FILE - 20200721 - 182102 - Workshop DCU80 PDF

Empty container handler 8-10
tonnes
Publ. no VDU01.01GB
Workshop Manual in original WORKSHOP MANUAL
DCU80–100
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DCU80–100
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................A:3
About the Workshop Manual........................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About the machine version......................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read maintenance manual ........................................................................ A:4
The workshop manual's contents............................................................... A:5
Function group structure ............................................................................ A:6
References between different information types ........................................ A:7
Product alternatives and optional equipment ............................................. A:8
Machine card.............................................................................................. A:9
Function descriptions ............................................................................... A:10
About the documentation .............................................................................. A:12
The documentation's parts ....................................................................... A:12
Ordering of documentation....................................................................... A:12
Feedback ................................................................................................. A:12
Workshop Manual DCU80–100 VDU01.01GB

A:2
VDU01.01GB Workshop Manual DCU80–100

A Foreword – Foreword A:3
A Foreword
About the Workshop Manual
General
Thank you for selecting Cargotec as your machine supplier. We hope
that we will meet your expectations.
Conditions
The instructions are based on use of general tools available in stores.
All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet
governing national regulations for lifting devices.
Cargotec will not accept any responsibility for modifications performed

without permission from Cargotec or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.
Storage
NOTE
The workshop manual should be accessible to service personnel.
About the machine version

The information in this publication corresponds to the machine's
design and appearance when delivered from Cargotec. There may be
differences due to customisation of the machine.
Cargotec reserves the right to change specifications and equipment

without prior notification. The information in the manual is valid at the
time of publication.
DANGER
External equipment may only be used if it is approved
by Cargotec.
Risk of fatal accidents and property damage!
Use only equipment approved by Cargotec.
Copyright
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Duplication by any means such as copying, printing, etc., is prohibited.

A:4 A Foreword – Reading instructions
Reading instructions
Warning information
Warnings inform of potential hazards that, if warnings are not heeded,
may result in personal injury or product damage.
DANGER
Situation that may lead to severe personal injury or
fatality if the rule is not followed.
WARNING
Situation that may lead to personal injury if the rule
is not followed.
CAUTION
Situation that may lead to product damage if the rule
is not followed.
Important information
Important information is indicated by NOTE, and is provided to
facilitate the work process, handling or increase understanding of the
information.
NOTE
Information that is important without being related to safety.
Read operator's manual

The symbol to the left is used in certain cases on the machine and
refers to important information in the operator's manual.
000262
Read the operator's manual
Read maintenance manual

The symbol to the left is used in certain cases on the machine and
001128
refers to important information in the maintenance manual.
Read the maintenance manual

A Foreword – Reading instructions A:5
The workshop manual's contents

The workshop manual contains information to facilitate maintenance
(part replacement) and is a supplement to the maintenance manual.
Accompanying the workshop manual is supplier documentation for
engine, transmission and drive axle. Where possible, the workshop
manual provides reference to supplier documentation instead of printing
the same information twice. Methods for preventive maintenance and
certain checks are found in the maintenance manual, no references
are given for these. Use the function groups to locate the information in
the maintenance manual.
The workshop manual is divided into the following sections.
A Foreword General information about the workshop manual's purpose, contents and reading
instructions 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 Driveline/Axle
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 respective function are described under each
subfunction. Consequently, common components are described in several
6 Suspension locations, but in general under 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 Diagrams Wiring diagrams, hydraulic diagrams and list of electrical components.
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 manual.

Function group structure

The information in the manual is divided in a structure of functions at
different levels, based on the machine's design and use, called function
groups.
The upper level (called main group) determines group, e.g., group 7
Load handling. The second level (called two-digit) determines function,
e.g., 7.2 Lifting/lowering. The third and fourth levels are used to break
down functions into smaller parts (components).
The function groups' structure for main group and two-digit group level
are common for all machines from Cargotec, e.g., 4.3 Power-assisted
brake system. Machine-unique adaptations of function groups are
done at the third and fourth group level, e.g., 4.3.9 Wheel brake and
4.3.9.1 Disc pack. This means that some function groups (headings)
will be left out of the documentation for certain machines since the
machine does not have that particular function or component. In turn,
this means that the function groups' numbering may 'skip', e.g., the
three-digit heading level 4.8.7 Oil cooler may be included for some
machines but not for others.
The idea is that the function groups are intended to work as a search
term to find different types of information between different sections and
manuals. The information under a function group is divided into smaller
sections according to the type of content, e.g., description or change.
The maintenance manual and workshop manual contain different

information. The maintenance manual only includes information
needed for preventive maintenance. The workshop manual includes
more in-depth information and repair instructions.
References are indicated by either section and group numbers, e.g.

"see section 4 Brakes, group 4.3.9 Wheel brakes" or with the section
and page number, e.g. "see Fuel level sensor, description page 4:24"
where 4:24 denotes section 4 Brakes, page 24.
References between Maintenance manual and Workshop manual are

only given in exceptional cases. If more information is desired for a
function group, the primary recommendation is to search under the
same function group in the other manual. For more in-depth information
on where different types of information are located and what references
are made, see References between different information types, page
A:7.

References between different information types

The maintenance manual and workshop manual are mainly divided
into function groups, see The workshop manual's contents, page A: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 the function

groups to find different types of information regarding the function or
component in question. As a complement to this, there are references
in accordance with the below.
Function descriptions Hydraulic diagrams

(Technical description) (Section E)
Component descriptions
Error codes
(Technical description, normally in
(Section D)
Workshop manual)
Diagnostics Wiring diagrams

(Technical description, 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
Diagnostics, 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
description, to enable fast finding of more information about the
component'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
description, to enable fast finding of more information about
components or function.

Product alternatives and optional equipment

The information in the manual is divided in modules. For product
alternatives and optional equipment, handling of the modules differs
depending on if it is the one or the other that is described, see below.
Special equipment is not described in the manual. If you're uncertain

about what equipment the machine should have, use the machine card
to decide which information applies, see Machine card, page A:9.
Product alternatives
Product alternatives are such options that exclude certain standard
equipment (e.g. engine option).
Equivalent information for different product alternatives is described

in separate sections following each other under the same function
group. To indicate that there are different alternatives, the supplement
"Product alternative" is used in the heading together with a simple
description of which alternative is described, e.g., "(Product alternative
Climate control unit ECC)". In addition, alternatives that are optional
are marked with the symbol for optional equipment.
Optional equipment
Optional equipment
000264
Optional equipment refers to options that can be added to standard

Symbol indicating optional equipment equipment for more or increased functions.
Information for optional equipment is described in separate sections

with the standard equipment as starting point. Description of the
optional equipment describes how the standard function is affected by
the option as well as which additional components are added.

Machine card
NOTE
If the machine has been modified after delivery the information on
the machine card may be lacking or incorrect.
IMPORTANT
Changes done on the machine shall be reported to
Cargotec so that the machine card can be updated.
A new updated machine card is sent on the request
of the customer.
The machine card indicates which drawings the machine is

manufactured after. In many cases these can be associated with
options and product alternatives. For more information on handling
product alternatives and optional equipment, see Product alternatives
and optional equipment, page A:8. The machine card is supplied with
the spare parts catalogue.
The machine card is divided in the same function groups as the spare
parts catalogue, maintenance manual, and workshop manual. For
practical reasons, the machine card only uses the first and second
level of the function group index. The function groups are written in
groups of four characters, e.g., group 0107 corresponds to group 1.7
Cooling system in the manual.
For more information about how the machine card is used for ordering
spare parts, see the parts catalogue's foreword.
If the information on the machine card is inadequate, contact Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.

Function descriptions
The function descriptions are schematic overviews that describe how a
function works as well as which components and signals work together.
The function descriptions describe the function in a logical flow from

input signal to desired output signal. Most functions require that preset
conditions are fulfilled for the function to be activated. In these cases,
the conditions are listed above the illustration.
The function descriptions use symbols to illustrate components such as

valves, sensors, etc.
Example of function description

1. Flag diagnostic test, indicates that signal can be 8. Description of the component's function
checked with diagnostic test, see group "8.4 Diagnostic
9. Position number, reference to position in illustration
test"
10. Flag pressure check connection (Check point),
2. Electric control signal (dashed single line)
indicates that there is pressure check connection for
3. Electric power (solid single line) checking the pressure signal
4. Hydraulic force (solid double line) 11. Hydraulic control signal (dashed double line)
5. Illustration of function, (lifting/lowering) 12. Position number in illustration, reference to row in
table
6. References to component and diagnostic menu
7. Signal description, reference value for signal out from
component

Symbol explanation function descriptions
Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols
are based on standard symbols for wiring and hydraulic diagrams.
1. Electric control signal
2. Electric force
3. Hydraulic control signal
4. Hydraulic force
5. Hydraulic oil pump with fixed displacement
6. Hydraulic oil pump with variable displacement
7. Hydraulic motor
8. Electric motor
9. Accumulator
10. Valve block
11. Filter
12. Radiator
13. Non-return valve
14. Shuttle valve
15. Restriction
16. Adjustable restriction
17. Spring brake cylinder
°C 18. Hydraulic cylinder
19. Disc brake
20. Thermal bypass valve
21. Inductive position sensor
°C °C
22. Electrically controlled solenoid valve
Pa Pa 23. Temperature sensor

24. Temperature-controlled switch
25. Pressure-controlled switch
26. Pressure sensor
27. Bulb
28. Horn or buzzer
29. Control and monitoring system, two control units with CAN bus
30. Relay
31. Double-acting hydraulic cylinder

A:12 A Foreword – About the documentation
About the documentation

The documentation's parts
The documentation for the machine consists of the following parts:
Operator's manual
The operator's manual is delivered with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied for the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual
• Supplier documentation for engine, transmission, and drive axle.
Ordering of documentation
Documentation is ordered from your Cargotec dealer.
Always specify publication number when ordering.
For publication number, see the machine card.
Feedback
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.
If you have any comments, please send them or fax them to the
address below. Thanks for your help!
Cargotec Sweden AB
Technical Documentation
Torggatan 3
SE-341 71 Lidhult
SWEDEN
Fax: +46 372 263 93

B:1
B Safety
Contents B Safety
Safety..................................................................................................................B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:5
Hydraulic system, depressurising............................................................... B:6
Oils ............................................................................................................. B:7
Fuel system ................................................................................................ B:8
AdBlue........................................................................................................ B:9
Clothing, etc. ............................................................................................ B:10
Several mechanics on the same machine................................................ B:10
Working under the machine ..................................................................... B:11
Lifting heavy components ........................................................................ B:11
Vibrations ................................................................................................. B:12
Noise ........................................................................................................ B:12
Solvents ................................................................................................... B:12
Fire and explosion risks............................................................................ B:13
Fluid or gas under pressure ..................................................................... B:15
Coolant ..................................................................................................... B:16
Refrigerant ............................................................................................... B:16
Air pollution .............................................................................................. B:17
Tensioned springs .................................................................................... B:17
Electrical system and electric motors ....................................................... B:18
Rotating components and tools................................................................ B:18
Tyres and rims.......................................................................................... B:19
Lifting equipment ...................................................................................... B:19
Welding .................................................................................................... B:20
Spare parts............................................................................................... B:21
Non-ionised radiation ............................................................................... B:22
Environment.................................................................................................. B:23
General .................................................................................................... B:23

B:2

B Safety – Safety B:3
B Safety
General safety information
Safety concerns everyone!
The safety information concerns everyone who works with the machine!
Persons who do not follow the safety instructions in this manual must
make absolutely sure that the work is performed without risks of
personal injury, without risks of machine damage, or property damage!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and be careful. Do not take any risks!
Cargotec has in this publication documented and warned for situations

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

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

B:4 B Safety – Safety instructions
Safety instructions
General
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position, page B:5
• Hydraulic system, depressurising, page B:6
• Oils, page B:7
• Fuel system, page B:8
• AdBlue, page B:9
• Clothing, etc., page B:10
• Several mechanics on the same machine, page B:10
• Working under the machine, page B:11
• Lifting heavy components, page B:11
• Vibrations, page B:12
• Noise, page B:12
• Solvents, page B:12
• Fire and explosion risks, page B:13
• Fluid or gas under pressure, page B:15
• Coolant, page B:16
• Refrigerant, page B:16
• Air pollution, page B:17
• Tensioned springs, page B:17
• Electrical system and electric motors, page B:18
• Rotating components and tools, page B:18
• Tyres and rims, page B:19
• Lifting equipment, page B:19
• Welding, page B:20
• Spare parts, page B:21
• Non-ionised radiation, page B:22

B Safety – Safety instructions B:5
Service position
General
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:

• Machine parked, that is, applied parking brake.
• Lifting carriage and attachment in completely lowered position.
• Engine off.
• System voltage off (with battery disconnector).
Machine with lifting carriage and attachment in

completely lowered position

Hydraulic system, depressurising
Before the hydraulic system is opened

1 Machine in service position, see Service position, page B:5.
2 Depressurise the hydraulic system by opening the relief valve for
the attachment (A).
DANGER
Fatal danger!
Extreme danger exists when working with hydraulics
when the hydraulic system is pressurised.
Depressurise the hydraulic system. Open the
accumulator drain valve.
3 Loosen lock nut (C) and open the drain valve for the brake
accumulators (B).
4 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
5 Turn the start key to position 0.
6 Disconnect the system voltage with the battery disconnector.
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
After the work has been completed
7 Close the relief valve for the attachment (A) and the drain valve for
the brake accumulators (B). Tighten the lock nut (C).
8 Start the engine and activate the hydraulic functions.
9 Turn off the engine.
10 Check that the hydraulic connections are sealed tightly.

Oils
The following safety instructions shall be followed for work when
handling oils.
WARNING
Warm and pressurised oil.
Always depressurise the hydraulic system before
starting work in the system. The hydraulic system is
pressurised and its oil can cause personal injury.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! The
oil can be corrosive to the eyes and skin, as well as
mucous membranes in the throat.
CAUTION
Always clean the area around components and
connections before loosening them, and plug the
connections. Dirt in oil systems causes increased
wear, which results in material damage.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also start fires. Waste oils/fluids shall always
be handled and taken care of by companies that are
authorised for this work.

Fuel system
handling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces
and may ignite.
Ensure that naked flames, sparks or red-hot/glowing
objects have been extinguished before starting work
on or in the vicinity of the fuel system.
Do not smoke in the vicinity of the machine when work
on the fuel system is in progress.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel can be corrosive to the eyes
and skin, as well as mucous membranes in the throat.
CAUTION
Always clean the area around components and
connections before loosening them, and plug
the connections. Dirt in the fuel system causes
malfunctions and engine stops in unwanted situations,
as well as increasing wear and material damage as a
consequence.
Always take actions to avoid spills. Where a container
cannot be used for draining, use a pump or hose for
safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment
and may also start fires. Fuel shall always be handled
and taken care of by companies that are authorised
for this work.

AdBlue
handling AdBlue.
WARNING
AdBlue spilled onto hot components evaporates
quickly. AdBlue can irritate the skin and eyes and
when inhaled.
Health hazard!
Turn your face away. Vaporised AdBlue can be
corrosive to the eyes, as well as mucous membranes
in the throat. In the event of inhalation, breathe fresh
air and seek medical advice if necessary.
Handle with care and avoid contact with skin, use
gloves. In the event of contact with skin and spillages
on clothing, rinse the skin with large amounts of water
and replace contaminated clothing and gloves. In
the event of contact with eyes, rinse thoroughly with
water for several minutes and seek medical advice if
necessary.
CAUTION
Switch off the engine and wait at least two minutes
before working on the AdBlue system.
Risk of unnecessarily large spill.
When the engine is switched off the AdBlue system
pumps back the AdBlue in the lines to the AdBlue tank.
Allow this process to run to completion before starting
work in order to reduce spill quantity.
CAUTION
AdBlue is very corrosive and penetrating.
AdBlue is extremely aggressive to wiring.
Wiring that has come into contact with AdBlue must
be replaced.
IMPORTANT
Avoid spilling AdBlue on the ground and in
watercourses.
Spillages on the ground must be absorbed with sand
or other absorbent, non-combustible material.

Risks
AdBlue is very corrosive and penetrating, spills not cleaned cause
damage to wiring, machine and tools. In the event of a spill there is
a risk that AdBlue causes oxidisation that is impossible to remove.
Cleaning with compressed air and water is not enough since AdBlue
oxidises the metal itself.
Safety actions
• Before working on the AdBlue system, switch off the engine and
wait for two minutes so that the AdBlue system can pump back
the solution to the tank. Do not switch off the system voltage with
the battery disconnector before two minutes have elapsed.
• If a connector has been exposed to AdBlue solution then
it must be replaced immediately in order that the AdBlue
solution penetrates no further into the wiring. AdBlue
penetrates at a speed of 0.6 m/h into wiring.
• Clean the machine immediately in the event of a spill in order to
prevent damage.
• Clean tools after the service work has been completed in order
to prevent damage.
• Fully protect all electrical connectors before the work, such as with
the AdBlue system's tank and lines.
• Always protect the AdBlue system's hoses, pump unit, metering
valve and tank when they are disconnected in order to prevent
spills and to protect the system against contaminants. Use a
plastic bag and straps.
Clothing, etc.
Clothes should be in good repair. Remove loose, hanging items (e.g.,
tie, scarf). Do not wear clothes with wide sleeves, pant legs, etc.
Remove jewellery as it may conduct electricity and get caught in
moving parts.
Long hair should be put up securely since it may otherwise get caught
in moving parts. Be careful when working with a welder or open flame
since hair is flammable.
Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
be extra careful so that accidental movements do not
injure another person. Communicate so that everyone
knows where everyone is and what they are doing.
Risks
Movements performed from the operator's station, e.g., all movement
of lifting equipment, may cause severe personal injuries.
Safety actions
• Make sure that the machine's lifting equipment is completely
lowered or secured in another way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you're working with.
• Do not work with the drive wheels on both sides of the truck at the
same time if the drive wheels on both sides are raised.

Working under the machine

Working under the frame
A raised vehicle may not, for any reason, be supported or lifted in
parts that belong to the wheel suspension or steering. Do not support
under mudguards or tanks either. Always support under the frame or
drive axle.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or
accidentally be lowered due to malfunctions or incorrect use.
Safety actions
• Use axle stands that withstand the load and stand securely.
• Lifting tools should be inspected and type approved for use.
Lifting heavy components
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to
move heavy components. Make sure that the device
is sturdy and intact.
Risks
Unsuitable lift slings, straps, etc. may break or glide.
The centre of gravity of the component can change during the course of
the work, and the component may then make unexpected movements
which may cause severe personal injuries and material damage.
A component lifted with lifting equipment can start to turn if the centre
of gravity changes.
A component lifted using an overhead crane may start to swing back

and forth, which can cause severe crushing injuries or material damage.
Safety actions
Lift with lifting device. Use lifting tools or other devices, especially
when such items are available for certain jobs.
If lifting must be performed without lifting device:

• Lift near the body.
• Keep your back vertical. Raise and lower with your legs and arms,
do not bend your back. Do not twist your body while lifting. Ask for
assistance - before lifting.
• Wear gloves. They're often good protection to reduce crushing
and cutting injuries to fingers.
• Always use protective shoes.

Vibrations
Use of vibrating tools, e.g. impact nut runner or grinder, for an extended
period of time may cause injuries as vibration is transmitted from tool
to hands. Most of all when fingers are cold.
Safety actions
• Use heavy gloves to protect against the cold and transfer of
vibrations.
• Switch between work duties to give the body time to rest.
• Vary work position and grip so that the body is not stressed in only
one position by the vibrations.
Noise
Noise louder than 85 dB (A) lasting for longer than 8 hours is deemed to
damage hearing. (Limit values may differ between different countries.)
High tones (high frequency) are more harmful than low tones at the
same sound level. Noise in the form of impulse sounds may also be
harmful, e.g., hammer blows.
Risks
Hearing damage may occur at noise levels higher than the limit value.
In severe cases, damage may be permanent.
Safety actions
• Use hearing protection. Make sure that it's tested and protects
against the right noise level.
• Limit noise with noise-absorbing dividers, for example,
noise-absorbing materials in roof and on walls.
Solvents
Fluids that (unlike water) dissolve grease, paint, lacquer, wax, oil,
glue, rubber, etc., are called organic solvents. Examples: Naphtha,
gasoline, thinner, alcohols, diesel, xylene, toluene, etc. Many solvents
are flammable.
Risks
Products with solvents give off vapours that may cause dizziness,
headache, and nausea. They may also cause irritation of mucous
membranes in the throat and respiratory tracts.
If dissolvent comes into direct contact with the skin it can dry and crack.
Higher risk of skin allergies. Solvents may also cause injuries if they
penetrate the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the central nervous
system may be injured. This manifests itself as trouble sleeping,
depressions, nervousness, poor memory, and general tiredness.
Continuous inhalation of gasoline and diesel vapours is suspected
of causing cancer.
Safety actions
• Avoid inhaling solvent fumes by providing good ventilation, or
wearing a fresh-air mask or respiratory device with a suitable filter
for the toxic gases.
• Never leave a solvent container without tight-sealing lid.
• Use solvents with a low content of aromatic compounds. This
reduces the risk of injuries.
• Avoid skin contact.
• Use protective gloves that are resistant to dissolvent (e.g. nitrile
rubber gloves)
• Make sure that the protective clothing is resistant to the dissolvents
that shall be used.

