments 1 Engine 1.1
Controls and instruments 2 Transmission 2.1
Controls and instruments 4 Brakes 4.1
Controls and instruments 7 Load handling 7.1
Controls and instruments 8 Control system 8.1
Controls and instruments 9 Frame, body, cab and accessories 9.1
Conversion table, area F Technical data -
Conversion table, length F Technical data -
Conversion table, pressure F Technical data -
Conversion table, SI-units F Technical data -
Conversion table, volume F Technical data -
Conversion table, weight F Technical data -
Coolant 1 Engine 1.7.7


Coolant B Safety -
Cooler hydraulic oil 10 Common hydraulics 10.6.2
Cooling fan 1 Engine 1.7.5
Cooling fan 10 Common hydraulics 10.6.3
Cooling fan 4 Brakes 4.8.9
Cooling system 1 Engine 1.7
Cooling system 2 Transmission 2.7
Copyright A Foreword -
Counterweights 9 Frame, body, cab and accessories 9.13.4
Defroster nozzles 9 Frame, body, cab and accessories 9.4.15
Diagnostics 8 Control system 8.4
Direction indicators 9 Frame, body, cab and accessories 9.6.6
Dissolvent B Safety -
Distribution block 9 Frame, body, cab and accessories 9.14.2
Distribution of electricity 11 Common electrics 11.5
Doors 9 Frame, body, cab and accessories 9.10.2
Drive axle 3 Power transmission 3.3
Drive axle block 4 Brakes 4.3.6
Drive axle block 4 Brakes 4.8.5
Electric motors B Safety -
Electric protection 11 Common electrics 11.2
Electronic box 11 Common electrics 11.5.2
ELSERV 8 Control system 8.4.8
Engine 1 Engine 1
Engine D Error codes -
ENGINE 8 Control system 8.4.6
Engine control unit 1 Engine 1.9.1
Engine heater 1 Engine 1.7.10
Entertainment and communication 9 Frame, body, cab and accessories 9.8
Entry lighting 9 Frame, body, cab and accessories 9.6.13
Environment B Safety -
Error code menu 8 Control system 8.1.10
Error code menu, description D Error codes -
Error codes engine (engine alternative Volvo TAD760VE) D Error codes -


Error codes engine, general D Error codes -
Error codes machine D Error codes -
Error codes motor (engine alternative Cummins QSB6.7) D Error codes -
Error codes, explanation D Error codes -
Error codes, transmission D Error codes -
Exhaust system 1 Engine 1.6.3
Expansion valve 9 Frame, body, cab and accessories 9.4.11
EXTRA 8 Control system 8.4.11
Feedback A Foreword -
Fine filter hydraulic oil 10 Common hydraulics 10.6.9
Fire and explosion risk B Safety -
Fire extinguisher 9 Frame, body, cab and accessories 9.2.3
Flashing hazard lights 9 Frame, body, cab and accessories 9.6.7
Flashing hazard lights 9 Frame, body, cab and accessories 9.7.2
Flex plates 2 Transmission 2.2.1
Floor covering 9 Frame, body, cab and accessories 9.11.4
Fluid or gas under pressure B Safety -
Footsteps and hand rail 9 Frame, body, cab and accessories 9.13.3
Form for copying A Foreword -
Frame, body, cab and accessories 9 Frame, body, cab and accessories 9
Fresh air and recirculation damper 9 Frame, body, cab and accessories 9.4.2
Fresh air filter 9 Frame, body, cab and accessories 9.4.1
Fuel system 1 Engine 1.2
Fuel system B Safety -
Fuel tank 1 Engine 1.2.1
Function descriptions A Foreword -
Function group structure A Foreword -
Fuses 11 Common electrics 11.2.2
Gear pump with fixed displacement 10 Common hydraulics 10.4.1
Gear selector and multi-function lever 2 Transmission 2.1.1
Gear selector and multi-function lever 9 Frame, body, cab and accessories 9.1.1
General A Foreword -
General B Safety -
General safety information B Safety -