Fire and explosion risks
DANGER
The operator's safety may not be jeopardised in case
of fire.
If possible, take the following actions at the slightest
sign of fire:
1. Stop the machine and turn the start key to stop
position.
2. Leave the cab.
3. Turn off the system voltage with the battery
disconnector.
4. Call the fire department.
5. Try to put out the fire.
If this is not possible, leave the machine and the
danger area.
DANGER
Smoke from a fire may be very toxic.
Smoke anaesthetises, suffocates, and kills! Smoke
from fires, even small amounts, can damage lungs
and respiratory organs.
Avoid inhaling smoke gases, do not stand in the
smoke. Use breathing protection when putting out a
fire and working with burnt materials.
DANGER
Tyres that have caught fire are difficult to extinguish
and can cause fires with explosive development.
Fatal danger!
Always take cover if tyres catch fire.
Examples of flammable and explosive substances are oils, gasoline,

diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres that have caught fire are difficult to extinguish and can
cause fires with explosive development.

Risks
Examples of causes of ignition are welding, cutting with a welding torch,
smoking, sparks from grinding machines, contact between hot machine
parts and flammable materials, heat generation in rag drenched with oil
or paint (linseed oil), and oxygen. Oxygen cylinders, lines, and valves
shall be kept free from oil and grease.
Fumes from, e.g., fuel are heavier than air and may "run" down into a
sloping plane, or down in a grease pit, where welding flames, grinding
sparks or cigarette glow may cause an explosion. Evaporated gasoline
explodes very forcefully.
Special cases
Gas oil with added gasoline has a reduced flash point. Risk of
explosion already at room temperature. Explosion risk for heated gas
oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,

keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, glowing welding sparks can cause ignition and explosive fires.
When a battery is being charged, the battery electrolyte's water is

divided into oxygen and hydrogen gas. This mixture is very explosive.
The risk of explosion is especially high when a booster battery or a
rapid-charge device is used since this increases the risk of sparks.
In today's machines there are a lot of electronics. When welding,

all control units must be unplugged and the electric power must be
turned off with the battery disconnector. Powerful welding currents may
otherwise short-circuit the electronics, destroy expensive equipment,
and may cause an explosion or fire.
Never weld on painted surfaces (remove paint, preferably by blasting at

least 10 cm around the welding or cutting point). Use gloves, breathing
protection, and protective safety glasses. Also, never weld near plastic
or rubber materials without first protecting them from the heat. Paint,
plastic, and rubber generate many substances when heated, and these
may be hazardous to health. Be careful with machines that have been
exposed to intense heat or fire.

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

engine compartment before starting the engine and after operation,
when the engine has been stopped. This ensures fast detection if
anything abnormal has happened or is about to occur. Pay special
attention to oil, fuel, or coolant leaks, loose bolts, worn or poorly
tensioned drive belts, loose connections, damaged hoses, and
electrical cables. The inspection only takes a few minutes and may
prevent serious problems and expensive repairs.
• Store hazardous substance in approved and sealed container.
• Make sure that there is no ignition source near flammable or
explosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.
• Always have a fire extinguisher close at hand.
Fluid or gas under pressure

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

a hard surface. Gas may flow out from damaged valves.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Changing tyres.
• Climate control unit (air conditioning).
• Cooling system.

Safety actions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than the
manufacturer's recommendations.
• A hydraulic hose that swells, e.g., at a connection, shows that it
is about to rupture. Replace it as soon as possible! Check the
connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Failed pressure accumulators shall first be drained of pressure and
then punctured before being discarded (to avoid risk of explosion).
Carefully drill a hole with 3 mm diameter after draining the pressure.
• Never feel with your hands to check for any leaks. A fine jet from
a hydraulic hose may have such high pressure that it easily cuts
through, e.g., a hand, causing very severe injuries.
• First open the cooling system's cap for the filling point, to release
the high pressure. Be careful. Hot steam and coolant may jet out.
Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in case of leaks or when the
cap on the expansion tank (filling point) is opened.
Glycol is highly toxic and deadly to ingest.
Safety actions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• First open the cap for the filling point, to release the high pressure.
Be careful. Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
Refrigerant is used in the machine's air conditioning system.
Work on the air conditioning system must be performed by

accredited/authorised and trained personnel according to national
legislation and local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite injuries.
Refrigerant that is heated (e.g., when repairing leaking climate/AC

system), generates gases that are very dangerous to inhale.

Safety actions
• Follow special instructions and equipment for refrigerant according
to the manual when working on the air conditioning unit. Any
person doing the work must have special accreditation. (Note
national legislation and local regulations!)
• Use protective gloves and safety glasses if there's a risk of leaks.
• For example, make sure that heat-producing sources or objects
are not close by (cigarette glow, welding flame).
Air pollution
Air pollution is the pollution in the air around us and that are regarded
as hazardous to health. Certain pollutants are more prevalent in some
environments.
The following health-hazardous air pollution is especially prominent in

workshops:
• Carbon monoxide (fumes) is found in exhaust gases. Odourless
and therefore extremely dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates can be found in some paints, fillers, adhesives and
foam plastics.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates may be released in the form of vapour, dust (or may

be found in aerosol) when cutting, grinding, or welding. May cause
irritation of mucous membranes with asthma-like symptoms as well as
impaired lung function. Even brief exposure to high levels may give
problems with permanent oversensitivity.
Safety actions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when there
is risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect air extraction to the exhaust pipe so that exhausts are led
out from the workshop.
Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g., pedals.
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs

Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety actions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electrical system and electric motors

Safety actions
Always turn off the battery disconnector when working on the electrical
system and electric motors.
Always block the machine's wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Rotating components and tools

Examples of rotating components and tools:
• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinding machines
Risks
Rotating components, e.g., fans or shafts, can cause severe injuries
if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in
the machine.
Safety actions
• If you use gloves when working with a drill, you must avoid using
them in a way that they risk becoming trapped in moving parts.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or pant legs.
• Do not use trousers with loosely hanging pockets.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.

Tyres and rims
DANGER
Tyres are to be considered as pressurised containers.
Handling incorrectly, they are a fatal hazard.
Parts can be thrown with explosive force and may
cause severe injuries.
Never repair damaged tyres, rims, or lock rings. Tyre
changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims, and lock rings may be ejected.
Inflating the tyres: Tyres, rims, or lock rings may be ejected.
Safety actions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims, and lock rings are free from damage. Never
repair damaged rims or lock rings.
• Tyres must be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected parts.
• Use protective screen and safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest care must be taken with regard to
securing the mast, carriage and attachment.
Get into the habit of always keeping the carriage lowered to the lowest
position when working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is extra high when depressurising the hydraulic

system, see Hydraulic system, depressurising, page B:6.
Safety actions
Do not start work until the carriage is fully lowered. If the nature of the
work requires the carriage to be raised, it must be secured in some way.

Welding
DANGER
Contact Cargotec Support before welding on the
machine.
CAUTION
In today's machines there are a lot of electronics.
All control units must be unplugged and the electric
power must be turned off with the battery disconnector
prior to all welding on the machine.
Powerful welding currents may otherwise short-circuit
the electronics, destroy expensive equipment, and
may cause an explosion or fire.

Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced by genuine spare parts:
• Drive axle
• Brake valve
• Accumulator charging valve
• Accumulator
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Steering spindle
• Hub
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Main valve load handling
• Valve block, lift cylinder
• Tilt cylinder
• Load holding valve, tilt
• Twistlocks
• Attachment complete
• Control breaker (for hydraulic function)
• Emergency switch
• Cab
• Frame
• All control units

Non-ionised radiation
WARNING
Extra equipment such as two-way radio, remote
controlled door opener, etc. may emit non-ionising
radiation. This type of equipment transmits on the
frequency band 100 - 500 MHz.
Danger of disturbances on active medical products
(e.g. a pacemaker).
Do not use a two-way radio, remote controlled door
opener, etc. when persons with active implanted
medical products are in the cab.
NOTE
Cargotec does not assume any responsibility for extra equipment
not installed by Cargotec or according to installation instructions
approved by Cargotec.

B Safety – Environment B:23
Environment
General
Our global environment is significantly affected by the world's
ever-increasing industrialisation. Nature, animals, and humans are
exposed daily to great risks in connection with handling of chemicals in
various forms.
Still there are no environmentally safe chemicals, e.g., oils and

coolants, on the market. Therefore, all who handle, perform service, or
repair machines must use the tools and methods that are necessary to
protect the environment in an environmentally correct way.
By following the simple rules below, you will contribute to protecting

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

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

and the environment. Therefore, handle batteries in an environmentally
safe manner and according to national regulations.
Oils and fluids

Oils freely released cause damage to the environment and may also
start fires. When emptying and draining oils or fuel, take actions to
prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorised

disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal any leaks.
Air conditioning system

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

The machine shall be equipped for work within a contaminated area
(polluted environment or health-hazardous area) before starting the
work. Also, special local instructions apply for handling and service
work on such a machine.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and electrical wiring.
Refrigerant type R134a is used if the machine is equipped with air

conditioning.

B:24

C:1
The information is available in the
Maintenance Manual
The information is available in the Maintenance Manual.
For information on how to order the Maintenance Manual, see the

section A Foreword.

C:2

0:1
0 Complete machine
Contents 0 Complete machine

Complete machine............................................................................................. 0:3
Troubleshooting, general work instructions.................................................0:3
Troubleshooting without an error code, example ........................................0:4
Troubleshooting with an error code, example .............................................0:5
Troubleshooting cable harnesses ...............................................................0:6
Troubleshooting hydraulic hoses.................................................................0:8

0:2

0 Complete machine – Complete machine 0:3
0 Complete machine
Troubleshooting, general work
instructions
When troubleshooting, it is important that the work is structured and
logical. The purpose of the troubleshooting described in the workshop
manual is to exclude components as the source of a fault so that the
real source can be identified. A suggested structured work method
is described below.
When troubleshooting, it is important to understand how the machine

functions. Certain faults can be identified directly using the function
descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnector, must be in position 1.
• Battery voltage, should be 24–28 V with the engine running.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• AdBlue (applies to engine options Volvo TAD572VE and Volvo
TAD871VE)
• 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 0:5.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
5 If there is no error code or the problem persists, read the
function description for the function affected in section 0–12. See
Troubleshooting without an error code, example, page 0:4.
The function description contains information on which components
are involved in the function and how these components work
together. In some cases, there is information on what conditions
are required in order for it to be possible to activate the function.
Measurement points are marked with flags in the function
description (C for measuring outlet, D for diagnostic menu).
Use the diagnostic menus to read signal and sensor values as
well as to activate individual components in order to identify
potential sources of error. For a more detailed description, see 8.4
Diagnostics, page 8:18.

0:4 0 Complete machine – Complete machine
Troubleshooting without an error code,

example
1 Choose suitable section 0–12 to locate the function and
subfunction 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 function
affected in order to locate where in the function chain that the
signal or reaction is incorrect.
Measurement points are marked with flags in function descriptions
(C for measuring outlet, D for diagnostic menu). The diagnostic
menus can be used to read individual signal and sensor values. In
some cases, it is also possible to activate individual components.
For a more detailed description of the diagnostic menus, see 8.4
Diagnostics, page 8:18.
4 The fault is probably between the two units where the signal is
incorrect. Start by checking the component that should be sending
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
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:8.
6 If the cables or hoses between the components seem to be intact,
then check the component that receives the signal.

Troubleshooting with an error code,

example
Error codes are indicators of malfunctions detected by the control
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 important
not to draw conclusions too hastily based on an error code.
1 Note the error code information on the display, e.g. 2/ B7570- / 3.
Also note when the error code was set, since this can help to
understand whether there were any external circumstances or an
operator action that caused the error code.
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
input signal to the control unit is correct; see section 8 Control
system, 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 function description, the function's included
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 usually controlled by measuring
the pressure (which is described under the function group).
Sometimes valves can be activated mechanically in order 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
0:6.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:8.
8 If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The system voltage must be switched off with the battery
disconnector!
9 Disconnect the cable harness from the component in question.

10 Make the system voltage with the battery disconnector.
11 Turn the ignition key lock to position I.
12 Check that voltage reaches the component.

Table Example of error code information in error code list
Connec-
tions
Lo- and Diag-
Ty- No- ca- Descrip- compo- nostic Refer-
pe SPN FMI de tion tion Limitation Action nents menu ence
B 7570 3 2 Sensor Incorrect Check the B7570 1.2 Fuel Sen-
fuel level display of cable harness D7971/C- System sor, fuel
(B7570), fuel volume between the 2:24 1/XX level, de-
high signal (empty or control unit and DIAG- scription,
voltage. full). the sensor using NOSE, page
the diagnostic page 1:35
menu. 8:21
Check the
sensor.
Troubleshooting cable harnesses

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.
3 Unplug the connector at the control unit or component in question.
CAUTION
Wipe and re-grease the connectors (applies to sealed
contacts).
Risk of corrosion on contact surfaces.
Clean all connectors loosened during troubleshooting
using electronic cleaner 923836.0826 and re-grease
them with connector grease 923836.0552.
CAUTION
AdBlue is very corrosive and penetrating.
be replaced.
4 Check if there is an open circuit.
NOTE
Some components cannot be checked without power supply to
the component. In such an event, proceed to point 5.
a. Measure resistance between connections to the component in

the connector at the control unit or component.
b. The measured resistance must correspond with the resistance
specified for the component. In the event of differences, there
may be an open circuit or short circuit 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
component in question.
b. Measure the resistance in one cable at a time. Measure
between the cable and a frame-connected part of the machine.
c. The multimeter should show infinite resistance.

Troubleshooting hydraulic hoses
WARNING
Warm and pressurised oil.
Always depressurise the hydraulic system before
starting work in the system. The hydraulic system is
pressurised and its oil can cause personal injury.
Avoid skin contact with the oil, use protective gloves.
Hot oil may cause burns, rashes and irritation! The
oil can be corrosive to the eyes and skin, as well as
mucous membranes in the 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 so where the
splice is located.
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.
Replace damaged hoses. Always check the O-rings on adapters
and couplings. Change when needed.

1:1
1 Engine
Contents 1 Engine
1 Engine................................................................................................................. 1:3
1.1 Controls and instruments ...............................................................................1:30
1.1.1 Ignition key lock.........................................................................................1:30
1.1.2 Accelerator ................................................................................................1:31
1.1.10 Start button................................................................................................1:33
1.2 Fuel system....................................................................................................1:34
1.2.1 Fuel tank ...................................................................................................1:34
1.2.2 Sensor fuel level........................................................................................1:35
1.2.12 AdBlue tank ...............................................................................................1:35
1.6 Air intake and exhaust outlet..........................................................................1:36
1.6.1 Air cleaning system ...................................................................................1:36
1.6.3 Exhaust system .........................................................................................1:36
1.6.4 Intercooler .................................................................................................1:37
1.6.8 After-treatment system ..............................................................................1:38
1.6.9 Pipes and hoses........................................................................................1:38
1.6.10 Cooling fan intercooler ..............................................................................1:39
1.7 Cooling system ..............................................................................................1:40
1.7.4 Radiator and expansion tank ....................................................................1:41
1.7.5 Cooling fan ................................................................................................1:44
1.7.8 Coolant level sensor..................................................................................1:44
1.7.10 Engine heater ............................................................................................1:45
1.9 Control system, engine ..................................................................................1:46
1.9.1 Engine control unit ....................................................................................1:46
1.10 Ignition/heating...............................................................................................1:47
1.11 Start and stop of engine.................................................................................1:48
1.11.1 Starter motor .............................................................................................1:48
1.11.2 Stopping device.........................................................................................1:48
1.11.3 Automatic stop of the engine a specific time after leaving the operator's
station .......................................................................................................1:49
1.11.4 Automatic stop function .............................................................................1:49

1:2

1 Engine – Engine 1:3
1 Engine
Engine, general
The engine is either a 4-cylinder (Volvo TAD572VE) or 6–cylinder
(other models) turbocharged low-emissions engine with intercooler.
The engine provides the power for propulsion and hydraulics.
The machine is equipped with one of the following engine options:
DCU80–100-45E MP (Medium Performance)

• Volvo TAD572VE Stage 4/Tier 4f
• Volvo TAD850VE Stage 3A/Tier 3
• Cummins QSB6.7 Stage 3A/Tier 3
DCU80–100-45E HP (High Performance)

• Volvo TAD871VE Stage 4/Tier 4f
• Volvo TAD851VE Stage 3A/Tier 3
Component supplier documentation
The workshop manual only describes components and work
descriptions that concern installation in the machine. For descriptions
and instructions for the engine's components and systems, refer to the
relevant supplier documentation.
References to supplier documentation are only provided in exceptional

cases. If information about a component is not found, the component
supplier documentation should be used.

1:4 1 Engine – Engine
Engine option Volvo TAD572VE, function

description
Condition Reference value Reference
Engine heater Disconnected (when cable is in start lock-out is Engine heater, description (electric engine
activated) heater), page 1:45
Transmission In neutral position Transmission, function description (transmission
alternative Dana TE14xxx), page 2:4
Pos Explanation Signal description Reference

1 The ignition key lock (S1500) sends U = 24 V Ignition key lock, description, page 1:30
voltage signals to Control unit KCU D1: Diagnostic menu, see 11.5 Distr of
(D7901) when the start key is turned to Electr 1/XX DIAGNOSE, page 8:78
position 1.
2 Control unit KCU (D7901) activates Checked by control 11.5.3.1 Control unit KCU (D7901), page
ignition voltage, which activates all the system, error shown 11:25
control units. with error code. D1: Diagnostic menu, see 11.5 Distr of
Electr 1/XX DIAGNOSE, page 8:78
3 If necessary, the intake air to the engine is U = 24 V 11.5.3.6 Control unit, engine (D7940), page
preheated. Control unit engine (D7940) 11:33
controls the preheating requirement and
feeds voltage to the preheating element
via a preheating relay.
4 The preheating element warms the engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
intake air. system, error shown 11:33
with error code.
5 When preheating is activated, Control Checked by control 11.5.3.6 Control unit, engine (D7940), page
unit engine (D7940) sends information system, error shown 11:33
on CAN bus drive-train to Control unit with error code. 11.5.3.4 Control unit KFU (D7971), page
KFU (D7971), which in turn sends the 11:31
information further on the CAN bus.


6 When preheating is activated, Control Checked by control 11.5.3.3 Control unit, KID (D7950), page
unit KID (D7950) shows Event menu system, error shown 11:29
preheating. with error code.
7 Start button (S1051) sends voltage signals U = 24 V Start button description, page 1:33
to Control unit KPU (D7902) when the D7: Diagnostic menu, see 1.11 Start & Stop
start button is activated. 2/XX DIAGNOSE, page 8:26
8 Control unit KPU (D7902) sends Checked by control 11.5.3.2 Control unit KPU (D7902), page
messages a start signal on the CAN bus, system, error shown 11:27
via Control unit KFU (D7971), to Control with error code. 11.5.3.4 Control unit KFU (D7971), page
unit engine (D7940). 11:31.
9 Control unit engine (D7940) supplies U = 24 V 11.5.3.6 Control unit, engine (D7940), page
voltage to the starter motor (M6540). 11:33
10 The starter motor (M6540) cranks the - Starter motor, description (engine option
engine. Volvo), page 1:48
11 The engine's sensor sends signals to Checked by control 11.5.3.6 Control unit, engine (D7940), page
Control unit, engine (D7940) that controls system, error shown 11:33
the injectors so the engine starts. with error code.
12 The accelerator pedal (B6900) sends a U = 0.5-4.5 V Accelerator pedal description, page 1:31
voltage signal to Control unit KPU (D7902) Lower voltage than 0.5 D12: Diagnostic menu, see 1.1 Controls &
proportional to pedal actuation. V and higher voltage Instr 1/XX DIAGNOSE, page 8:21
than 4.5 V is used to
detect faults in cable
harnesses and controls.
13 Control unit KPU (D7902) sends a Checked by control 11.5.3.2 Control unit KPU (D7902), page
message with engine speed request system, error shown 11:27
on the CAN bus, via Control unit KFU with error code.
(D7971), to Control unit engine (D7940).
14 Control unit, engine (D7940) increases the Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine speed. system, error shown 11:33
with error code.
15 Make-contact (closing switch) coolant U = 24 V Sensor coolant level, description, page 1:44
level sends a voltage signal to Control
unit, engine (D7940) if the coolant level is
low in the expansion tank.
16 Control unit, engine (D7940) sends engine Checked by control 11.5.3.6 Control unit, engine (D7940), page
data and warning messages on the CAN system, error shown 11:33
bus. with error code. D16: Diagnostic menus, engine: 8.4.1
Engine, page 8:21
17 Control unit KID (D7950) shows engine Checked by control 11.5.3.3 Control unit, KID (D7950), page
data on the display. system, error shown 11:29.
with error code.
18 The fuel level sensor (B7570) sends a U = 0.5-4.5 V Sensor, fuel level, description, page 1:35
voltage signal proportional to the fuel level Lower voltage than 0.5 D18: Diagnostic menu, see 1.2 Fuel
in the tank to the KFU control unit (D7971). V and higher voltage System 1/XX DIAGNOSE, page 8:21
19 Control unit KFU (D7971) sends fuel level Checked by control 11.5.3.4 Control unit KFU (D7971), page
on the CAN bus. system, error shown 11:31
with error code.
20 Control unit KID (D7950) shows the fuel - 11.5.3.3 Control unit, KID (D7950), page
level in the operating menu for the engine. 11:29
Event menu for low fuel level is shown in
the display if the fuel level is below 10%
for more than 10 seconds.


21 Exhaust cleaning U = 0.5-4.5 V After-treatment system, description, page
AdBlue level and temperature sensor 1:38
sends a voltage signal proportional to
the AdBlue level and temperature in the
tank to Control unit after-treatment system
(UDS).
22 In the event of cold AdBlue, Control unit U = 24 V After-treatment system, description, page
after-treatment system (UDS) supplies 1:38
voltage to the water valve.
23 The water valve routes hot water to the - After-treatment system, description, page
AdBlue tank to heat it. 1:38
24 Sensor exhaust gas temperature sends U = 0.5-4.5 V After-treatment system, description, page
a voltage signal proportional to the 1:38
temperature of the exhaust gases to
Control unit after-treatment system (UDS).
There is a damper located after the
intercooler that helps to increase the
temperature of the exhaust gas when
necessary.
25 The NOx sensor continuously measures U = 0.5-4.5 V After-treatment system, description, page
the amount of nitrogen oxide in exhaust 1:38
gases and sends a voltage signal to the
26 Control unit after-treatment system (UDS) U = 24 V After-treatment system, description, page
supplies voltage to the AdBlue pump. 1:38
27 The AdBlue pump pumps AdBlue from the - After-treatment system, description, page
AdBlue tank. Depending on the content 1:38
of nitrogen oxides in the exhaust gases,
the correct quantity of AdBlue is injected
into in the silencer's inlet. AdBlue and
exhaust gases are mixed before passing
the catalyst for the after-treatment system,
which is located centrally in the silencer.
28 If the levels of nitrogen oxides in the - After-treatment system, description, page
exhaust gases are too high, Control unit 1:38
after-treatment system (UDS) sends a
request to Control unit engine (D7940) on
the CAN bus to limit the engine speed.
29 Control unit, engine (D7940) limits the Checked by control 11.5.3.6 Control unit, engine (D7940), page
with error code.
30 Speed limitation Checked by control Transmission, function description
The output shaft speed sensor system, error shown (transmission alternative Dana TE14xxx),
(B7580) sends the transmission control with error code. page 2:4
unit (D7930) pulses with frequency D30: Diagnostic menu, see 2.8 Control
proportional to output shaft rpm. System 10/XX DIAGNOSE, page 8:31
31 The transmission control unit (D7930) Checked by control 11.5.3.7 Control unit, transmission (D7930),
transmits speed on CAN bus. system, error shown page 11:35
with error code. D30: Diagnostic menu, see 2.8 Control
System 10/XX DIAGNOSE, page 8:31
32 Control unit KFU (D7971) recalculates Checked by control 11.5.3.4 Control unit KFU (D7971), page
the rotation speed of the output shaft to system, error shown 11:31
machine speed and sends the speed on with error code.
the CAN bus.
33 The KID control unit (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
machine's speed. system, error shown 11:29
with error code.


34 If the limit for the machine's speed limit Checked by control 11.5.3.4 Control unit KFU (D7971), page
is exceeded, Control unit KFU (D7971) system, error shown 11:31
sends reduce engine speed on the CAN with error code.
bus.
35 Control unit, engine (D7940) reduces Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine speed until it is correct. system, error shown 11:33
with error code.
36 Sensor oil temperature transmission Checked by Control 11.5.3.7 Control unit, transmission (D7930),
(B7660) sends a voltage signal unit, transmission, error page 11:35
proportional to the oil temperature to shown with error code. D36: Diagnostic menu, see 1.7 Cooling
Control unit control unit (D7930). system 8/XX DIAGNOSE, page 8:24
37 Control unit transmission (D7930) Checked by control 11.5.3.7 Control unit, transmission (D7930),
transmits the temperature on the CAN system, error shown page 11:35
bus. with error code.
38 Control unit engine (D7940) transmits the 11.5.3.6 Control unit, engine (D7940), page
temperature on the CAN bus. 11:33
39 Sensor hydraulic oil temperature, hydraulic Checked by Control Sensor, hydraulic oil temperature,
oil tank (B7660) sends voltage signals unit, KFU, error shown description, page 10:27
proportional to the oil temperature to with error code. D39: Diagnostic menu, see 1.7 Cooling
Control unit KFU (D7971). system 8/XX DIAGNOSE, page 8:24
40 Control unit KFU (D7971) controls Visco Checked by control 11.5.3.4 Control unit KFU (D7971), page
clutch (M6580) from 0–100 % depending system, error shown 11:31
on the temperatures of the engine, with error code. D40: Diagnostic menu, see 1.7 Cooling
transmission and hydraulic oil. system 4/XX DIAGNOSE, page 8:23 and
1.7 Cooling system 5/XX DIAGNOSE, page
8:23.
41 Visco clutch (M6580) regulates the drive Checked by control Cooling fan, description, page 1:44
ratio for the cooling fan which increases system, error shown
the air flow through the cooling unit. with error code.
42 Visco clutch (M6580) sends a pulse signal Checked by control Cooling fan, description, page 1:44
with frequency proportional to the fan system, error shown D41: Diagnostic menu, see 1.7 Cooling
speed to Control unit KFU (D7971). with error code. system 5/XX DIAGNOSE, page 8:23

Component location engine option Volvo

TAD572VE
Left
1. Sensor, coolant level (B7590) 6. Viscous hub
2. Sight glass coolant level 7. Alternator
3. Filling coolant 8. Turbo / Connection exhaust system
4. Expansion tank 9. Starter motor (M6540)
5. Cooling fan

Right
1. Filter, crankcase ventilation 7. Control unit, engine (D7940)
2. Dipstick 8. Intercooler
3. Oil filling 9. Transmission oil cooler
4. Preheating element 10. Condenser air conditioning unit
5. Fuel filter 11. Water cooler
6. Oil filter 12. Hydraulic oil cooler

Engine option Volvo TAD850VE and Volvo

TAD851VE, function description

position 1.
with error code.
5 When preheating is activated, Control Checked by control 11.5.3.4 Control unit KFU (D7971), page
on CAN bus drive-train to Control unit with error code.
KFU (D7971), which in turn sends the


via Control unit KFU (D7971), to Control with error code.
unit engine (D7940).
9 Control unit engine (D7940) supplies U = 24 V 11.5.3.4 Control unit KFU (D7971), page
voltage to the starter motor (M6540). 11:31.
with error code.
bus. with error code. Diagnostic menus engine: 8.4.1 Engine,
page 8:21
with error code.
with error code.


with error code.
the CAN bus.
with error code.
bus.
with error code.
proportional to the oil temperature to shown with error code. Diagnostic menu, see 1.7 Cooling system
Control unit control unit (D7930). 8/XX DIAGNOSE, page 8:24
29 Control unit engine (D7940) transmits the Checked by control 11.5.3.6 Control unit, engine (D7940), page
temperature on the CAN bus. system, error shown 11:33
with error code.
30 Sensor hydraulic oil temperature, hydraulic Checked by Control unit, Sensor, hydraulic oil temperature,
oil tank (B7660) sends voltage signals KFU, error shown with description, page 10:27
proportional to the oil temperature to error code. Diagnostic menu, see 1.7 Cooling system
Control unit KFU (D7971). 8/XX DIAGNOSE, page 8:24
clutch (M6580) from 0–100% of the engine system, error shown 11:31
speed depending on the temperatures of with error code. Diagnostic menu, see 1.7 Cooling system
the engine, transmission and hydraulic oil. 4/XX DIAGNOSE, page 8:23 and 1.7
Cooling system 5/XX DIAGNOSE, page
8:23
ratio for the cooling fan which increases system, error shown
the air flow through the cooling unit. with error code.
with frequency proportional to the fan system, error shown Diagnostic menu, see 1.7 Cooling system
speed to Control unit KFU (D7971). with error code. 4/XX DIAGNOSE, page 8:23 and 1.7
8:23

34 Control unit KFU (D7971) controls Cooling Checked by control 11.5.3.4 Control unit KFU (D7971), page
fan intercooler left (M6590-LE) and system, error shown 11:31
Cooling fan intercooler right (M6590-RI) with error code. Diagnostic menu, see 1.7 Cooling system
from 0–100% depending on charge air 6/XX DIAGNOSE, page 8:23, 1.7 Cooling
temperature from Control unit, engine system 8/XX DIAGNOSE, page 8:24 and
(D7940). 1.7 Cooling system 9/XX DIAGNOSE, page
At a predetermined interval, Control unit 8:24
KFU (D7971) changes the direction of the
cooling fans in order to clean dirt from the
intercooler.
35 Cooling fan intercooler left (M6590-LE) - Intercooler, description, page 1:37
and Cooling fan intercooler right
(M6590-RI) increase the air flow through
the intercooler.
36 Cooling fan intercooler left (M6590-LE) Checked by control Intercooler, description, page 1:37
and Cooling fan intercooler right system, error shown Diagnostic menu, see 1.7 Cooling system
(M6590-RI) send a pulse signal with with error code. 7/XX DIAGNOSE, page 8:23
frequency proportional to the fan speed to
Control unit KFU (D7971).

Engine option Volvo TAD871VE, function

description

position 1.
with error code.
5 When preheating is activated, Control Checked by control 11.5.3.4 Control unit KFU (D7971), page
on CAN bus drive-train to Control unit with error code.
KFU (D7971), which in turn sends the


via Control unit KFU (D7971), to Control with error code.
unit engine (D7940).
9 Control unit engine (D7940) supplies U = 24 V 11.5.3.4 Control unit KFU (D7971), page
voltage to the starter motor (M6540). 11:31.
with error code.
bus. with error code. Diagnostic menus engine: 8.4.1 Engine,
page 8:21
with error code.
with error code.


21 Exhaust cleaning U = 0.5-4.5 V After-treatment system, description, page
AdBlue level and temperature sensor 1:38
sends a voltage signal proportional to
the AdBlue level and temperature in the
tank to Control unit after-treatment system
(UDS).
22 In the event of cold AdBlue, Control unit U = 24 V After-treatment system, description, page
after-treatment system (UDS) supplies 1:38
voltage to the water valve.
23 The water valve routes hot water to the - After-treatment system, description, page
AdBlue tank to heat it. 1:38
24 Sensor exhaust gas temperature sends U = 0.5-4.5 V After-treatment system, description, page
a voltage signal proportional to the 1:38
temperature of the exhaust gases to
There is a damper located after the
intercooler that helps to increase the
temperature of the exhaust gas when
necessary.
25 The NOx sensor continuously measures U = 0.5-4.5 V After-treatment system, description, page
the amount of nitrogen oxide in exhaust 1:38
gases and sends a voltage signal to the
26 Control unit after-treatment system (UDS) U = 24 V After-treatment system, description, page
supplies voltage to the AdBlue pump. 1:38
27 The AdBlue pump pumps AdBlue from the - After-treatment system, description, page
AdBlue tank. Depending on the content 1:38
of nitrogen oxides in the exhaust gases,
the correct quantity of AdBlue is injected
into in the silencer's inlet. AdBlue and
exhaust gases are mixed before passing
the catalyst for the after-treatment system,
which is located centrally in the silencer.
28 If the levels of nitrogen oxides in the - After-treatment system, description, page
exhaust gases are too high, Control unit 1:38
after-treatment system (UDS) sends a
request to Control unit engine (D7940) on
the CAN bus to limit the engine speed.
29 Control unit, engine (D7940) limits the Checked by control 11.5.3.6 Control unit, engine (D7940), page
with error code.
with error code.
the CAN bus.
with error code.
bus.


with error code.
proportional to the oil temperature to shown with error code. Diagnostic menu, see 1.7 Cooling system
Control unit control unit (D7930). 8/XX DIAGNOSE, page 8:24
38 Control unit engine (D7940) transmits the Checked by control 11.5.3.6 Control unit, engine (D7940), page
temperature on the CAN bus. system, error shown 11:33
with error code.
39 Sensor hydraulic oil temperature, hydraulic Checked by Control unit, Sensor, hydraulic oil temperature,
oil tank (B7660) sends voltage signals KFU, error shown with description, page 10:27
proportional to the oil temperature to error code. Diagnostic menu, see 1.7 Cooling system
Control unit KFU (D7971). 8/XX DIAGNOSE, page 8:24
clutch (M6580) from 0–100 % of the engine system, error shown 11:31
speed depending on the temperatures of with error code. Diagnostic menu, see 1.7 Cooling system
the engine, transmission and hydraulic oil. 4/XX DIAGNOSE, page 8:23 and 1.7
8:23
ratio for the cooling fan which increases system, error shown Diagnostic menu, see 1.7 Cooling system
the air flow through the cooling unit. with error code. 4/XX DIAGNOSE, page 8:23 and 1.7
8:23
with frequency proportional to the fan system, error shown Diagnostic menu, see 1.7 Cooling system
speed to Control unit KFU (D7971). with error code. 4/XX DIAGNOSE, page 8:23 and 1.7
8:23
43 Control unit KFU (D7971) controls Cooling Checked by control 11.5.3.4 Control unit KFU (D7971), page
fan intercooler left (M6590-LE) and system, error shown 11:31
Cooling fan intercooler right (M6590-RI) with error code. Diagnostic menu, see 1.7 Cooling system
from 0–100 % depending on charge air 6/XX DIAGNOSE, page 8:23, 1.7 Cooling
temperature from Control unit, engine system 8/XX DIAGNOSE, page 8:24 and
(D7940). 1.7 Cooling system 9/XX DIAGNOSE, page
At a predetermined interval, Control unit 8:24
KFU (D7971) changes the direction of the
cooling fans in order to clean dirt from the
intercooler.
44 Cooling fan intercooler left (M6590-LE) - Intercooler, description, page 1:37
and Cooling fan intercooler right
(M6590-RI) increase the air flow through
the intercooler.
45 Cooling fan intercooler left (M6590-LE) Checked by control Intercooler, description, page 1:37
and Cooling fan intercooler right system, error shown Diagnostic menu, see 1.7 Cooling system
(M6590-RI) send a pulse signal with with error code. 7/XX DIAGNOSE, page 8:23
frequency proportional to the fan speed to

Component location, engine option Volvo

TAD8xxVE
Left
5. Cooling fan

Right
1. Filter, crankcase ventilation 8. Intercooler
2. Dipstick 9. Transmission oil cooler
3. Oil filling 10. Condenser air conditioning unit
4. Preheating element 11. Water cooler
5. Fuel filter 12. Hydraulic oil cooler
6. Oil filter 13. Cooling fan intercooler
7. Control unit, engine (D7940)

Engine option Cummins QSB6.7, function

description

1 The ignition sends voltage signals to U = 24 V Cab overview, page 9:5.
all control units when the ignition key D1: 11.5 Distr of Electr 1/XX DIAGNOSE, page
(S1500) is turn to position 1. 8:78.
2 If necessary, the intake air to U = 24 V 11.5.3.6 Control unit, engine (D7940), page
the engine is preheated. Control 11:33.
unit engine (D7940) controls the
preheating requirement and feeds
voltage to the preheating element via
a preheating relay.
3 The preheating element warms the - -
engine intake air.
4 The start button (S1051) sends a U = 24 V Cab overview, page 9:5
voltage signal to the Control unit D4: 1.11 Start & Stop 1/XX DIAGNOSE, page
KPU (D7902) when the start button 8:26.
is activated.
5 Control unit KPU (D7902) sends - 11.5.3.2 Control unit KPU (D7902), page 11:27.
a start signal on the CAN bus to
6 Control unit KFU (D7971) supplies U = 24 V 11.5.3.6 Control unit, engine (D7940), page
voltage to the starter motor. 11:33.
7 The starter motor (M6540) cranks - Engine option Cummins QSB6.7, function
the engine. description, page 1:20


8 The engine's sensor sends signals - 11.5.3.6 Control unit, engine (D7940), page
to Control unit, engine (D7940) that 11:33.
controls the injectors so the engine
starts.
9 The accelerator pedal (B6900) U = 0.5-4.5 V Cab overview, page 9:5.
sends the KPU control unit (D7902) Voltage lower than 0.5 V D9: 1.1 Controls & Instr 1/XX DIAGNOSE, page
a voltage signal proportional to the and higher than 4.5 V is 8:21.
pedal actuation. used to detect faults in
cable harnesses and the
accelerator pedal sensor.
10 Control unit KPU (D7902) sends Checked by control 11.5.3.2 Control unit KPU (D7902), page 11:27.
messages with speed requests on system, error shown with
the CAN bus, via Control unit KFU error code.
(D7971), to Control unit engine
(D7940).
11 Control unit, engine (D7940) - 11.5.3.6 Control unit, engine (D7940), page
increases the engine speed. 11:33.
12 Sensor coolant level sends a voltage U = 0.5-4.5 V Sensor coolant level, description, page 1:44.
signal to Control unit engine (D7940)
if the coolant level is low in the
expansion tank.
13 Control unit, engine (D7940) sends Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine data and warning messages system, error shown with 11:33.
on the CAN bus. error code.
14 Control unit KIF (D7950) shows - 11.5.3.3 Control unit, KID (D7950), page 11:29.
engine data via figures on the
display.
15 The fuel level sensor (B7570) sends U = 0.5-4.5 V Sensor, fuel level, description, page 1:35
a voltage signal proportional to the Lower voltage than 0.5 V D18: Diagnostic menu, see 1.2 Fuel System
fuel level in the tank to the KFU and higher voltage than 1/XX DIAGNOSE, page 8:21
control unit (D7971). 4.5 V is used to detect
faults in cable harnesses
and controls.
16 Control unit KFU (D7971) sends low Checked by control 11.5.3.4 Control unit KFU (D7971), page 11:31.
fuel level on the CAN bus. system, error shown with
error code.
17 Control unit KID (D7950) shows the - 11.5.3.3 Control unit, KID (D7950), page 11:29.
fuel level in the operating menu.
18 Speed limitation Checked by control Transmission, function description (transmission
The output shaft speed sensor system, error shown with alternative Dana TE14xxx), page 2:4
(B7580) sends the transmission error code. D30: Diagnostic menu, see 2.8 Control System
control unit (D7930) pulses with 10/XX DIAGNOSE, page 8:31
frequency proportional to output
shaft rpm.
19 The transmission control unit Checked by control 11.5.3.7 Control unit, transmission (D7930),
(D7930) transmits speed on CAN system, error shown with page 11:35.
bus. error code.
20 Control unit KID (D7950) shows the - 11.5.3.3 Control unit, KID (D7950), page 11:29.
speed on the display.
21 If output shaft speed is so high that it - 11.5.3.4 Control unit KFU (D7971), page 11:31.
is equivalent to the machine's speed
limitation limit, then Control unit KFU
(ECU7971) sends reduce engine
speed on the CAN bus.
22 Control unit, engine (D7940) reduces - 11.5.3.6 Control unit, engine (D7940), page
engine speed until it is correct. 11:33.