Glass/windows/mirrors 9 Frame, body, cab and accessories 9.9
Headlights 9 Frame, body, cab and accessories 9.6.1
Heat exchanger heat 9 Frame, body, cab and accessories 9.4.4
Heat exchanger, cooling 9 Frame, body, cab and accessories 9.4.13
Heating coil 9 Frame, body, cab and accessories 9.3.3
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
Height limitation 8 Control system 8.2.6
Height warning 8 Control system 8.2.7
Hood engine compartment 9 Frame, body, cab and accessories 9.13.2
Horn 9 Frame, body, cab and accessories 9.7.1
Hoses, pipes and valves 10 Common hydraulics 10.5
HYD 8 Control system 8.4.5
Hydraulic and brake systems, depressurising B Safety -
Hydraulic cylinders 10 Common hydraulics 10.7.1
Hydraulic diagram DCF 80-100, electric servo 11 Common hydraulics -
Hydraulic diagrams, compilation 11 Common hydraulics -
Hydraulic oil 10 Common hydraulics 10.6.8
Hydraulic oil 4 Brakes 4.8.14
Hydraulic oil filter 10 Common hydraulics 10.6.7
Hydraulic oil filter 4 Brakes 4.3.2
Hydraulic oil pump 4 Brakes 4.3.1
Hydraulic oil pump 5 Steering 5.2.1
Hydraulic oil pump 7 Load handling 7.2.1
Hydraulic oil tank 4 Brakes 4.8.1
Ignition 1 Engine 1.1.1
Important information A Foreword -


Initiation 8 Control system 8.5.1
Instrument and control panels 9 Frame, body, cab and accessories 9.11.1
Insulation 9 Frame, body, cab and accessories 9.11.5
Intercooler 1 Engine 1.6.4
Interior fittings, plastic 9 Frame, body, cab and accessories 9.11.2
Interior fittings, textile 9 Frame, body, cab and accessories 9.11.3
Interior lighting 9 Frame, body, cab and accessories 9.6.11
Levelling 7 Load handling 7.8
Levelling cylinder 7 Load handling 7.8.3
Lift and lower 7 Load handling 7.2
Lift cylinder 7 Load handling 7.2.7
Lifting equipment B Safety -
Lifting heavy components B Safety -
Lifting hook 7 Load handling 7.9.2
Lighting system 9 Frame, body, cab and accessories 9.6
LIGHTS 8 Control system 8.4.2
Lines 9 Frame, body, cab and accessories 9.14.3
Link arm 5 Steering 5.2.6
Load carrier 7 Load handling 7.9
Load handling 7 Load handling 7
Load retention valve 7 Load handling 7.7.6
Lubrication system 2 Transmission 2.6
Machine card A Foreword -
Main beam, side lift attachment 7 Load handling 7.5.5
Make-contact (closing switch) brake lights 4 Brakes 4.3.8
Mast 7 Load handling 7.2.9
Mast 7 Load handling 7.7.8
Mast position sensor 7 Load handling 7.2.10
Mechanical seat adjustment 9 Frame, body, cab and accessories 9.3.7
Moisture filter 9 Frame, body, cab and accessories 9.4.9
Monitor, reversing camera 9 Frame, body, cab and accessories 9.9.7
Monitoring 8 Control system 8.2
NO (normally open) switch, coolant level 1 Engine 1.7.8
Noise B Safety -


Non-ionised radiation B Safety -
Nut, washer and clamp 6 Suspension 6.3.3
Oil cooler 2 Transmission 2.6.3
Oil cooler 2 Transmission 2.7.3
Oils B Safety -
Oils and lubricants, recommendation F Technical data -
OLS 8 Control system 8.4.10
Ordering documentation A Foreword -
Other 10 Common hydraulics 10.7
Other functions 7 Load handling 7.10
Overload system 8 Control system 8.2.1
Paint/coatings 9 Frame, body, cab and accessories 9.15
Parking brake system 4 Brakes 4.5
Parking brake unit 4 Brakes 4.5.4
Passenger seat 9 Frame, body, cab and accessories 9.3.8
Pause heater 9 Frame, body, cab and accessories 9.4.19
Pipes and hoses 10 Common hydraulics 10.2.4
Pipes and hoses 4 Brakes 4.3.10
Pipes and hoses 5 Steering 5.2.13
Pipes and hoses 7 Load handling 7.2.13
Position sensor, spreading 7 Load handling 7.5.6
Power assisted system 5 Steering 5.2
Power transmission 3 Power transmission 3
Power-assisted brake system 4 Brakes 4.3