23 Sensor oil temperature transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(B7660) sends a voltage signal transmission, error shown page 11:35
proportional to the oil temperature to with error code. Diagnostic menu, see 1.7 Cooling system 8/XX
Control unit transmission (D7930). DIAGNOSE, page 8:24
transmits the temperature on the system, error shown with page 11:35
CAN bus. error code.
25 Control unit engine (D7940) - 11.5.3.6 Control unit, engine (D7940), page
transmits the temperature on the 11:33
CAN bus.
26 Sensor hydraulic oil temperature, Checked by Control unit, Sensor, hydraulic oil temperature, description,
hydraulic oil tank (B7660) sends KFU, error shown with page 10:27
voltage signals proportional to the error code. Diagnostic menu, see 1.7 Cooling system 8/XX
oil temperature to Control unit KFU DIAGNOSE, page 8:24
(D7971).
27 Control unit KFU (D7971) controls Checked by control 11.5.3.4 Control unit KFU (D7971), page 11:31
Visco clutch (M6580) from 0–100 % system, error shown with Diagnostic menu, see 1.7 Cooling system 4/XX
of the engine speed depending on error code. DIAGNOSE, page 8:23 and 1.7 Cooling system
the temperatures of the engine, 5/XX DIAGNOSE, page 8:23
transmission and hydraulic oil.
28 Visco clutch (M6580) regulates the Checked by control Cooling fan, description, page 1:44
drive ratio for the cooling fan which system, error shown with
increases the air flow through the error code.
cooling unit.
29 Visco clutch (M6580) sends a pulse Checked by control Cooling fan, description, page 1:44
signal with frequency proportional to system, error shown with D32: Diagnostic menu, see 1.7 Cooling system
the fan speed to Control unit KFU error code. 5/XX DIAGNOSE, page 8:23
(D7971).

Component placement engine option

Cummins QSB6.7 Stage 3A/Tier 3
Left
5. Cooling fan 10. Relay starter motor (K3600)

Right
1. Dipstick 6. Water cooler
2. Filling point engine oil 7. Transmission oil cooler
3. Fuel filter 8. Condenser air conditioning unit
4. Control unit, engine (D7940) 9. Hydraulic oil cooler
5. Intercooler

Components on the machine, component

location
1. Control unit, transmission (D7930) 7. Control unit KFU (D7971)

2. Diagnostic socket engine 8. Ignition key lock (S1500)
3. Control unit after-treatment system (UDS) (only engine 9. Start button (S1501)
option Volvo TAD572VE and Volvo TAD871VE) 10. Control unit, KID (D7950)
4. Sensor fuel level (B7570) 11. Accelerator pedal (R6900)
5. Fuel tank 12. Control unit KPU (D7902)
6. Fuel prefilter 13. Control unit KCU (D7901)

Engine and transmission, separation

Separation
2 Mark up and disconnect the requisite hoses and cables before
separating engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
Lifting points, engine option Volvo

3 Connect lifting equipment to the engine or the transmission.
018798
Lifting points, engine option Cummins QSB6.7

018968
Lifting points, transmission

4 Use a jack to secure the transmission. If the transmission shall be
lifted out, secure the rear part of the engine in an equivalent way.

5 Engine option Volvo

Remove the cover plugs over the holes to access the
transmission's attaching bolts and for the turning tool.
Holes for the flex plate's attaching bolt and turning tool
1 6 Engine option Cummins QSB6.7

Remove the cover plate and cover plug for the flywheel on the
left-hand side of the engine for access to the transmission's
attaching screws and for the turning tool.
Remove the flex plate's fastening bolts (x8).
Rotate the engine using Volvo special tool 999 3590, until the flex
plate's screws are visible in the hole.
8 Engine option Cummins QSB6.7
Remove the flex plate's fastening bolts (x8).
Rotate the engine using Cummins special tool 3824591, until the
016114
flex plate's screws are visible in the lower hole.

9 Take up the slack in the hoisting equipment.
2
1. Cover plug NOTE
2. Cover plate Do not lift the engine or transmission.
10 Remove the screws (12 pcs) between the engine and the
transmission.
11 Loosen the engine or transmission mounts and separate the
engine and transmission. The brackets can be detached either
from the mountings in the frame or from the mounting in the
engine/transmission.
NOTE
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
1. Attaching bolts

Assembly
12 Insert two studs into the flywheel housing as a guide when the
engine is installed.
13 Clean the contact faces on the flywheel and flex plates. Check
that the flex plates are flat and not worn. Damaged or worn parts
must be replaced.
14 Apply lubricating grease to the converter connection - both on the

engine and the transmission.
15 Check that the holes for the flex plate's mounting in the flywheel
are just in front of the flex plate's retaining nuts.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
16 Install the engine or transmission mounts. This step only applies
when the brackets have been removed from the engine or
transmission.
For tightening torque, see Table Tightening torque, engine and
transmission brackets, page 1:29.
17 Carefully connect the engine to the transmission.
008301
18 Remove the stud bolts. Fit the bolts (x12) between the engine and
the transmission. Tighten to a torque of 49 Nm.
19 Slide the converter in toward the flywheel and check that they mate
correctly, use a fitter's bar if necessary. Check to ensure that the
flex plates rest against the flywheel.
20 Fit the screws that secure the flex plates at the flywheel in two
steps. First fit the screws without tightening them. Then rotate the
flywheel one more revolution and tighten the screws to 49 Nm
(oiled screw).
NOTE
Turn the engine over to access each screw on the flex plate.
Engine option Cummins QSB6.7
1. Attaching bolts NOTE

The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.

Fit the cover plugs over the holes to access the transmission's
attaching bolts and for the turning tool.
22 Engine option Cummins QSB6.7
Fit the cover plug and cover washer over the holes to access the
transmission's attaching bolts and for the turning tool.

23 Tighten and secure the engine or the transmission in the frame.
Table Tightening torque, engine and transmission brackets
Screw location Tightening torque, oiled

screw
Engine bracket in damper pad 169 Nm
Bracket in transmission 402 Nm
Transmission bracket in frame 169 Nm
24 Detach the lifting equipment from the engine or the transmission.

25 Remove the jack under the transmission or the engine.
26 Connect the requisite hoses and cables for the engine and
transmission. Check and fill fluids as required.
27 Bleed air from the engine's fuel system before starting.

1:30 1 Engine – Controls and instruments
1.1 Controls and instruments

1.1.1 Ignition key lock
Ignition key lock, description
The ignition key lock (S1500) is fitted on the steering panel, see Cab
0 overview, page 9:5. The ignition key lock controls the switching on and
off of the ignition voltage, see Ignition voltage (15), function description,
I
page 11:17.
012815
Ignition key lock, replacement

1 2 2 Remove the cover.

015784
1. Cover
2. Ignition key lock

1 Engine – Accelerator 1:31
3 Remove the screw.

4 Remove the nut.
5 Disconnect the connector.
6 Replace the ignition key lock.
7 Fit in the reverse order.
015785
1 2 3
1. Contact
2. Screw
3. Nut
1.1.2 Accelerator
Accelerator pedal description
The accelerator pedal actuates a sensor via a linkage in the pedal
assembly, see Cab overview, page 9:5. Sensor accelerator pedal
(R6900) sends two voltage signals (for increased safety) proportional
to the pedal's position to Control unit KPU (D7902).
The signals can be checked with the diagnostic menu, see 1.1 Controls
& Instr 1/XX DIAGNOSE, page 8:21.
Accelerator pedal, replacement

2 Pull one edge of the cover away to facilitate access to the
accelerator pedal.
3 Disconnect the cable harness from the connector.
4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
7 Calibrate the accelerator pedal, see Accelerator pedal, calibration,
page 1:32.
1. Accelerator
2. Brake pedal

1:32 1 Engine – Accelerator
Accelerator pedal, calibration

1 Stop the machine on level ground and apply the parking brake.
3 Fully depress the accelerator pedal at least once before starting
calibration.
4 Navigate to the menu for service and settings with or and
confirm with .
014981
5 Enter the code for calibration with or . Confirm each digit

with .
Code is obtained from Cargotec Support.
NOTE
The code determines which service menus are activated.
015625
6 Select 1. ENGINE by scrolling with or and confirm with .

020505
7 Select 1.2 Controls & Instruments by scrolling with or and

confirm with .

1 Engine – Start button 1:33
8 Select CALIBRATE by scrolling with or and confirm with .
9 Navigate to 1.1 Controls & Instr 1/XX CALIBRATE, menu 1 with

/ .
10 Row 1 shows the accelerator pedal's top position.
Row 2 shows the accelerator pedal's current value for signal A.
Row 3 shows the accelerator pedal's lowered value for signal A.
Row 4 shows the accelerator pedal's current value for signal B.
Row 5 shows the accelerator pedal's lowered value for signal B.
11 Release the pedal SLOWLY all the way and save the value using
the function key .
12 Navigate to 1.1 Controls & Instr 1/XX CALIBRATE, menu 2 with

/ .
13 Press the accelerator pedal right down and save the value using
the function key .
1.1.10 Start button

Start button description
The start button (S1051) is fitted on the steering panel, see Cab
overview, page 9:5. The start button controls the starting and stopping
of the engine. The signal can be checked with the diagnostic menu,
for engine option Volvo 1.11 Start & Stop 2/XX DIAGNOSE, page
8:26 applies, and for engine option Cummins 1.11 Start & Stop 1/XX
DIAGNOSE, page 8:26 applies.
016899

1:34 1 Engine – Fuel system
1.2 Fuel system

Fuel system, description
The fuel system distributes fuel between the cylinders and by doing so
controls the engine output power and rpm.
The fuel tank is located on the left-hand side of the machine and is
equipped with a sensor for the fuel level. The amount of fuel in the
tank is shown in an operating menu on the display in the cab. Fuel
prefilter with water separator and fuel filter are fitted on the engine
or in its vicinity.
When the engine is started, the fuel pump draws fuel from the tank
through the fuel filter and forces it to the unit injectors. The unit injectors
spray in the fuel and atomises the fuel to the engine's combustion
chamber.
The water separator is equipped with electrical indication, an error code

is generated when the water separator must be drained of water.
WARNING
The engine's fuel system operates at very high
pressure. The pressure is so high that the jet can
damage the skin, which results in serious injuries.
Use protective gloves and protective safety goggles,
avoid skin contact with fuel. If a component is to be
loosened, hold a rag over the coupling as protection
and collect the fuel. Fuel can be corrosive to the eyes
and skin, as well as mucous membranes in the throat.
1.2.1 Fuel tank

Fuel tank, description
The fuel tank is located on the left-hand side of the machine.
1. Fuel filler
2. Manhole cover for cleaning
3. Sensor fuel level (B7570)
4. Drain plug, under tank

1 Engine – Sensor fuel level 1:35
1.2.2 Sensor fuel level

Sensor, fuel level, description
The fuel level sensor is inserted in the fuel tank from above.
The fuel level sensor (B7570) sends a voltage signal proportional to

the fuel level in the tank to the KFU control unit (D7971). An event
menu is shown in the display if the fuel level is below 10 % for more
than 10 seconds.
The signal from the sensor can be checked with the diagnostic menu
1.2 Fuel System 1/XX DIAGNOSE, page 8:21.
1. Fuel filler
Fuel level sensor, replacement

2 Disconnect the cable harness from the sensor. Note the cable's
clamping.
3 Clean the area on the tank around the level sensor.
4 Unscrew the level sensor.
The sensor is threaded into the tank.
5 Screw in a new level sensor.
6 Connect the cable harness to the sensor and attach the cable in
the same way as before.
1. Fuel filler
1.2.12 AdBlue tank

AdBlue tank, description
See After-treatment system, description, page 1:38.

1:36 1 Engine – Air intake and exhaust outlet
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air cleaning system, description
The air cleaning system consists of an air cleaner with filter, filter
indicator, pipes and hoses. There are two filters in the air cleaner that
purify the air and a dust reservoir that collects larger particles. The dust
reservoir can be emptied without opening the air cleaner.
Combustion in the engine requires air. Free unobstructed flow for

fresh air and exhaust gases is essential for efficient engine operation.
Particles are collected in the filter material when the air filters clean the
air to the engine. Over time, a great deal of particle matter is collected
and the filter does not let through sufficient air for efficient combustion,
the filter must then be changed. The filter indicator measures the
negative pressure on the engine side of the filter. When the filter is
clogged the negative pressure is higher and the indicator indicates
that it is time to replace the filter.
As an option the machine can be equipped with a raised air intake with
pre-cleaner. It consists of an extension of the inlet to the air filter and
a pre-cleaner that sorts out larger particles by creating vortices in the
air intake. The pre-cleaner does not contain any parts that need to
be replaced. During operation in dirty environments this means that
A. Air cleaner less dusty air is sucked into the air cleaner, and in this way the service
B. Filter indicator life of the air filters is extended.
C. Dust reservoir
D. Intake
1.6.3 Exhaust system

Exhaust system, description
The exhaust system is mounted in the frame. Heat protection is fitted
between the engine and exhaust system to protect cables, etc. A flex
pipe between the turbo and silencer takes up the engine's movement.
The exhaust gases are led through a channel in the counterweight
between the exhaust pipe and end pipe.
Engine option Volvo TAD 572VE and Volvo TAD871VE: the silencer
is a combined silencer and catalytic converter and is a part of the
after-treatment system, see After-treatment system, description, page
1:38.
WARNING
1. End pipe
Hot exhaust system!
2. Silencer
Risk of burn injuries.
3. Exhaust pipe
Never touch hot components, e.g. turbo, exhaust pipe,
4. End pipe silencer or catalytic converters!
Leakage in the exhaust system may cause disruptions in the exhaust

cleaning with abnormal exhaust values and error codes as a result.

1 Engine – Intercooler 1:37
1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air-air intercooler which is located in the
cooling unit behind the engine (Volvo TAD572VE and Cummins QSB
6.7) or in its own cooling unit on the right-hand side of the machine
(Volvo TAD8xxVE)
See also Cooling system, description, page 1:40.
Cooling unit, engine option Volvo TAD572VE

1. Intercooler
2. Transmission oil cooler
3. Condenser air conditioning unit
4. Water cooler
Cooling unit, engine option Volvo TAD8xxVE
5. Hydraulic oil cooler
1. Intercooler
4. Water cooler
Cooling unit Cummins QSB6.7

1. Intercooler
4. Water cooler

1:38 1 Engine – After-treatment system
1.6.8 After-treatment system

After-treatment system, description
The after-treatment system cleans the exhaust gases after the engine
and is based on SCR-technology (Selective Catalytic Reduction), i.e.
catalytic exhaust cleaning. The system is used in order to fulfil statutory
emissions requirements.
Diesel engines with even more efficient combustion in combination

with exhaust after-treatment provide significantly reduced emissions
of nitrogen oxides and particles.
SCR technology is based on exhaust gases being after treated through

the addition of AdBlue solution which is injected into the exhaust gases
before they pass through the catalyst. The additives, together with
the catalyst, convert nitrogen oxides into nitrogen and water vapour,
natural substances in our environment.
The after-treatment system has its own control unit, Control unit
after-treatment system (UDS) (Urea Dosing System), which receives
signals from the system's sensors and controls the injection of AdBlue.
Control unit after-treatment system (UDS) sends information and error
code information to the machine via Control unit engine (D7940).
For more information, see supplier documentation, engine.
Engine option Volvo TAD572VE and Volvo TAD871VE

1. Sensor NOx after after-treatment
2. Catalyst/silencer
3. Injection unit
4. NOx sensor before after-treatment
5. Sensor exhaust gas temperature
6. Connection, cooling system engine
7. AdBlue tank
8. AdBlue pump unit
9. Water valve
10. Control unit, after-treatment system (UDS)
1.6.9 Pipes and hoses

Piped and hoses, description
The air inlet and exhaust outlet components are linked together by
pipes and hoses.
Pipes and hoses, replacement

2 Remove the exhaust pipe's pipes and hoses.
3 Remove the cable ties holding the hoses and cables together.
NOTE
Protect the engine's air intake and hoses with a seal, e.g. a
plastic bag.
4 Remove the hose clamps holding the air hose to air filter and turbo.
5 Remove the hose clamps holding the charge air hoses.
6 Remove the charge air hoses.
7 Fit in reverse order.
8 Check the connections with regard to leakage.

1 Engine – Cooling fan intercooler 1:39
1.6.10 Cooling fan intercooler

Cooling fan intercooler, description (engine option
VolvoTAD8xxVE)
Cooling fans intercooler left and right (M6590-LE and M6590-RI)
are electric fans which increase the air flow through the intercooler
if required.
The cooling fans are supplied with ignition voltage via the fuses
(F9958-BK4 and F99558-BK5). The speed of the cooling fans is
controlled by Control unit KFU (D7971) depending on the charge air
temperature from Control unit, engine (D7930). At predetermined
intervals, Control unit KFU (D7971) changes the direction of the cooling
fans in order to clean dirt from the intercooler.
The signal can be checked with the diagnostic menu, see 1.7 Cooling
system 6/XX DIAGNOSE, page 8:23, 1.7 Cooling system 8/XX
DIAGNOSE, page 8:24 and 1.7 Cooling system 9/XX DIAGNOSE,
page 8:24.
Intercooler Volvo TAD8xxVE

1. Intercooler
2. Cooling fan intercooler left and right

1:40 1 Engine – Cooling system
1.7 Cooling system

Cooling system, description
The engine is water-cooled and the coolant is cooled in the radiator
which is located at the rear of the engine compartment in the frame.
The engine's cooling system is also used in order to heat the cab and
the AdBlue tank. The engine's cooling system heats and cools the
engine oil with a built-in heat exchanger on the engine.
The engine's cooling fan is controlled electronically and regulates the air
flow through the radiator, intercooler, transmission oil cooler, hydraulic
oil cooler and the A/C unit's condenser. Engine option Volvo TAD8xxVE
has a separate intercooler on the right-hand side of the machine.
The cooling system in the machine consists of the following main parts:
• Engine cooling system, see supplier documentation engine.
• Water cooler, part of cooling unit.
• Expansion tank, fitted on the cooling unit in the engine
compartment.
• Sensor coolant level (B7590), in the expansion tank connected
to Control unit engine (D7940).
• Cooling fan, located in front of the radiator.
• Visco clutch.
The cooling fan's speed is controlled actively depending on the
temperature of the engine, hydraulic oil and transmission.
• Intercooler, part of the cooling unit, (engine option Volvo TAD575VE
and Cummins QSB6.7).
Intercooler separate (engine option Volvo TAD8xxVE).
• Cooling fans intercooler right and left (engine option Volvo
TAD8xxVE).
The speed of the cooling fans is controlled actively depending on
the charge air temperature.

1 Engine – Radiator and expansion tank 1:41
1.7.4 Radiator and expansion tank

Radiator and expansion tank, description (engine
option Volvo TAD572VE)
The radiator for the engine is located in the cooling unit which is located
behind the engine.
There is an expansion tank fitted on the cooling unit which means that
the coolant can cope with temperature changes without disappearing
from the engine, and it counteracts air pockets being formed in the
cooling system.
The function of the cooling unit is to cool:

• Engine coolant
• Transmission oil (cooled in the lower part of the cooling unit), see
Transmission oil cooler, description, page 2:13.
• Charge air, see Intercooler, description, page 1:37.
• Refrigerant in the air conditioning unit.
• Hydraulic oil
Cooling unit Volvo TAD572VE

1. Expansion tank
2. Sensor, coolant level (B7590)
3. Sight glass coolant level
4. Intercooler
7. Water cooler
9. Thermostat transmission oil
10. Connection, cooling cab

1:42 1 Engine – Radiator and expansion tank

option Volvo TAD8xxVE)
behind the engine.
cooling system.

• Engine coolant
• Transmission oil (cooled in the upper part of the cooling unit), see
• Hydraulic oil
The charge air is cooled in a separate intercooler on the right-hand

side of the machine.
Cooling unit, Volvo TAD8xxVE

1. Expansion tank
4. Intercooler
7. Water cooler

1 Engine – Radiator and expansion tank 1:43

option Cummins)
behind the engine.
cooling system.

• Engine coolant
• Transmission oil, see Transmission oil cooler, description, page
2:13.
• Charge air (cooled in the upper part of the cooling unit), see
Intercooler, description, page 1:37.
• Hydraulic oil
Cooling unit Cummins QSB6.7

1. Expansion tank
4. Intercooler
7. Water cooler
Radiator, replacement
NOTE
Read safety instructions for coolant before starting work, see
section B Safety.
1 Machine in service position, see section B Safety.

2 Drain the coolant from the engine, see Maintenance manual.
3 Drain the transmission oil from the transmission, see Maintenance
Manual.
4 Drain the hydraulic oil from the hydraulic system, see Maintenance
manual.
5 Drain the air conditioning of refrigerant, see General
recommendations for work on the air conditioning unit, page 9:23.
6 Detach the hoses for intercooler, engine, hydraulic system and
transmission cooling, for the radiator's expansion tank and
condenser.
7 Remove the screws that secure the cooling unit to the frame.

1:44 1 Engine – Cooling fan
8 Connect lifting eyes and lifting equipment to the threaded holes in

the top of the cooling unit.
9 Carefully lift the cooling unit out of the frame.
11 Refill the air conditioning with refrigerant, see General
recommendations for work on the air conditioning unit, page 9:23.
12 Fill with transmission oil, see Maintenance manual.
13 Fill with hydraulic oil, see Maintenance manual.
14 Fill with coolant, see Maintenance manual.
15 Check and top up fluids as necessary.
1.7.5 Cooling fan

Cooling fan, description
The cooling fan is powered by the engine via an electrically control
Visco clutch. If necessary, the drive ratio and the air flow through
the cooling unit are increased. The cooling fan is fitted in front of the
cooling unit.
The cooling fan's drive ratio is controlled by the Visco clutch (M6580).
The clutch is supplied with voltage by Control unit KFU (D7971)
depending on engine, transmission temperature and hydraulic oil
temperature, from Control unit, engine (D7940). The clutch also has
a rotation speed sensor that sends fan speed back to Control unit
KFU (D7971).
system 4/XX DIAGNOSE, page 8:23 and 1.7 Cooling system 5/XX
DIAGNOSE, page 8:23.
CAUTION
The Visco clutch (or fan with the Visco clutch fitted)
must not be laid down horizontally but must be
handled in vertical position.
Product damage.
1.7.8 Coolant level sensor

Sensor coolant level, description
The cooling system is equipped with an sensor (level switch) that
activates an alarm on the display if the coolant level is too low. The
sensor is located in the expansion tank. Coolant level sensor (B7590)
sends a voltage signal to the Engine control unit (D7940).

1 Engine – Engine heater 1:45
Sensor coolant level, replacement

2 Drain the coolant from the expansion tank using suction equipment
for fluid or via the drain on the radiator, see Maintenance manual.
3 Disconnect the cable harness from the sensor.
4 Remove the sensor from the expansion tank.
5 Fit the new sensor on the expansion tank.
The sensor has a conical thread that is pretreated with thread lock.
Do not tighten the sensor too hard.
6 Connect the cable harness to the sensor.
7 Fill the system with coolant, see Maintenance manual.
1.7.10 Engine heater

Engine heater, description (electric engine heater)
The machine can be equipped with electrically-driven engine heater

in different units together with heater, hydraulic oil tank, oil tank brake
system and preparation for cab fan. The engine heater heats the
engine and facilitates starting when the machine has been switched off
for a long time and is intended for use in cold climates.
The engine heater is supplied with high voltage from an external mains
power connector. The mains power connector is fitted on one of the
terminal boxes above the left-hand footstep. The machine has a start
interlock function that prevents the engine being started when a power
cable is connected to the mains power connector. The sensor for the
start interlock function is an optical sensor that can react to objects
other than the connected power cable.
For more information see supplier documentation engine.
Terminal boxes, engine, cab and tank heater CAUTION

1. Mains power connector high voltage
2. Sensor, start interlock function The engine heater is connected to high voltage (110
3. Terminal box, start interlock, engine and cab - 400 V).
heater High voltage.
4. Terminal box, heater hydraulic oil tank and oil Installation and reconnection of the engine heater may
tank brake system only be performed by personnel authorised for work
with high voltage.
Engine heater, description (diesel heater)
The machine can be equipped with a diesel-driven engine heater that

heats the engine's cooling system and the cab heating, see Diesel
heater, description, page 9:45.

1:46 1 Engine – Control system, engine
1.9 Control system, engine

Control system engine, description (engine
option Volvo)
The engine is controlled by a control system whose central unit is a
control unit.
The system consists of sensors, control unit (D7940) and electric

injectors, amongst other things. The sensors provide input signals to
the control unit, which in turn controls the injectors. The fuel quantity
is calculated by the control unit based on signals from the sensors
on the engine and a CAN message about the desired engine speed
(from the accelerator pedal).
If serious malfunctions are detected by the control system on the

engine, then engine power is limited to protect the engine from further
damage.
Control system engine, description (engine

option Cummins)
The engine is controlled by a control system whose central unit is a
control unit.
The system consists of sensors, control unit (D7940) and electric

injectors, amongst other things. The sensors provide input signals to
the control unit, which in turn controls the injectors. The fuel quantity
is calculated by the control unit based on signals from the sensors
on the engine and a CAN message about the desired engine speed
(from the accelerator pedal).
If serious malfunctions are detected by the control system on the

engine, then engine power is limited to protect the engine from further
damage.
1.9.1 Engine control unit

Control unit, engine, general
See 11.5.3.6 Control unit, engine (D7940), page 11:33 and supplier
documentation, engine.

1 Engine – Ignition/heating 1:47
1.10 Ignition/heating
Ignition/heating, description (engine option
Volvo)
The engine is equipped with preheating of the induction air, for faster
start at low temperatures. The preheating is activated automatically
when the ignition is switched on and the engine's management system
detects that there is a need for preheating. When preheating is
activated, the event menu for preheating is shown in the display.
Ignition/heating, description (engine option

Cummins)
The engine is equipped with preheating of the induction air, for faster
start at low temperatures. The preheating is activated automatically
when the ignition is switched on and the engine's management system
detects that there is a need for preheating. Preheating is activated by
Control unit engine (D7940) when required.

1:48 1 Engine – Start and stop of engine
1.11 Start and stop of engine

1.11.1 Starter motor
Starter motor, description (engine option Volvo)
The engine is started and stopped with the start button. The start button
sends signals to Control unit dashboard panel (D7902) which, via
Control unit frame (D7971), sends messages via CAN bus drive-train
to Control unit engine (D7940). Starter motor (M6540) is supplied with
voltage directly from the starter batteries. A relay on the starter motor
(solenoid) is activated by Control unit engine (D7940).
On machines with engine and hydraulic oil heater, engine start is

prevented when the electrical cable to the heaters is connected.
Starter motor, description (engine option Cummins)

The engine is started and stopped with the start button. The start button
sends signals to Control unit dashboard panel (D7902) via Control
unit frame (D7971), which sends messages via CAN bus drive-train to
Control unit engine (D7940). Starter motor (M6540) is supplied with
voltage directly from the starter batteries. A relay on the starter motor
(solenoid) is activated by Control unit frame (D7971) via Relay starter
motor (K3600).
On machines with engine and hydraulic oil heater, engine start is

prevented when the electrical cable to the heaters is connected.
1.11.2 Stopping device

Stopping device, description (engine option Volvo)
The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.
The engine is stopped by means of pushing the start button or switching

off the ignition on the ignition key lock.
There is also a stop button on the engine that can be used in an

emergency to stop the engine, e.g. if the engine cannot be stopped
by other means.
As an option, the machine can be equipped with one or several

types of automatic function that can switch off the engine:
• Automatic stop of the engine a specific time after leaving the
operator's station, description, page 1:49
• Automatic stop function, description, page 1:49
•
NOTE
The battery disconnector cannot and must not be used as
emergency stop!

1 Engine – Automatic stop of the engine a specific time after leaving the operator's station 1:49
Stopping device, description (engine option Cummins)

The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.
The engine is stopped by means of pushing the start button or switching

off the ignition on the ignition key lock.
As an option, the machine can be equipped with one or several

types of automatic function that can switch off the engine:
• Automatic stop of the engine a specific time after leaving the
operator's station, description, page 1:49
• Automatic stop function, description, page 1:49
•
NOTE
The battery disconnector cannot and must not be used as
emergency stop!
1.11.3 Automatic stop of the engine a specific

time after leaving the operator's station
Automatic stop of the engine a specific time after
leaving the operator's station, description
The machine may be equipped with a function that turns the engine
off if the driver leaves the cab for more than a certain time. During
programming of the control system, the engine is not shut down
automatically in order to ensure the voltage feed to the control units.
Five minutes is the normal standard setting, but the time can be
changed by a service technician via the display login.
1.11.4 Automatic stop function

Automatic stop function, description
The machine may be equipped with an automatic stop function. This

means that the engine is stopped when the machine is considered to
be inactive. The control system monitors a number of conditions for
auto-stopping the engine and when these are fulfilled the engine is
stopped after a certain delay (can be set via the menus in the machine).
The following conditions apply:

• The machine has operating temperature.
• Battery charging status is OK.
• The machine is stationary running at idling speed in neutral
position.
• Load handling functions are inactive.
• Parking brake is activated.
When the engine has been stopped automatically, the engine must be
started in the normal way.

1:50

2:1
2 Transmission
Contents 2 Transmission
2 Transmission ..................................................................................................... 2:3
2.1 Controls and instruments .................................................................................2:9
2.1.1 Gear selector and multi-function lever.........................................................2:9
2.2 Torque converter/Clutch system .................................................................... 2:11
2.2.1 Flex plates ................................................................................................. 2:11
2.3 Mechanical transmission................................................................................2:12
2.6 Lubrication system .........................................................................................2:13
2.6.3 Transmission oil cooler..............................................................................2:13
2.7 Cooling system ..............................................................................................2:15
2.7.3 Oil cooler ...................................................................................................2:15
2.7.4 Cooling fan ................................................................................................2:15
2.8 Control system transmission..........................................................................2:16
2.8.1 Transmission control unit ..........................................................................2:17
2.8.2 Brake pressure sensor ..............................................................................2:17
2.8.3 Transmission cable harness......................................................................2:17

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, general
The transmission converts the engine's power to drive the hydraulics
and for propulsion of the machine.
Depending on machine model, the machine is equipped with one of

the following transmission options:
• DCU80–100-45E MP (Medium Performance): DANA TE143xx
• DCU80–100-45E HP (High Performance): DANA LTE144xx
Dana TE143xx
The transmission is fully automatic with torque converter and freewheel
function. It has 3 forward gears and 3 backward gears.
The torque converter and gearbox work together via a common

hydraulic system. The torque converter is a hydraulic clutch positioned
between the engine's output shaft and the transmission's input shaft.
The hydraulic oil pumps and the oil pump for the transmission's control
and lubrication are connected to the engine via the power take-off on
the transmission.
Gear positions are selected by means of pressure being modulated

with electric valves that are controlled by Control unit transmission
(D7930). The control unit uses sensors for pressure, temperature and
engine speed in order to determine which gear position should be
activated and solenoid valves in order to activate the gear.
Dana LTE144xx
The transmission is fully automatic with torque converter, freewheel
function and lock-up. It has 4 forward gears and 4 reverse speeds.
The hydraulic pumps for working hydraulics are mounted on the
transmission.
The torque converter and gearbox work together via a common

hydraulic system. The torque converter is a hydraulic clutch positioned
between the engine's output shaft and the transmission's input shaft.
The hydraulic oil pumps and the oil pump for the transmission's control
and lubrication are connected to the engine via the power take-off on
the transmission.
Gear positions are selected by means of pressure being modulated

with electric valves that are controlled by Control unit transmission
(D7930). The control unit uses sensors for pressure, temperature and
engine speed in order to determine which gear position should be
activated and solenoid valves in order to activate the gear.
and instructions for the transmission's components and systems, refer
to the relevant supplier documentation.


2:4 2 Transmission – Transmission
Transmission, function description

(transmission alternative Dana TE14xxx)
Parking brake Released Parking brake system, function description, page 4:31
Sensor, operator-in- Not activated (operator in seat) Sensor operator in seat, description, page 9:17
seat

1 Travel direction selector (S1310) Neutral: US1310:5 = 24 V Travel direction selector and parking brake,
sends a voltage signal to the Forward: US1310:2 = 24 V description, page 2:9
KPU control unit (D7902). D1: Diagnostic menu, see 2.1 Controls & Instr
Reverse: US1310:3 = 24 V
1/XX DIAGNOSE, page 8:28
2 Travel direction selector on Neutral: US1310-2:8 = 24 V Control lever (EGO), description, page 7:8
Control lever (S8150) Forward: US1310-2:7 = 24 V D1: Diagnostic menu, see 2.1 Controls & Instr
Gear selector (S1310-2) sends Reverse: US1310-2:10 = 24 V 1/XX DIAGNOSE, page 8:28.
voltage signals to Control unit
KPU (D7901).
3 Travel direction selector on Neutral: US1310-3:6 = 24 V Linear levers, description, page 7:5
linear lever Forward: US1310-3:5 = 24 V D3: Diagnostic menu, see 2.1 Controls & Instr
Gear selector (S1310-2) sends Reverse: US1310-3:7 = 24 V 1/XX DIAGNOSE, page 8:28
voltage signals to Control unit
KPU (D7901).
4 If the travel direction selector is Parking brake applied: US1310: Travel direction selector and parking brake,
in position for activated parking 4 = 24 V description, page 2:9
brake (S1310) then a voltage Parking brake released: US1310: D1: Diagnostic menu, see 2.1 Controls & Instr
signal is sent to Control unit =0V 1/XX DIAGNOSE, page 8:28
4
KPU (D7902), at which point
neutral position is selected in
the transmission.


5 Switch on steering panel Checked by control system, Cab overview, page 9:5
Switches for manual shifting up, error shown with error code. D5: Diagnostic menu, see 2.1 Controls & Instr
manual shifting down and for 4/XX DIAGNOSE, page 8:29
automatic shifting send voltage
signals to Control unit KPU
(D7902).
6 Accelerator pedal (B6900) U = 0.5-4.5 V Accelerator pedal description, page 1:31
sends voltage signals to Control D6: Diagnostic menu, see 1.1 Controls & Instr
unit KPU (D7902). 1/XX DIAGNOSE, page 8:21
7 The KPU control unit (D7902) Checked by control system, 11.5.3.2 Control unit KPU (D7902), page 11:27.
sends the required throttle on error shown with error code. 11.5.3.4 Control unit KFU (D7971), page 11:31
the CAN bus to the Engine
control unit (D7940) via KFU
(D7971).
8 Control unit KPU (D7902) sends Checked by control system, 11.5.3.2 Control unit KPU (D7902), page 11:27.
the selected shifting program error shown with error code. 11.5.3.4 Control unit KFU (D7971), page 11:31
(neutral, forward, backward
or gear 1-3) on the CAN bus D8: Diagnostic menu, see 2.1 Controls & Instr
via Control unit KFU (D7971), 4/XX DIAGNOSE, page 8:29.
to Control unit transmission
(D7930).
9 The transmission's oil pump - Lubrication system, description, page 2:13
pumps oil when the engine is
running.
10 The transmission's oil filter - Lubrication system, description, page 2:13
cleans the oil from impurities.
11 The oil cooler cools the - Transmission oil cooler, description, page 2:13
transmission oil.
12 The transmission control unit Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) transmits temperature transmission, error shown with page 11:35
information on the CAN bus. error code.
13 Control unit transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) supplies voltage to transmission, error shown with page 11:35
valve block transmission control error code.
(A3) in order to obtain the
desired function.
14 Solenoid valves for travel Checked by Control unit, Transmission, component location
direction and gear position transmission, error shown with (transmission alternative Dana TE14xxx), page
in valve block transmission error code. 2:7
control (A3) activate gears in the
transmission and the engine's
power is transmitted to the
transmission's output shaft.
15 Sensor rpm turbine (B7510), Checked by Control unit, Transmission, component location
Sensor rpm inner transfer shaft transmission, error shown with (transmission alternative Dana TE14xxx), page
(B7520), Sensor engine speed error code. 2:7
(B7530) and Sensor rpm output
shaft (B7580) send pulse signals
with frequency proportional to
the rotation speeds to Control
unit transmission (D7930).
16 Sensor oil temperature Checked by Control unit Transmission, component location
transmission (B7660) sends a transmission and sent to D7950 (transmission alternative Dana TE14xxx), page
voltage signal proportional to for display. Error code is sent if 2:7
the oil temperature to Control the oil temperature is too high. D16: Diagnostic menu, see 2.6 Lubrication Sys
unit control unit (D7930). 1/XX DIAGNOSE, page 8:30
17 Control unit, transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) controls gear shifting transmission, error shown with page 11:35
according to selected shifting error code.
program.


18 Control unit KID (D7950) shows Checked by Control unit, 11.5.3.3 Control unit, KID (D7950), page 11:29
transmission information in transmission, error shown with
operating menus. error code.
19 If the signal from Sensor rotation Checked by Control unit, 11.5.3.4 Control unit KFU (D7971), page 11:31
speed output shaft (B7580) transmission, error shown with
indicates that the speed of the error code.
machine exceeds the speed
limitation, then Control unit KFU
(D7971) sends a request for
reduced engine speed on CAN
bus drive-train.
20 Control unit, engine (D7940) Checked by Control unit, 11.5.3.6 Control unit, engine (D7940), page
reduces the engine speed. transmission, error shown with 11:33
error code.
21 Declutch U = 0.5-4.5 V Brake pressure sensor, description, page 4:27
The brake pressure sensor D21: Diagnostic menu, see 4.3 Power Assisted
(B7681) sends a voltage signal 3/XX DIAGNOSE, page 8:34 or 2.2 Torq Conv
corresponding to the brake Clutch 1/XX DIAGNOSE, page 8:29
pressure to the KFU control unit
(D7971).
22 Control unit KFU (D7971) sends Checked by Control unit, 11.5.3.4 Control unit KFU (D7971), page 11:31
brake pressure information on transmission, error shown with
CAN bus drive-train. error code.
23 Control unit transmission Checked by Control unit, 11.5.3.7 Control unit, transmission (D7930),
(D7930) supplies voltage to transmission, error shown with page 11:35
Valve block transmission control error code.
in order to declutch the drive
if the criteria for declutch are
fulfilled.
24 Control unit transmission Checked by control system, 11.5.3.7 Control unit, transmission (D7930),
(D7930) transmits the error shown with error code. page 11:35
temperature on the CAN
bus.
25 Control unit KFU (D7971) Checked by control system, 11.5.3.4 Control unit KFU (D7971), page 11:31
controls Visco clutch cooling error shown with error code. D25: Diagnostic menu, see 1.7 Cooling system
fan (M6580) from 0–100% of 4/XX DIAGNOSE, page 8:23 and 1.7 Cooling
the engine speed depending system 8/XX DIAGNOSE, page 8:24.
on engine and transmission
temperature.
26 Visco clutch cooling fan (M6580) Checked by control system, Cooling fan, description, page 1:44
regulates the drive ratio for the error shown with error code.
cooling fan which increases the
air flow through the cooling unit.
27 Visco clutch cooling fan (M6580) Checked by control system, Cooling fan, description, page 1:44
sends a pulse signal with error shown with error code. D27: Diagnostic menu, see 1.7 Cooling system
frequency proportional to the 5/XX DIAGNOSE, page 8:23
fan speed to Control unit KFU
(D7971).

Transmission, component location

(transmission alternative Dana TE14xxx)
1. Oil dipstick, red 9. Valve unit transmission (A3)

2. Filling point for transmission oil 10. Sensor engine speed (B7530)
3. Transmission oil cooler, Volvo TAD552VE 11. Sensor, oil temperature sump (B7660)
4. Transmission oil cooler, Volvo TAD8xxVE 12. Sensor rpm turbine (B7510)
5. Transmission oil cooler, Cummins QSB6.7 13. Sensor, drum rpm (B7520)
6. Thermostat 14. Sensor rpm output shaft (B7580)
7. Power take-off 15. Output shaft
8. Oil filter transmission

1. Control unit, transmission (D7930) 7. Accelerator pedal (B6900)

2. Diagnostic socket, transmission 8. Switch, shifting program
3. Travel direction selector, control lever (S1310-3) 9. Control unit, KID (D7950)
(only apples to linear levers)
10. Travel direction selector, control lever (S1310-2) (only
4. Travel direction selector (S1310) apples to control lever EGO)
5. Control unit KFU (D7971) 11. Control unit KCU (D7901)
6. Brake pressure sensor (B7681) 12. Control unit KPU (D7902)
Engine and transmission, separation

See Engine and transmission, separation, page 1:26.