Pressure limiting valve 10 Common hydraulics 10.2.3
Pressure reducer 7 Load handling 7.2.3
Pressure reducer 7 Load handling 7.7.3
Pressure switch 9 Frame, body, cab and accessories 9.4.10
Priority valve 10 Common hydraulics 10.5.2
Priority valve 5 Steering 5.2.2
Product alternatives and optional equipment A Foreword -
Propeller shaft 3 Power transmission 3.2
Pump unit 9 Frame, body, cab and accessories 9.14.1
Pumps 10 Common hydraulics 10.4
Radiator and expansion tank 1 Engine 1.7.4
Read operator’s manual A Foreword -
Read the Maintenance manual A Foreword -
Reading instructions A Foreword -
Reading out error code D Error codes -
Reading-lamp 9 Frame, body, cab and accessories 9.11.8
Rear view mirror 9 Frame, body, cab and accessories 9.9.5
Rear window 9 Frame, body, cab and accessories 9.9.4
Redundant CAN bus 11 Common electrics 11.6.2
References between different information types A Foreword -
Refrigerant B Safety -
Relief valve, attachment 10 Common hydraulics 10.2.2
Relief valve, attachment 7 Load handling 7.4.7
Reversing camera 9 Frame, body, cab and accessories 9.9.6
Revolving beacon 9 Frame, body, cab and accessories 9.6.8
Revolving beacon 9 Frame, body, cab and accessories 9.7.3
Rim 6 Suspension 6.3.2
RMI (Remote Machine Interface) 11 Common electrics 11.6.5
Roof grating 9 Frame, body, cab and accessories 9.2.5
Roof window 9 Frame, body, cab and accessories 9.9.3
Rotating components and tools B Safety -
Running lights 9 Frame, body, cab and accessories 9.6.2
Safety and emergency equipment 9 Frame, body, cab and accessories 9.2
Safety concerns everyone! B Safety -


Safety instructions B Safety -
Safety valves 10 Common hydraulics 10.2
Seat 9 Frame, body, cab and accessories 9.3
Seat belt 9 Frame, body, cab and accessories 9.2.2
Seat buzzer 9 Frame, body, cab and accessories 9.2.4
Seat cushion 9 Frame, body, cab and accessories 9.3.1
Sensor cab temperature 9 Frame, body, cab and accessories 9.4.17
Sensor fuel level 1 Engine 1.2.2
Sensor hydraulic oil temperature 10 Common hydraulics 10.6.4
Sensor hydraulic oil temperature 4 Brakes 4.8.10
Sensor hydraulic pressure lift cylinder 7 Load handling 7.2.8
Sensor, ambient temperature 9 Frame, body, cab and accessories 9.4.18
Sensor, engine temperature 9 Frame, body, cab and accessories 9.4.6
Sensor, operator-in-seat 9 Frame, body, cab and accessories 9.3.14
Sensor, temperature outlet fan 9 Frame, body, cab and accessories 9.4.16
Sensor, temperature refrigerant 9 Frame, body, cab and accessories 9.4.12
Service indicator 8 Control system 8.2.4
Service position B Safety -
Servo filter 7 Load handling 7.2.2
Servo filter 7 Load handling 7.7.4
Setup 8 Control system 8.5
Several mechanics on the same machine B Safety -
Shuttle valve 10 Common hydraulics 10.5.3
Shuttle valve 5 Steering 5.2.9
Shuttle valve 7 Load handling 7.2.6
Shuttle valve 7 Load handling 7.4.4
Side shift 7 Load handling 7.4
Side shift cylinder 7 Load handling 7.4.3
Side window 9 Frame, body, cab and accessories 9.9.2
Signalling system 9 Frame, body, cab and accessories 9.7
Solenoid valve parking brake 4 Brakes 4.5.3
Spare parts B Safety -
Specifications for data and volume F Technical data -
Specifications oil, lubricants and fluids F Technical data -