2 Transmission – Controls and instruments 2:9

2.1.1 Gear selector and multi-function lever
Travel direction selector and parking brake,
description
Travel direction selector and parking brake control both selection of
travel direction and activation of the parking brake.
The travel direction selector and parking brake (S1310) send voltage
signals to Control unit KPU (D7902), which in turn provides information
about the selected gear via the CAN bus to the Control unit KFU
(D7971). Control unit KFU (D7971) sends information about selected
gear to Control unit transmission (D7930) on CAN bus drive-train.
The signals can be checked with the diagnostic menu, see 2.1 Controls
& Instr 1/XX DIAGNOSE, page 8:28.
1. Travel direction selector and parking brake
Travel direction selector and parking brake,

replacement
2 Remove the screws and the cover.
3 Remove the cover.
Allow the gaiter over the travel direction selector and parking brake
to remain in place.
015776
4 Remove the cover.

5 Remove the screws that hold the travel direction selector and
parking brake.
015782
1 2 3
1. Cover
2. Screw
3. Travel direction selector and parking brake

2:10 2 Transmission – Gear selector and multi-function lever
6 Disconnect the contact.

7 Replace the travel direction selector and parking brake.
NOTE
The cable harness must be reassembled in the same way as
previously, to avoid any possible damage.
015783
Travel direction selector, control lever, general

See Control lever (EGO), description, page 7:8.
Travel direction selector, linear levers, general
On machines with linear levers, there is an additional travel direction

selector on the left-hand lever, see Linear levers, description, page 7:5.

2 Transmission – Torque converter/Clutch system 2:11
2.2 Torque converter/Clutch system

Torque converter/clutch, description
The torque converter transmits the engine's power to the transmission.
2.2.1 Flex plates

Flex plates, changing
2 Before the flex plate can be replaced, the engine and transmission
must be split, see Engine and transmission, separation, page 2:8
3 Remove the bolts holding the flex plate to the transmission.
4 Replace the flex plate and tighten the screws securing the flex plate
to the transmission crosswise to a torque of 40 Nm (oiled screws).
5 Fit the transmission, see Engine and transmission, separation,
page 2:8.
6 Before the machine is taken into service, the transmission must be
calibrated, see Maintenance manual.
007774
Flex plate attachment (transmission alternative Dana

TE14xxx)

2:12 2 Transmission – Mechanical transmission
2.3 Mechanical transmission

Mechanical transmission, description
The transmission is built with all gears constantly in mesh. It is shifted
by means of hydraulic pressurising of clutch plates for each of the
gears. The clutch plates connect the input shaft with the main shaft or
tubular shaft, depending on which gear has been selected. Shifting
takes place without the transmission being disengaged from the engine.
Depending on transmission alternative, the transmission has three

forward gears and three backward (Dana TE143xx) or four forward
gears and four backward (Dana TE144xx). The electrical shifting
system is automatic but it is also possible to change gear manually with
the switch on the steering panel.
The FORWARD and REVERSE clutches are electro-hydraulically

modulated, which means that the clutch pressure is built up gradually.
This allows shifting between FORWARD and REVERSE and vice
versa whilst travelling at a speed that is lower than the set limit value.
Modulation also provides smooth shifting between FORWARD and
REVERSE.
The transmission is equipped with a declutch function that allows the

engine speed to be increased without machine propulsion in order to
obtain more hydraulic power for the load handling functions. Declutch
is activated at a specific brake pressure.
The transmission is equipped with a freewheel function. This function

makes it possible to disengage the transmission if the propeller shaft
needs to spin faster than the transmission's output shaft. This leads to
reduced wear on the transmission.
High modulation (i.e. smooth driving/intense slipping between gears)

results in high wear on the transmission and high oil temperature.
Sensor for oil temperature gives a warning when the oil is hotter than
120 °C. If the sensor for oil temperature indicates 125 °C then the
transmission enters "limp-home" operating mode, see section D error
codes, group 2 Transmission.

2 Transmission – Lubrication system 2:13
2.6 Lubrication system

Lubrication system, description
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 from any impurities via an oil filter.
The transmission oil cooler is located in the cooling unit behind the
engine and a thermostat in the cooler means that the oil comes
up to operating temperature more quickly. In the event of high oil
temperature, a warning is activated in Control unit KID (D7950) and
performance is reduced, if the oil temperature continues to increase
then the transmission is disengaged.
See also supplier documentation, transmission.
2.6.3 Transmission oil cooler

Transmission oil cooler, description
The transmission oil cooler is located in the cooling unit behind the
engine and a temperature-controlled bypass valve in the cooler means
that the oil comes up to operating temperature more quickly. When the
oil is cold, the valve is open and releases the oil past the radiator. When
the oil is hot, the valve is closed the oil flows through the transmission
oil cooler. The valve starts to close at 70 °C and is fully closed when
the temperature reaches 80 °C.
In the event of high oil temperature, a warning is activated in Control

unit KID (D7950) and performance is reduced, if the oil temperature
continues to increase then error codes are generated and the
transmission is disengaged.
For more information, see supplier documentation, transmission.
1. Transmission oil cooler Volvo TAD552VE

2. Transmission oil cooler Volvo TAD8xxVE
3. Transmission oil cooler Cummins QSB6.7

2:14 2 Transmission – Transmission oil cooler
Bypass valve, transmission oil cooler, replacement
NOTE
Read safety instructions for oil before starting work, see section
B Safety.

2 Drain the oil from the transmission, see Maintenance manual.
3 Remove the bypass valve.
4 Fit the new bypass valve.
5 Fill with transmission oil, see Maintenance manual.
6 Start the engine and check sealing.
7 Check the transmission oil level, see Maintenance manual.
1. Bypass valve Volvo TAD552VE

2. Bypass valve Volvo TAD8xxVE
3. Bypass valve Cummins QSB6.7

2 Transmission – Cooling system 2:15
2.7 Cooling system

Cooling system, description
The transmission is cooled by the lubrication system see Lubrication
system, description, page 2:13.
2.7.3 Oil cooler

Oil cooler, description
2.7.4 Cooling fan

The transmission oil cooler is cooled by the engine's cooling fan, see
Cooling fan, description, page 1:44.

2:16 2 Transmission – Control system transmission
2.8 Control system transmission

Transmission control system, description
Depending on transmission alternative, the transmission has three
forward gears and three backward (Dana TE143xx) or four forward
gears and four backward (Dana TE144xx). The transmission has
functions for manual shifting as standard and automatic shifting and
electronic declutch via the brake pedal.
Control unit transmission controls shifting based on signals from the

pressure, temperature and engine speed sensors. Gear selection
takes place by means of activating the solenoid valves that distribute
control pressure in the transmission, so that the selected gear gives
the correct speed.
Tools for advanced diagnostics are available from Dana's dealers, for
more information contact Cargotec Sweden AB.
In the event of serious faults in the transmission, the control unit

protects the transmission by means of limiting the functions in the
transmission.
The machine engages neutral position
The machine is equipped with a safety function that results in the
transmission shifting to neutral position if the operator leaves the
operator's station. The system uses the same switch in the driver's
seat as the warning for released parking brake in order to sense when
the operator leaves the operator's station.
If the buzzer sounds when the operator sits down in the seat and
releases the parking brake, the switch in the seat may not be working.
In which case, it is not possible to select any travel direction.
In an emergency situation, the machine can be operated by bypassing

the safety system, for more detailed information, see section 8 Control
system, group 8.2.2 Bypass.
WARNING
Safety interlocks blocked.
No safety system is engaged! Risk of tipping and
rolling over!
Only use by-pass in emergency situations!
1 Release the load.

2 Activate switch for by-pass.
3 Select travel direction.
4 Drive the machine to service. Speed is limited to 10 km/h.

2 Transmission – Transmission control unit 2:17
Transmission, calibration
See Maintenance manual.
2.8.1 Transmission control unit

Control unit transmission, general
See 11.5.3.7 Control unit, transmission (D7930), page 11:35.
2.8.2 Brake pressure sensor

Sensor brake pressure, general
See Brake pressure sensor, description, page 4:27
2.8.3 Transmission cable harness

Transmission cable harness, description
The sensors fitted on the transmission send signals to the Transmission
control unit (D7930) via wiring. The wiring is routed through a cable
duct where the transmission and engine are secured together and then
on to the Transmission control unit (D7930).

2:18

3:1
3 Driveline/Axle
Contents 3 Driveline/Axle
3 Driveline/Axle..................................................................................................... 3:3
3.2 Propeller shaft..................................................................................................3:3
3.3 Drive axle .........................................................................................................3:4

3:2

3 Driveline/Axle – Driveline/Axle 3:3
3 Driveline/Axle
Driveline/Axle, description
The machine's power transmission consists of universal drive shaft and
drive axle with differential and hub reduction.
3.2 Propeller shaft

Propeller shaft, description
The propeller shaft transfers engine power from the transmission to the
drive axle. The propeller shaft has two joints, which means that the
engine and drive axle can move in relation to each other.
Propeller shaft, replacement

2 Secure the propeller shaft so that it does not fall down when the
attaching bolts are removed.
3 Remove the propeller shaft's attaching bolts and lift away the
propeller shaft.
4 Clean the contact surfaces (cross-toothed) on the drive axle and
transmission.
5 Fit the propeller shaft in position with the coupling upward.

6 Fit the propeller shaft attaching bolts and tighten to the
recommended torque. Retighten the attaching bolts after 50h
operating time.
Tightening torque oiled screw:
• Propeller shaft to drive axle 115 Nm
• Propeller shaft to transmission 98 Nm

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

Drive axle, general
The drive axle transmits the engine power to the wheels. A differential
is fitted after the drive axle's input shaft, which changes the reduction
ratio, distributes the power between right and left-hand drive wheels
and also makes it possible for the drive wheels to rotate at different
speeds during cornering. The half shaft transmits the power from the
differential to the wheel hubs. Hub reductions are fitted at the wheel
hubs that change the reduction ratio between wheel and engine in
order to reduce the stress on the half shaft.
and instructions for the drive axle's components and systems, refer to
the relevant supplier documentation.
1. Hub reduction
2. Half shaft (internal)
3. Differential (internal)
4. Drive axle housing
Drive axle, replacement
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
1 Park the machine with blocks behind the steering wheels.

2 Depressurise the brake and hydraulic systems, see Hydraulic
system, depressurising, page B:6.
NOTE
Leave the valves open during replacement.
3 Turn the start key to position 0 and switch off the main power.
4 Insert wedges between the steering axle and the frame.

3 Driveline/Axle – Drive axle 3:5
5 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 contaminants.
004501
2
1. Hydraulic hoses
2. Cable harness
6 Remove the cover (position 3) on the parking brake.

3
004505
3. Cover, parking brake
7 Undo the lock nut (position 4) and screw out the adjusting screw
(position 5), this releases the pressure from brake spring. Screw
until the brake pads release from the brake disc. Refit the cover on
the parking brake (position 3).
6
8 Detach the hydraulic hose (position 6) from the parking brake.
NOTE
5 Plug all connections immediately to protect the hydraulic system
from contaminants.
4
004506
4. Lock nut
5. Adjusting screw
6. Hydraulic hose, parking brake

9 Detach 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
10 Connect lifting equipment to the front lifting points on the machine.

11 Tension the lifting equipment so that the machine's weight is partly
taken up by the lifting equipment.
Lifting machine
12 Remove the bolts that secure the drive axle in the frame.
13 Raise the front part of the machine carefully and ensure that
neither machine nor drive axle start to roll.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
Attaching bolts drive axle
uncontrollably.
14 When the machine has been raised sufficiently, carefully roll the
drive axle away from the machine.
15 Raise and secure the drive axle so that tyres and components can
be safely removed from the drive axle.
DANGER
The drive axle may twist or tip over when handling
the wheels.
Crushing injury!
Before starting to work on a loose drive axle, always
secure the drive axle to prevent it from twisting and
tipping over forwards, backwards or sideways.

16 Remove the drive wheels from the drive axle, see Maintenance
manual.
17 Raise and secure the new drive axle so that tyres and components
can be safely fitted.
DANGER
The drive axle may twist or tip over when handling
the wheels.
Crushing injury!
Before starting to work on a loose drive axle, always
secure the drive axle to prevent it from twisting and
tipping over forwards, backwards or sideways.
18 Transfer parts from the old drive axle to the new one.
NOTE
from contaminants.
19 Clean contact surfaces on drive axle and frame. Also clean the
contact surface for the bolts on the underside of the drive axle.
20 Remove the nuts for drive axle attachment, blow clean and refit
the nuts.
21 Transfer the guide pins to the new drive axle.
22 Fit the drive wheels on the new drive axle, see Maintenance
manual.
23 Lower the drive axle down in front of the machine. Fit the
mountings on the drive axle, aligned with the mountings in the
frame.
24 Carefully roll the drive axle into place under the frame.
CAUTION
Crushing injury!
uncontrollably.
25 Carefully lower the machine towards the drive axle. Check that the
guide pins fit the holes in the frame.
26 Rustproof the bolts with suitable paint.

27 Connect the hydraulic hoses (position 1) and cable harness

(position 2) to the distribution block on the drive axle.
28 Connect the hydraulic hose to the parking brake.
29 Connect the drive shaft to the drive axle, tighten the bolts to a
torque of 115 Nm. (Check-tighten the attaching bolts after 50
operating hours.)
30 Check the oil level in the drive axle.
31 Close the valves that were opened for draining the pressure in the
hydraulic system.
1
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
32 Start the machine and bleed the brakes, see Wheel brakes,
bleeding, page 4:22 and Parking brake, bleeding, page 4:36.
004501
2 33 Check for leaks.

1. Hydraulic hoses 34 Adjust the parking brake, see Maintenance manual
2. Cable harness 35 Test-run the machine carefully and check the function of drive axle
and brakes.

Drive axle, replacement (drive axle alternative

Kalmar TLX)
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
Technical data.
1 Park the machine with blocks behind the steering wheels.
NOTE
3 Insert wedges between the steering axle and the frame.
4 Detach the hydraulic hoses (position 1) and cable harness
(position 2) from the distribution block.
NOTE
from contaminants.
5 Remove the cover (position 3) on the parking brake.

3
004505
3. Cover, parking brake

6 Undo the lock nut (position 4) and screw out the adjusting screw
(position 5), this releases the pressure from brake spring. Screw
until the brake pads release from the brake disc. Refit the cover on
the parking brake (position 3).
6
7 Detach the hydraulic hose (position 6) from the parking brake.
NOTE
5 Plug all connections immediately to protect the hydraulic system
from contaminants.
4
004506
4. Lock nut
5. Adjusting screw
6. Hydraulic hose, parking brake
8 Detach 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
9 Lift the machine so that the wheels are off the ground.
10 Remove the drive wheels from the drive axle, see Maintenance
manual.
11 Support the drive axle under the hubs.
CAUTION
Crushing injury!
Lifting machine Make sure that the drive axle does not roll away
uncontrollably.

12 Remove the bolts that secure the drive axle in the frame.
13 Lift away the drive axle.
CAUTION
Crushing injury!
uncontrollably.

14 Transfer parts from the old drive axle to the new one.
NOTE
from contaminants.
15 Clean contact surfaces on drive axle and frame. Also clean the
contact surface for the bolts on the underside of the drive axle.
16 Remove the nuts for drive axle attachment, blow clean and refit
the nuts.
17 Transfer the guide pins from the old drive axle to the new drive axle.
18 Lift the drive axle into place under the frame. Check that the guide
pins fit in the frame.
CAUTION
Crushing injury!
uncontrollably.
19 Insert the new screws securing the drive axle in the frame. Tighten
to 1380 Nm.
20 Fit the drive wheels, see Maintenance manual.
21 Rustproof the bolts with suitable paint.
22 Lower the machine.
23 Connect the hydraulic hoses (position 1) and cable harness
(position 2) to the distribution block on the drive axle.
24 Connect the hydraulic hose to the parking brake.
25 Connect the drive shaft to the drive axle, tighten the bolts to a
torque of 200 Nm. (Retighten the attaching bolts after 50 operating
hours.)
26 Check the oil level in the drive axle.
27 Start the machine and bleed the brakes, see and Parking brake,
bleeding, page 4:36.
28 Check for leaks.
1. Hydraulic hoses
29 Adjust the parking brake, see Maintenance manual
2. Cable harness
30 Test-run the machine carefully and check the function of drive axle
and brakes.

3:12

4:1
4 Brakes
Contents 4 Brakes
4 Brakes................................................................................................................. 4:3
4.1.1 Brake pedal .................................................................................................4:4
4.1.2 Switch parking brake ...................................................................................4:5
4.3 Power-assisted brake system ..........................................................................4:6
4.3.1 Brake oil pump ............................................................................................4:8
4.3.2 Oil filter brake system................................................................................4:13
4.3.3 Accumulator charging valve ......................................................................4:13
4.3.4 Accumulator ..............................................................................................4:14
4.3.5 Brake valve ...............................................................................................4:17
4.3.6 Drive axle block .........................................................................................4:20
4.3.9 Wheel brake ..............................................................................................4:21
4.3.10 Pipes and hoses........................................................................................4:23
4.3.11 Accumulator pressure sensor....................................................................4:24
4.3.12 Brake pressure sensor ..............................................................................4:27
4.5 Parking brake system ....................................................................................4:31
4.5.1 Brake oil pump ..........................................................................................4:33
4.5.3 Solenoid valve parking brake ....................................................................4:33
4.5.4 Parking brake unit .....................................................................................4:35
4.5.6 Pipes and hoses........................................................................................4:36
4.5.10 Sensor parking brake pressure .................................................................4:36
4.8 Temperature control, cleaning and oil brake system......................................4:40
4.8.1 Hydraulic oil tank .......................................................................................4:41
4.8.3 Brake oil pump ..........................................................................................4:42
4.8.4 Accumulator charging valve ......................................................................4:42
4.8.5 Drive axle block .........................................................................................4:42
4.8.6 Wheel brake ..............................................................................................4:42
4.8.7 Hydraulic oil cooler ....................................................................................4:42
4.8.13 Pipes and hoses........................................................................................4:42
4.8.14 Oil, brake system ......................................................................................4:42

4:2

4 Brakes – Brakes 4:3
4 Brakes
Brakes, general
Brakes are designed to facilitate stopping the machine. The brakes act
on the drive axle (the steering axle has no brakes).
The brake system uses the oil in the common hydraulic system, but the
brake circuit is pressurised by its own hydraulic pump.
The brake system is divided into three functions:

• Power-assisted brake system, description, page 4:6
• Parking brake system, description, page 4:31
• Temperature control, cleaning and oil brake system, description,
page 4:40

4:4 4 Brakes – Controls and instruments

4.1.1 Brake pedal
Brake pedal, description
The brake pedal (1) acts on the brake valve via a lever. A spring
causes the pedal to automatically return to rest position. It is important
to keep the area around the pedal clean. Dust and dirt can cause the
pedal to jam or not become fully depressed.
Brake pedal, checking and adjustment

2 Clean the floor around the brake pedal and check that nothing
blocks movement of the brake pedal.
3 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1-1.5 mm. If
necessary, adjust the brake pedal's adjusting screw to the correct
clearance.
4 Check that the pedal moves smoothly.
Adjusting screw, zero position
5 Lubricate the pedal hinge with "EP2" universal grease.

6 Check that the rubber on the pedal is intact and that the tread
pattern isn't worn out. Change when needed.
7 Check the brake valve; see .
Lubrication points, brake pedal. (The illustration

shows a loose brake pedal.)
Brake pedal, replacement
NOTE
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 Brakes – Switch parking brake 4:5
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 axle 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 declutch pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal's attaching bolt and lift away the brake
pedal.
9 Transfer the pedal rubber to the new pedal.
10 Fit the new brake pedal.
Mounting of steering wheel shaft and steering valve
in pedal assembly. 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.
hydraulic system.
NOTE
the lock ring.
15 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment, page 4:4.
4.1.2 Switch parking brake

Switch, parking brake, general
Parking brake activation is by means of the switch for travel direction
selector and parking brake, see Travel direction selector and parking
brake, description, page 2:9.