Speed limitation 8 Control system 8.2.3
Spreader beam 7 Load handling 7.5.4
Spreading (positioning) 7 Load handling 7.5
Spreading cylinder 7 Load handling 7.5.3
Start battery 11 Common electrics 11.3.1
Start/stop 1 Engine 1.11
Starter motor 1 Engine 1.11.1
Steering 5 Steering 5
Steering axle cradle 5 Steering 5.2.5
Steering axle cradle 6 Suspension 6.2.1
Steering cylinder 5 Steering 5.2.4
Steering valve 5 Steering 5.2.3
Stopping device 1 Engine 1.11.2
Storage A Foreword -
Sun visors 9 Frame, body, cab and accessories 9.11.6
Suspension 6 Suspension 6
Suspension 6 Suspension 6.2
Switch, automatic spreading 7 Load handling 7.1.13
Switch, direction indicators 9 Frame, body, cab and accessories 9.1.22
Switch, lock twistlock/lock tongue 7 Load handling 7.1.2
Switch, spreading 20'-40' 7 Load handling 7.1.3
Switch, stop at 30' 7 Load handling 7.1.4
Tail lights 9 Frame, body, cab and accessories 9.6.3
Tank 10 Common hydraulics 10.3.1
Tank heater 10 Common hydraulics 10.6.1
Tanks and accumulators 10 Common hydraulics 10.3
Temperature control, cleaning and hydraulic oil 10 Common hydraulics 10.6
Temperature control, cleaning and hydraulic oil 4 Brakes 4.8
Tensioned springs B Safety -
Terminal console 9 Frame, body, cab and accessories 9.11.7
The documentation’s parts A Foreword -
The workshop manual’s contents A Foreword -
Thermal bypass valve 4 Brakes 4.8.8
Tightening torque, connections for air conditioning F Technical data -


Tightening torque, ORFS connections F Technical data -
Tightening torques, recommendations F Technical data -
Tilt 7 Load handling 7.7
Tilt cylinder 7 Load handling 7.7.7
Tiltable cab 9 Frame, body, cab and accessories 9.10.4
Torque converter/Clutch system 2 Transmission 2.2
TRANSM 8 Control system 8.4.7
Transmission 2 Transmission 2
Transmission D Error codes -
Transmission cable harness 2 Transmission 2.8.3
Transmission control unit 2 Transmission 2.8.1
Trolley 7 Load handling 7.2.11
Troubleshooting cable harnesses 0 Complete machine -
Troubleshooting hydraulic hoses 0 Complete machine -
Troubleshooting with an error code, example 0 Complete machine -
Troubleshooting without an error code, example 0 Complete machine -
Troubleshooting, general work instructions 0 Complete machine -
Twistlocks 7 Load handling 7.9.1
Tyres 6 Suspension 6.3.1
Tyres and rims 6 Suspension 6.3
Tyres and rims B Safety -
Unit explanations F Technical data -
Valve block quick-lift 7 Load handling 7.2.12
Valve block, main pump relief 7 Load handling 7.4.6
Valve block, main pump relief 7 Load handling 7.8.5
Vibration B Safety -
Voltage feed 11 Common electrics 11.5.1
Warning information A Foreword -
Warning parking brake 9 Frame, body, cab and accessories 9.7.4
Washer motor and reservoir 9 Frame, body, cab and accessories 9.5.4
Water valve 9 Frame, body, cab and accessories 9.4.5
Wheel brakes 4 Brakes 4.3.9