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

Power-assisted brake system, description
The power-assisted brake system consists of hydraulic oil tank, brake
oil pump, brake system oil filter (high-pressure filter), accumulator
charging valve (part of the main valve), accumulator, brake valve,
pressure sensor, brake cylinder and wheel brake units.
The oil pump pumps oil (from the tank) which is cleaned in the brake
system oil filter. The accumulator charging valve routes pressure to
the accumulator that stores the pressure, or routes the oil through
the wheel brake for cooling the brake discs. The brake valve routes
pressure from the accumulator to the brake cylinder. The brake cylinder
compresses the discs in the brake units which brakes the machine.
Make-contact (closing switch) brake pressure emits a signal so that the
brake light is switched on when the brake cylinder is pressurised.
When the accumulator is charged, the accumulator charging valve

routes oil through the drive axle's brake units and cools the brakes, and
then routes the oil back to the tank.
As an option, the power-assisted brake system can be equipped

with a fine filter located on the system's return line.
Power-assisted brake system, function

description

1 The brake oil pump pumps oil from the P = 20.5±1.0 MPa (when the Tank, description, page 10:6
hydraulic oil tank. accumulators are charged) Brake oil pump, description, page 4:8
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page
4:42
3 The accumulator charging valve is part - Accumulator charging valve, description,
of the main valve and routes oil flow for page 4:13
charging the accumulators or through Main valve, description, page 10:23
the brake system's cooling circuit.

4 Brakes – Power-assisted brake system 4:7

4 The accumulators store oil pressure. See the pressure plate, Accumulator, description, page 4:14
Accumulator pressure brake
system, on the left frame
member.
5 The brake valve directs pressure from - Brake valve, description, page 4:17
the accumulators to the distribution
block in proportion to pedal depression.
6 The drive axle block shares the pressure See the pressure plate, Drive axle block, description, page 4:20
to right and left brake cylinder. Brake pressure, on the left
frame member.
7 The brake cylinders compress the discs - Wheel brakes, description, page 4:21
in the wheel brakes.
8 The wheel brakes brake the machine. - Wheel brakes, description, page 4:21
9 The brake pressure sensor (B7681) U = 0.5-4.5 V Brake pressure sensor, description, page
sends a voltage signal corresponding to 4:27
the brake pressure to the KFU control D9: Diagnostic menu, see 4.3 Power
unit (D7971). Assisted 3/XX DIAGNOSE, page 8:34
10 If the voltage signal from Sensor brake U = 24 V 11.5.3.4 Control unit KFU (D7971), page
pressure (B7681) is equivalent to brake 11:31
pressure above 0.2 MPa: D10: Diagnostic menu, see 9.6 Lighting
Control unit KFU (D7971) activates Sys 5/XX DIAGNOSE, page 8:68
voltage feed to Brake lights (H4110-LE
and H4110-RI).
11 Brake lights (H4110-LE and H4110-RI) - Brake lights, description, page 9:58
are switched on. D10: Diagnostic menu, see 9.6 Lighting
Sys 5/XX DIAGNOSE, page 8:68
12 If the voltage signal from Sensor brake Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
pressure (B7681) is equivalent to brake error shown with error code. 11:31
pressure above the limit for transmission
declutch:
Control unit KFU (D7971) sends
declutch on CAN bus drive-train.
It is also possible to make a setting so
that there is a requirement for the engine
speed to be above a certain limit in order
that declutch should be activated.
13 Control unit transmission (D7930) Checked by control system, 11.5.3.7 Control unit, transmission
disengages the engine drive. error shown with error code. (D7930), page 11:35
14 The accumulator pressure sensor U = 0.5-4.5 V Accumulator pressure sensor, description,
(B7683) sends a voltage signal page 4:24
equivalent to the pressure in the D14: Diagnostic menu, see 4.3 Power
accumulators to Control unit KFU Assisted 3/XX DIAGNOSE, page 8:34
(D7971).
15 If the voltage signal from Sensor Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
accumulator pressure (B7683) is error shown with error code. 11:31
equivalent to pressure below 11.5 MPa: D14: Diagnostic menu, see 4.3 Power
Control unit KFU (D7971) sends a Assisted 3/XX DIAGNOSE, page 8:34
warning about low pressure on the CAN
bus.
16 KID control unit (D7950) activates the Checked by control system, 11.5.3.3 Control unit, KID (D7950), page
event menu low accumulator pressure. error shown with error code. 11:29
17 Control unit, engine (D7940) limits the Checked by control system, 11.5.3.6 Control unit, engine (D7940),
engine speed error shown with error code. page 11:33
18 The fine filter cleans part of the oil from - Fine filter hydraulic oil, description, page
the cooling circuit. 10:30
Hydraulic diagram, basic machine, see Hydraulic diagram, basic

machine, page E:4.

4:8 4 Brakes – Brake oil pump
4.3.1 Brake oil pump

Brake oil pump, description
The brake system has a gear pump with fixed displacement. The brake
oil pump is located at the front of the right-hand main pump. The pump
generates hydraulic force that is stored in the accumulators for brake
force to the power-assisted brake, as well as oil flow used for cooling
the wheel brakes and the hydraulic oil (circulates the hydraulic oil
through the oil cooler). The switch-over between power generation and
flow is regulated by the accumulator charging valve which is part of the
main valve, see Accumulator charging valve, description, page 4:13.
The brake oil pump is driven by the main pump's shaft from the
transmission's power take-off. The pump's rotation speed is directly
dependent on engine speed. The pump flow rate increases with engine
speed and varies with the rotation speed of the input shaft.
As an option, the hydraulic system can be equipped with a fine

filter. The filter is fitted on the accumulator charging valve's return line
and filters the hydraulic oil.
1. Brake oil pump

2. Hydraulic oil pump 1
Brake oil pump, checking
NOTE
Read safety instructions for oil before starting work, see section B
Safety.
Checking the pump pressure

1 Operate and warm up the machine so that the oil in the brake
system reaches operating temperature, at least 50 °C.
a Use the operating menus transmission and hydraulics to check
the oil temperature.
2 Machine in service position, Service position, page B:5.
3 Depressurise the hydraulic systems, See section B Safety.
b
014520
Operating menu transmission and hydraulic system

a. Oil temperature transmission
b. Oil temperature hydraulic system

4 Brakes – Brake oil pump 4:9
4 Connect a pressure gauge (0-25 MPa) to the pump measuring

outlet on the accumulator charging valve.
5 Start the engine and let it idle.
hydraulic system.
NOTE
the lock ring.
7 Check the pump pressure during charging.

During charging, the pressure should increase to 16.5±0.3 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
8 Check the pressure during cooling.
During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
Measuring outlet, pump pressure
11 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
hydraulic system.
NOTE
the lock ring.
Checking the accumulator charging
CAUTION
Accumulator charging has two pressure limits that are
dependent on each other. Both the upper pressure and
the lower pressure must be within specified limits.
Reduced brake performance.
The machine must not be taken into service with
incorrect brake pressure.

14 Connect a pressure gauge (0-25 MPa) to the accumulator

measuring outlet on the accumulator charging valve.
hydraulic system.
NOTE
the lock ring.
17 Check that the pressure increases slowly to 16.5±0.3 MPa.

18 Check that Sensor accumulator pressure shows the correct
pressure in the display, see Sensor accumulator pressure,
checking, page 4:25.
19 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 11.5±0.5 MPa.
The pressure level depends on the setting of the boost pressure's
upper limit in step 6.
Measuring outlet, accumulator pressure
measuring outlet.
hydraulic system.
NOTE
the lock ring.

Brake oil pump, replacement
NOTE
B Safety.

NOTE
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake system
from impurities.
1. Pressure hose (to brake system)

2. Suction hose (from tank)
4 Remove the attaching bolts, pull the pump out backwards and
lift it away.
5 Transfer the connection adapters to the new pump.

6 Brush sealing silicone on the sealing face of the brake pump, see
section F Technical data.
The illustration shows a separate pump.
7 Fit the brake pump on the main pump.

Install the pump and check that the pump's splines engage in the
shaft in the main pump.
Fit the pump's attaching bolts.
8 Connect the suction hose to the brake pump.
NOTE
Change the O-rings. Check that the O-rings are positioned
correctly.
9 Fill the brake pump with oil through the connection for the pressure
hose.
10 Connect the pressure hose to the brake pump.
NOTE
correctly.
1. Pressure hose (to brake system) 11 Close the valves that were opened for draining the pressure in the
hydraulic system.
NOTE
the lock ring.
12 Turn on the system voltage and start the engine.

13 Check that the hose connections and seal between the hydraulic
oil pump and brake pump seal tight.
Check the feed pressure from the brake pump, see Brake oil
pump, checking, page 4:8.
14 Check the oil level in the hydraulic oil tank, see Maintenance
manual.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the brake system as well.

4 Brakes – Oil filter brake system 4:13
4.3.2 Oil filter brake system

Oil filter brake system, general
See Oil filter brake system, description, page 4:42.
4.3.3 Accumulator charging valve

Accumulator charging valve, description
The accumulator charging valve is part of the main valve, see Main
valve, description, page 10:23. The main valve handles several
functions in the brake and hydraulic systems. The main valve is fitted on
the frame member on the right-hand side of the engine compartment.
The description of the main valve is divided into the following functions:
• Accumulator charging valve, see Accumulator charging valve,
description, page 4:13.
• Control valve lifting/lowering and tilt, see Control valve, lift and tilt,
description, page 7:19 and Control valve, lift and tilt, description,
page 7:64.
• Valve block servo pressure, see Valve block servo pressure,
The accumulator charging valve distributes the oil from the pump
between pressure storage and cooling of the wheel brakes.
The accumulator charging valve stores pressure by directing the oil to

the accumulators. The wheel brakes are cooled by oil being directed to
the drive axle cooling circuit and then on to the hydraulic system cooler.
The hydraulic oil in the hydraulic oil tank is cooled in this way.
The accumulator charging valve prioritises charging of the accumulators

above cooling. A restriction of the charging means that a small quantity
1. Measuring outlet, pump pressure (P) of oil also flows to cooling during accumulator charging. At idle the flow
2. Relief valve from the pump is so small that all oil flows to pressure storage.
3. Accumulator pressure sensor (B7683)
The drain valve (position 8) is used to relieve the pressure in the
4. Connection, brake valve (B) accumulators to the tank. The valve opens a connection between the
5. Connection, accumulators (ACC) accumulators and the wheel brake's cooling circuit. The oil is drained
through the wheel brake to the tank.
6. Measuring outlet, accumulator pressure (M)
7. Sensor parking brake (B7682) (LB) There is a measuring outlet for measuring the pump pressure (position
1) and accumulator pressure (position 6) on the accumulator charging
8. Drain valve
valve. The pressures are individual to each machine and the values
9. Solenoid valve parking brake (Y6420) are specified on the pressure plate on the left-hand frame member, see
10. Adjusting screw Pressure plate, page 10:3.
11. Connection, wheel brake (T) Also fitted on the accumulator charging valve is Solenoid valve parking
12. Connection, parking brake caliper (HB) brake (Y6420) (position 9), Sensor parking brake (B7682) (position 7)
13. Connection from pump (P) and Sensor accumulator pressure (B7683) (position 3).
• Solenoid valve parking brake, description, page 4:33
• Accumulator pressure sensor, description, page 4:24
• Sensor parking brake pressure, description, page 4:36

4:14 4 Brakes – Accumulator
Accumulator charging, checking and adjustment
NOTE
Safety.

2 Check the accumulator's charging, see Brake oil pump, checking,
page 4:8.
3 If necessary, adjust the accumulator charging pressure on the
pressure relief slide.
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 drain valve and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
6 Close the drain valve on the accumulator charging valve.
NOTE
the lock ring.
Adjusting screw accumulator charging pressure
Accumulator charging valve, replacement

valve, replacement, page 10:24.
4.3.4 Accumulator
Accumulator, description
The accumulators store pressure so that there is a pressure reserve in
the event of engine or brake system malfunction. The brake system
has two accumulators connected in parallel that are fitted on the front
right-hand side of the engine compartment.
The accumulators are of the diaphragm type. Each accumulator is

divided into two compartments by a diaphragm. One side of the
diaphragm is pressurised by nitrogen gas. The other side is pressurised
by the hydraulic oil, which compresses the nitrogen gas.
The accumulator has pressure check connections for checking the gas
pressure on the opposite side of the pressure connection.

4 Brakes – Accumulator 4:15
Accumulator, checking
NOTE
Safety.

NOTE
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 accurate.
Test equipment can be ordered from Cargotec.
• Checking with test equipment: continue with step 4.
• Checking in machine: continue with step 6.
Checking with test equipment

4 Remove the accumulators and test them with the test equipment
designed for the purpose, see Accumulator, replacement, page
4:16.
The accumulators' gas pressure must match with the pressure
plate.
5 Continue with step 17.
Checking in the machine

6 Detach one of the accumulators from the distribution block. Plug
the connections on the distribution block with plugs that can
withstand the system pressure. Plug the connections on the
accumulators to protect against impurities.
7 Connect a pressure gauge (0-25 MPa) to the accumulator

measuring outlet on the accumulator charging valve.
9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
10 Check that the plugs seal properly.
12 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
When the pressure reaches approx. 10 MPa the pressure must
decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is switched off
then the accumulator does not have any precharge pressure. This
indicates internal leakage and the accumulator must be replaced.
If the pressure can be reduced slowly to a pressure below 10 MPa
then the pre-charge pressure is too low and the accumulator must
be replaced or given to authorised personnel for maintenance.
13 Depressurise the hydraulic system, see Hydraulic system,
depressurising, page B:6.

4:16 4 Brakes – Accumulator
14 Mark up and disconnect the tested accumulator. Plug the

connections. Connect one of the other accumulators to the
distribution block.
15 Repeat steps 8 - 14 until all accumulators have been checked.
Installation and final checking

17 Connect all accumulators to the distribution blocks. If necessary,
replace or fill deficient accumulators.
NOTE
Check that the seals are intact, clean and in the correct position.

hydraulic system.
NOTE
the lock ring.
20 Check that the accumulators' connections are sealed tightly.

21 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must be
switched on.
Accumulator, replacement
NOTE
B Safety.

2 Turn off the engine and turn off the system voltage.
NOTE
4 Detach the accumulator's clamp and remove the bolt.

5 Detach the accumulator from the distribution block.
NOTE
Hold the block firmly so that the other accumulator does not work
loose.

4 Brakes – Brake valve 4:17
6 Bend the clamp away and remove the accumulator.
7 Fit the new accumulator.
NOTE
Check that the seal is intact, clean and in the correct position.
8 Secure the accumulator's clamp and tighten the bolt.

hydraulic system.
NOTE
the lock ring.

11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking, page
4:15 steps 18-19.
4.3.5 Brake valve

Brake valve, description
The brake valve controls the hydraulic pressure to the brakes and is
pressurised by the accumulator. The brake valve is fitted under the
brake pedal in the cab floor.
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 optimum pedal responsiveness and
increased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).
1. Tank return (T]

2. Pressure to wheel brake [B]
3. Pressure feed [P]

4:18 4 Brakes – Brake valve
Brake valve, checking
NOTE
B Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches
operating temperature, at least 50 °C.
b
014520

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

brake pressure on the drive axle block.
4 Start the machine and run it at idling speed until the accumulator is
charged and the accumulator charging valve changes to cooling.
Measuring outlet, brake pressure
5 Press down the pedal completely and read off the pressure.
Compare with the value specified on the pressure plate.
7 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.
Pressure plate, brake pressure

4 Brakes – Brake valve 4:19
8 Release the pedal. The brake pressure should go down to 0 MPa

straight away.
If the brake pressure does not go down all the way to 0 MPa then
the pedal's zero position may have to be adjusted. The pedal's
zero position is adjusted with the screw under the pedal, see .
If the brake pedal is correctly adjusted and the pressure does not
fall to 0 MPa, the brake valve is not sealed and can cause the
brakes to remain applied and then overheat during operation.
Replace the brake valve if it is not sealed.
Adjusting screw, zero position 9 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
Brake valve, replacement
NOTE
B Safety.

NOTE
3 Mark up and detach the hydraulic hoses from the brake valve.
NOTE
from contaminants.
4 Secure the brake valve with tensioning straps or similar so that it

cannot fall when the attaching bolts are loosened.
1. Tank return (T]

2. Pressure to wheel brake [B]
3. Pressure feed [P]
5 Remove the brake valve attaching bolts.

6 Remove the brake valve.
7 Transfer the connection adapters to the new brake valve.
8 Fit the new brake valve.

4:20 4 Brakes – Drive axle block
9 Connect the hydraulic hoses to the brake valve in accordance

with the marking.
NOTE
correctly.
10 Close the valves opened for draining the pressure in the hydraulic
system, see Hydraulic system, depressurising, page B:6.
NOTE
the lock ring.
11 Turn on the system voltage and start the engine. Run the engine
at idle speed.
12 Check the brake valve; see Brake valve, checking, page 4:18.
13 Check that the brake valve's connections are sealed tightly.
14 Bleed the wheel brakes' brake cylinders, see .
4.3.6 Drive axle block

Drive axle block, description
The drive axle block distributes oil flow and brake pressure to the right
and left-hand wheel brakes. The drive axle block is fitted on a bracket
above the drive axle differential.
The drive axle block has a measuring outlet for brake pressure and for
measuring back pressure in the disc brake's cooling circuit.
The drive axle block has a bypass valve which leads oil directly from
the cooling circuit intake to the cooling circuit return if the resistance
in the axle becomes too great. This protects the wheel brake seals,
e.g. when the oil is cold.
Sensor brake pressure (B7681) is fitted in the drive axle block, see
Brake pressure sensor, description, page 4:27.
1. Connection brake cooling, return from wheel

brake
2. Measuring outlet, back pressure brake cooling
3. Connection brake cooling, to wheel brake
4. Connection brake cylinder, to wheel brake
5. Brake pressure sensor (B7681)
6. Connection brake pressure, from brake valve
7. Measuring outlet, brake pressure
8. Connection brake cooling, from accumulator
charging valve
9. Connection brake cooling, return to radiator

4 Brakes – Wheel brake 4:21
4.3.9 Wheel brake

Wheel brakes, description
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 uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to efficient cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
The wheel brakes have two main sections - disc pack and brake
1 2
cylinder. The disc pack performs the braking. The brake cylinder
presses the discs in the disc pack together during braking.
000016
Wheel hub and brake, cross-section

1. Disc pack
2. Brake cylinder

4:22 4 Brakes – Wheel brake
Wheel brakes, bleeding
NOTE
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work where the brake system has been opened or
after work on the wheel brake.
Brake cylinder
2 Position a ring spanner on the bleed nipple and connect a
transparent 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.
For this reason, allow at least two litres of oil pass through the
Bleed nipple, brake cylinder, on top of the drive axle bleed nipple during bleeding to ensure that no air pockets remain
at the wheel hub's inner short side (left-hand side). in the system.
5 Close the bleed nipple.

6 Move the spanner and hose and repeat steps 2–5 on the other
side.
manual.
Wheel brake, replacement

See supplier documentation, drive axle.

4 Brakes – Pipes and hoses 4:23
4.3.9.1 Disc pack
Disc pack, description

The disc pack consists of several thin coated 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

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

See Pipes and hoses, general, page 10:19.

4:24 4 Brakes – Accumulator pressure sensor
4.3.11 Accumulator pressure sensor

Accumulator pressure sensor, description
Sensor accumulator pressure (B7683) detects the pressure for the
accumulators. The sensor is fitted on the accumulator charging
valve on the lifting beam in front of the transmission in the engine
compartment. The sensor is used to detect pressure drops in the brake
system. The limit level for warning of low brake pressure is selected so
that pressure for at least eight brake applications is available when the
warning for low brake pressure is activated.
Sensor, accumulator pressure (B7683) is supplied with voltage by,

and sends voltage signals proportional to the accumulator pressure to
The signal can be checked with the diagnostic menu, see 4.3 Power
Assisted 3/XX DIAGNOSE, page 8:34.