Wheel brakes 4 Brakes 4.8.6
Wheel hub 5 Steering 5.2.8
Wheel hub 6 Suspension 6.2.3
Wheel spindle 5 Steering 5.2.7
Wheel spindle 6 Suspension 6.2.2
Windscreen 9 Frame, body, cab and accessories 9.9.1
Wings 9 Frame, body, cab and accessories 9.13.1
Wiper front 9 Frame, body, cab and accessories 9.5.1
Wiper motor front 9 Frame, body, cab and accessories 9.5.5
Wiper motor rear 9 Frame, body, cab and accessories 9.5.7
Wiper motor roof 9 Frame, body, cab and accessories 9.5.6
Wiper rear 9 Frame, body, cab and accessories 9.5.3
Wiper roof 9 Frame, body, cab and accessories 9.5.2
Wiper/washer system 9 Frame, body, cab and accessories 9.5
Work lights, front wing 9 Frame, body, cab and accessories 9.6.14
Working lights, attachment 9 Frame, body, cab and accessories 9.6.12
Working lights, cab 9 Frame, body, cab and accessories 9.6.10
Working lights, mast 9 Frame, body, cab and accessories 9.6.9
Working under the machine B Safety -
Writing desk 9 Frame, body, cab and accessories 9.11.9

VDCF03 - 02GB - DCF80-100 Workshop Manual

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VDCF03 - 02GB - DCF80-100 Workshop Manual

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A Foreword

9 Frame, body, cab and accessories

G Terminologi och Index

Table of Contents A Foreword

Workshop manual DCF 80-100 VDCF03.02GB

VDCF03.02GB Workshop manual DCF 80-100

About the Workshop Manual

Thank you for choosing Kalmar Industries as your machine supplier.

The instructions are based on the use of generally available standard

About machine version

The information in this publication corresponds to the machine’s de-

Extreme hazard to personal health and risk of proper-

Only use equipment that is approved by Cargotec.

Workshop manual DCF 80-100 VDCF03.02GB

Warnings provide information about potential dangers that, if the warn-

Important information is denoted with NOTE and is intended to facili-

Read operator’s manual

Read the operator’s manual

Read the Maintenance manual

Read the Maintenance manual

VDCF03.02GB Workshop manual DCF 80-100

The workshop manual’s contents

The workshop manual contains information for corrective mainte-

B Safety Keep in mind for your safety.

C Preventive maintenance Reference to maintenance manual: Preventive maintenance.

E Schematics Wiring and hydraulic diagrams.

Workshop manual DCF 80-100 VDCF03.02GB

Function group structure

The information in the manual is divided in a structure of functions at

VDCF03.02GB Workshop manual DCF 80-100

References between different information types

The maintenance manual and workshop manual are mainly divided

Function descriptions Hydraulic diagrams

Component descriptions Error codes

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop manual DCF 80-100 VDCF03.02GB

Product alternatives and optional equipment

The information in the manual is divided into modules. If a product al-

Optional equipment refers to options that can be added to standard

VDCF03.02GB Workshop manual DCF 80-100

The machine card indicates of which drawings the machine consists.

Workshop manual DCF 80-100 VDCF03.02GB

The function descriptions are schematic overviews that describe how

40 7 Lasthantering 7.5 Spridning

F ruts ttning B rv rde H nvisning

10 D797-1 D791-1 8,9,17,18

Pos F rklaring Signalbeskrivning H nvisning

VDCF03.01SE Verkstadsmanual DCF 90-100

VDCF03.02GB Workshop manual DCF 80-100

1. Flag diagnostics, indicates that the signal can be checked with a

Workshop manual DCF 80-100 VDCF03.02GB

Symbol explanation function descriptions

D790-1 13. Bulb

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

VDCF03.02GB Workshop manual DCF 80-100

About the documentation

The documentation for the machine consists of the following parts:

Documentation is ordered from the dealer.

Workshop manual DCF 80-100 VDCF03.02GB

Cargotec’s ambition is that you who work with maintenance of Kalmar

To: Cargotec Sweden AB

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