4 Brakes – Accumulator pressure sensor 4:25
Sensor accumulator pressure, checking
NOTE
B Safety.
NOTE
Read the safety instructions for working in the electronic box or
under the cab, see .
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 °C.
a The temperature can be checked with Operating menu,
transmission and hydraulic system.
b
014520


accumulator pressure on the accumulator charging valve.
Measuring outlet, accumulator pressure
4 To be able to read the signal from the sensor, first navigate to the
menu for service and settings with or and confirm with .
014981

4:26 4 Brakes – Accumulator pressure sensor
5 Enter diagnostic code 1111, with or . Confirm each digit with

.
NOTE
015625
6 Select 4. BRAKES by scrolling with or and confirm with .
7 Select 4.3 Power Assisted System by scrolling with or and

confirm with .
8 Select DIAGNOSE by scrolling with or and confirm with .
9 Select 4.3 Power Assisted 3 by scrolling with or .

For a more detailed description, see 4.3 Power Assisted 3/XX
10 Start the engine and compare the pressure in the diagnostics
menu with the measured pressure on the pressure gauge.
measuring outlet.

4 Brakes – Brake pressure sensor 4:27
Accumulator pressure sensor, replacement
NOTE
B Safety.

NOTE
3 Disconnect the electrical connections and replace the sensor.

hydraulic system.
NOTE
the lock ring.
4.3.12 Brake pressure sensor

Brake pressure sensor, description
Sensor brake pressure (B7681) controls activation of the brake light
when the machine is braked. The sensor is fitted on the drive axle
block which is fitted on a bracket above the drive axle differential.
Sensor, brake pressure (B7681) is supplied with voltage by, and sends
voltage signals proportional to the brake pressure to Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 4.3 Power
Assisted 3/XX DIAGNOSE, page 8:34.

4:28 4 Brakes – Brake pressure sensor
Sensor brake pressure, checking
NOTE
B Safety.
NOTE
1 Operate and warm up the machine until the oil in the brake system
reaches operating temperature, at least 50 °C.
b
014520

Measuring outlet, brake pressure

014981

4 Brakes – Brake pressure sensor 4:29

.
NOTE
015625
6 Select 4.3 Power Assisted System by scrolling with or and

confirm with .
8 Select 4.3 Power Assisted 3 by scrolling with or .

For a more detailed description, see 4.3 Power Assisted 3/XX
9 Start the engine and brake.
Compare the pressure in the diagnostics menu with the measured
pressure on the pressure gauge.
10 Stop the engine and turn the start key to position I.
measuring outlet.

4:30 4 Brakes – Brake pressure sensor
Brake pressure sensor, replacement
NOTE
B Safety.

NOTE

hydraulic system.
NOTE
the lock ring.
6 Start the machine and bleed the brake cylinders for the wheel
brakes, see Wheel brakes, bleeding, page 4:22

4 Brakes – Parking brake system 4:31
4.5 Parking brake system

Parking brake system, description
The parking brake system consists of hydraulic oil tank, brake oil pump,
brake system oil filter (high-pressure filter), accumulator charging valve
(part of the main valve), accumulator, travel direction selector (parking
brake control), parking brake break-contact (opening switch) and
parking brake unit.
The brake oil pump pumps oil (from the tank) which is cleaned in
the oil filter. The accumulator charging valve routes pressure to
the accumulators that store the pressure. The parking brake unit is
released with pressure from the accumulators by means of the parking
brake valve in the accumulator charging valve pressurising the parking
brake caliper. Break contact (opening switch) parking brake emits a
signal so that Indicator light parking brake illuminates when the parking
brake is applied.
Parking brake system, function description

Accumulator pressure Above limit for warning Power-assisted brake system, function description, page 4:6
Service brake Activated Power-assisted brake system, function description, page 4:6

1 The brake oil pump pumps oil from the P = 16.5±0.3 MPa Hydraulic oil tank, general, page 4:41
hydraulic oil tank. Brake oil pump, description, page 4:8
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page 4:42
3 The accumulator charging valve is part - Accumulator charging valve, description,
of the main valve and routes oil flow for page 4:13
charging the accumulators or through Main valve, description, page 10:23
the brake system's cooling circuit.
4 The accumulators store oil pressure. See the pressure plate on Accumulator, description, page 4:14
the left-hand frame beam.

4:32 4 Brakes – Parking brake system

5 Travel direction selector (S1310) sends Applied parking brake: Travel direction selector and parking brake,
a voltage signal to Control unit KPU US1310-4 = 24 V description, page 2:9
(D7902) depending on position. Gear selected or neutral D5: Diagnostic menu, see 4.5 Park Brake
To release the parking brake, the position: US1310-4 = 0 V Sys 1/XX DIAGNOSE, page 8:35
accumulator pressure must be approved
and the service brake applied before
the travel direction selector (S1310)
is moved from the position for applied
parking brake.
6 The brake pressure sensor (B7681) U = 0.5-4.5 V Brake pressure sensor, description, page
sends a voltage signal corresponding to 4:27
the brake pressure to the KFU control D6: Diagnostic menu, see 4.3 Power
unit (D7971). Assisted 3/XX DIAGNOSE, page 8:34
7 If the voltage signal from Sensor, brake Checked by control 11.5.3.4 Control unit KFU (D7971), page
pressure (B7681) is equivalent to brake system, error shown with 11:31
pressure above 0.2 MPa, Control unit error code. D6: Diagnostic menu, see 4.3 Power
KFU (D7971) sends service brake Assisted 3/XX DIAGNOSE, page 8:34
applied on the CAN bus.
8 The accumulator pressure sensor U = 0.5-4.5 V Accumulator pressure sensor, description,
(B7683) sends a voltage signal page 4:24
equivalent to the pressure in the D8: Diagnostic menu, see 4.3 Power
accumulators to Control unit KFU Assisted 3/XX DIAGNOSE, page 8:34
(D7971).
9 If the voltage signal from Sensor, Checked by control 11.5.3.4 Control unit KFU (D7971), page
accumulator pressure (B7683) is system, error shown with 11:31
equivalent to pressure above 11.5 error code. D8: Diagnostic menu, see 4.3 Power
MPa, Control unit KFU (D7971) sends Assisted 3/XX DIAGNOSE, page 8:34
accumulator pressure approved on the
CAN bus.
10 The KPU control unit (D7902) sends Checked by control 11.5.3.2 Control unit KPU (D7902), page
release the parking brake or apply system, error shown with 11:27
parking brake on the CAN bus. error code.
11 Control unit KFU (D7971) activates or Released parking brake: 11.5.3.4 Control unit KFU (D7971), page
cancels activation of Solenoid valve U = 24 V 11:31
parking brake (Y6420). Applied parking brake: U D11: Diagnostic menu, see 4.5 Park Brake
=0V Sys 3/XX DIAGNOSE, page 8:35
12 Solenoid valve parking brake (Y6420) Released parking brake: Solenoid valve parking brake, description,
acts on the valve slide which changes U = 24 V page 4:33
position and routes pressure from the Applied parking brake: U
accumulators to the parking brake =0V
caliper or drains the pressure from the
parking brake caliper to tank.
13 Release: Released parking brake: Parking brake unit, description, page 4:35
The brake caliper is pressurised and P = accumulator pressure
releases the parking brake. Applied parking brake: P
Application: = 0 MPa
The brake caliper is drained of pressure
and the spring applies the parking brake.
14 Sensor parking brake pressure (B7682) U = 0.5-4.5 V Sensor parking brake pressure, description,
sends voltage signals equivalent to the page 4:36
pressure for the parking brake caliper to D14: Diagnostic menu, see 4.5 Park Brake
Control unit KFU (D7971). Sys 3/XX DIAGNOSE, page 8:35
The pressure indicates that the parking
brake is released or applied
15 Control unit KFU (D7971) sends Parking Checked by control 11.5.3.4 Control unit KFU (D7971), page
brake released or Parking brake applied system, error shown with 11:31


16 Control unit KPU (D7902) switches off or Released parking brake: 11.5.3.2 Control unit KPU (D7902), page
switches on indicator light parking brake. Light switched off 11:27
Applied parking brake:
Light on

machine, page E:4.

Brake oil pump, general
See Brake oil pump, description, page 4:8.

Oil filter brake system, general
See Oil filter brake system, description, page 4:42.
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
Solenoid valve parking brake (Y6420) 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 4:13.
The solenoid valve opens a connection between the accumulators and

the parking brake caliper on activation. This means that the parking
brake caliper is pressurised and the parking brake is released. When
the voltage feed to the solenoid valve is cut off, the connection between
the accumulators and parking brake caliper is closed. Instead, a
connection between the parking brake caliper and tank is opened and
the parking brake is applied. This means that the parking brake is
applied if the machine becomes de-energised or if the brake system
becomes depressurised.
The solenoid valve is voltage fed by the KFU control unit (D7971) on
activation.
The signal can be checked with the diagnostic menu, see 4.5 Park
Brake Sys 3/XX DIAGNOSE, page 8:35.

4:34 4 Brakes – Solenoid valve parking brake
Solenoid valve parking brake, checking
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 it at idling speed until the accumulator
charging valve changes to cooling.
2 Let the ignition key lock be in the I position.
3 Release the parking brake with the travel direction selector and
check that the parking brake's brake caliper releases. The brake
caliper should be able to move.
4 Actuate the service brake pedal, apply the parking brake with the
travel direction selector and check that the parking brake's calipers
are applied.
Solenoid valve parking brake, replacement
NOTE

NOTE
3 Detach the electrical connection from the solenoid valve.

4 Remove the nut that attaches the solenoid to the valve.
5 Remove the solenoid from the valve.
6 Unscrew the valve from the accumulator charging valve.
7 Replace the valve. Tighten to a torque of 30 Nm.
8 Fit the solenoid coil. Tighten to a torque of 4.1 Nm.
9 Fit the remaining components in the reverse order.
hydraulic system.
NOTE
the lock ring.
at idle speed.
12 Test the parking brake a couple of times.

4 Brakes – Parking brake unit 4:35
4.5.4 Parking brake unit

Parking brake unit, description
The parking brake unit keeps the machine stationary when parked.
The parking brake unit is fitted 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
activated before the pressure drops so low that the parking brake
is applied. If the parking brake is applied while the machine is in
motion, the brake disc and brake pads must be replaced.
1. Parking brake pad

2. Parking brake caliper
3. Brake disc parking brake
The brake caliper has a spring section and a hydraulic section. The
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine
is braked if a serious fault arises. The clearance between brake pads
and brake disc is adjusted by changing the position of an adjustment
piston that runs in the release cylinder. The adjustment is also used
in order to release the parking brake mechanically in the event of
emergency situations.
1. Brake pads
2. Adjustment piston
3. Release cylinder
4. Thrust spring
5. adjusting screw

4:36 4 Brakes – Pipes and hoses
Parking brake, bleeding
NOTE
B Safety.
1 Park the machine with blocks at the steering wheels and the drive
wheels.
2 Position a ring spanner on the bleed nipple on the parking brake
caliper and connect a transparent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3 Start the machine and apply the parking brake.
4 Open the bleed nipple on the parking brake caliper and allow oil to
run out of it until the oil is free of air bubbles.
5 Close the bleed nipple.
manual.
Bleed nipple, parking brake

4.5.10 Sensor parking brake pressure

Sensor parking brake pressure, description
Sensor parking brake pressure (B7682) detects the pressure to the
parking brake caliper. The sensor is fitted on the accumulator charging
valve on the lifting beam in front of the transmission in the engine
compartment.
Sensor, parking brake pressure (B7682) is supplied with voltage by,

and sends voltage signals proportional to the parking brake pressure to
The signal can be checked with the diagnostic menu, see 4.5 Park
Brake Sys 3/XX DIAGNOSE, page 8:35.

4 Brakes – Sensor parking brake pressure 4:37
Sensor parking brake pressure, checking
NOTE
B Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 °C.
014520


parking brake pressure on the accumulator charging valve.
4 Apply the parking brake.
Measuring outlet parking brake pressure
014981

4:38 4 Brakes – Sensor parking brake pressure

.
NOTE
015625
8 Select 4.5 Parking Brake by scrolling with or and confirm

with .
10 Select 4.5 Park Brake Sys 3 by scrolling with or .

For a more detailed description, see 4.5 Park Brake Sys 3/XX
11 Start the engine and release the parking brake, compare the
pressure in the diagnostics menu with the measured pressure on
the pressure gauge.
measuring outlet.

4 Brakes – Sensor parking brake pressure 4:39
Sensor parking brake pressure, replacement
NOTE
B Safety.

NOTE

hydraulic system.
NOTE
the lock ring.
6 Start the machine and bleed the parking brake, see Parking brake,
bleeding, page 4:36.

4:40 4 Brakes – Temperature control, cleaning and oil brake system
4.8 Temperature control, cleaning

and oil brake system
Temperature control, cleaning and oil brake
system, description
The cooling of the brake system cools the hydraulic oil and in this way
regulates the temperature in the whole hydraulic system.
The temperature control system consists of hydraulic oil tank, brake

oil pump, brake system oil filter (high pressure filter), accumulator
charging valve (part of the main valve), accumulator, wheel brake units,
radiator, temperature sensor and thermal bypass valve. As an option,
there is a fine filter fitted on the system's return line.
The brake system is cooled by hydraulic oil that is circulated through the
brake system's oil filter, the wheel brakes and the hydraulic oil cooler.
The radiator is fitted in the cooling unit which is cooled by the engine's
cooling fan. On machines with fine filter, part of the oil is filtered through
the filter, see Fine filter hydraulic oil, description, page 10:30.
The brake oil pump pumps oil (from the hydraulic oil tank) which is
cleaned in the oil filter before it supplies the accumulator charging
valve. When the accumulators are charged, the accumulator charging
valve routes oil through the drive axle's brake units and cools the
brakes. The oil passes through the cooler back to the tank. The drive
of the engine's cooling fan increases when the temperature of the
hydraulic oil needs to be decreased. A thermal bypass valve routes the
hydraulic oil past the cooler if the oil temperature is low and through
the cooler if the oil temperature is too high. The temperature sensor
controls fan activation and temperature warning in the display.
If the temperature in the brake system becomes too high then the
speed of the machine is limited in order to protect the brakes.
Temperature control, cleaning and oil brake

system, function description

4 Brakes – Hydraulic oil tank 4:41

1 The brake oil pump pumps oil from the P = 20.5±1.0 MPa Brake oil pump, description, page 4:8
hydraulic oil tank. Tank, description, page 10:6
2 Oil filter brake system cleans the oil. - Oil filter brake system, description, page
4:42
3 The accumulator charging valve is part Max. 0.1 MPa Accumulator charging valve, description,
of the main valve and controls the oil page 4:13
for charging the accumulators or to the Main valve, description, page 10:23
drive axle block.
4 The drive axle block distributes the oil to - Drive axle block, description, page 4:20
the cooling circuit of both wheel brakes.
The bypass valve in the distribution
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.
5 The oil cools the wheel brake. - Wheel brakes, description, page 4:21
6 The cooler cools the oil. - Hydraulic oil cooler, description, page
10:26
7 The thermal bypass valve routes oil past approx. 50 °C Bypass valve, hydraulic oil cooler,
the cooler if the oil temperature is low. description, page 10:28
8 Sensor, hydraulic oil temperature R = 25 kΩ at 20 °C Sensor, hydraulic oil temperature,
hydraulic oil tank (B7660) detects the description, page 10:27
hydraulic oil temperature and sends D8: Diagnostic menu, see 10.6 Oil
a voltage signal proportional to the Temp/Clean 1/XX DIAGNOSE, page 8:76
oil temperature to Control unit KFU
(D7971).
9 Control unit KFU (D7971) sends oil Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
temperature information on the CAN error shown with error code. 11:31
bus.
10 Control unit KFU (D7971) controls Visco Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
clutch (M6580) from 0–100 % depending error shown with error code. 11:31
on the temperatures of the engine, D10: Diagnostic menu, see 1.7 Cooling
transmission and hydraulic oil. system 4/XX DIAGNOSE, page 8:23 and
1.7 Cooling system 5/XX DIAGNOSE,
page 8:23.
11 Visco clutch (M6580) regulates the drive - Cooling fan, description, page 1:44
ratio for the cooling fan which increases
the air flow through the cooling unit.
12 If the oil temperature increases Checked by control system, 11.5.3.3 Control unit, KID (D7950), page
above 85 °C then Control unit KID error shown with error code. 11:29
(D7950) activates a warning for high oil
temperature in the display.
13 If the oil temperature increases above Checked by control system, 11.5.3.4 Control unit KFU (D7971), page
90 °C then Control unit transmission error shown with error code. 11:31
(D7930) limits the speed of the machine
in order to protect the brakes.

machine, page E:4.
4.8.1 Hydraulic oil tank

Hydraulic oil tank, general
See Tank, description, page 10:6.


Brake oil pump, general
4.8.4 Accumulator charging valve

Accumulator charging valve, general
See Accumulator charging valve, description, page 4:13.
4.8.5 Drive axle block

Drive axle block, description
See Drive axle block, description, page 4:20.
4.8.6 Wheel brake

Wheel brake, general
See Wheel brakes, description, page 4:21 and supplier documentation,
drive axle.
4.8.7 Hydraulic oil cooler

Hydraulic oil cooler, general
See Hydraulic oil cooler, description, page 10:26.

Oil filter brake system, description
The oil filter brake system cleans impurities from the oil in the brake
system. The filter is fitted on a bracket in front of the transmission.
The brake system's oil filter is a high-pressure filter with removable filter
insert. It is fitted between the pump and accumulator charging valve
part of the main valve. The oil is cleaned when it is forced through
the filter insert's filter material (which is glass fibre) before reaching
the accumulator charging valve.
A bypass valve located between the intake and outlet protects the
insert. If resistance through the filter surface becomes too great, the
bypass valve opens a passage past the insert. The bypass function
opens if the oil is viscous (cold or too low/high viscosity) or if the filter
insert is clogged with dirt.
NOTE
When the filter is clogged, the oil is directed past the filter without
1. Oil filter brake system cleaning. It is therefore very important to replace the filter at the
prescribed interval.

4.8.14 Oil, brake system

Oil brake system, general
See section F Technical data.

5:1
5 Steering
Contents 5 Steering
5 Steering .............................................................................................................. 5:3
5.1.1 Steering wheel ............................................................................................5:4
5.2 Power assisted system ....................................................................................5:5
5.2.1 Hydraulic oil pump.......................................................................................5:6
5.2.2 Priority valve................................................................................................5:6
5.2.3 Steering valve .............................................................................................5:8
5.2.4 Steering cylinder .......................................................................................5:10
5.2.5 Steering axle cradle .................................................................................. 5:11
5.2.6 Link arm .................................................................................................... 5:11
5.2.7 Wheel spindle............................................................................................5:12
5.2.8 Wheel hub .................................................................................................5:12
5.2.13 Pipes and hoses........................................................................................5:12
5.2.14 Control valve steering ...............................................................................5:12
5.2.22 Valve block servo pressure, general .........................................................5:14

5:2

5 Steering – Steering 5:3
5 Steering
Steering, general
The steering function means steering the machine during operation.
The machine is steered with the rear wheels by a power assisted
system.

5:4 5 Steering – Controls and instruments

5.1.1 Steering wheel
Steering wheel, description
The steering wheel is used for steering the machine. The steering
wheel is bolted onto the steering wheel shaft with a nut. The steering
wheel shaft transfers the movement of the steering wheel to the control
valve.
Steering wheel
Steering wheel, replacement

2 Remove the steering wheel cover plate.
3 Loosen the nut but allow it to remain fitted with several threads.
4 Pull the steering wheel straight up so that it releases from the cone.
5 Remove the nut and the steering wheel.
6 Position the new steering wheel on the steering wheel shaft’s cone.
7 Fit the nut and tighten to a torque of 25 Nm.
8 Fit the steering wheel cover.

5 Steering – Power assisted system 5:5
5.2 Power assisted system

Power assisted system, description
The function of the power assisted system is to steer the machine.
Machine steering is servo assisted with pressure from hydraulic oil
pump 1.
The steering consists of steering wheel, steering axle, steering valve,

hydraulic oil pump, control valve steering, priority valve, steering
cylinder, link arms and wheel spindles.
The steering wheel acts on the steering valve (via the steering column)
which, via pilot pressure to Control valve steering, controls the oil
pressure from the hydraulic oil pump to the steering cylinder. The
priority valve is fitted on Control valve steering, and it prioritises the oil
supply to the steering valve above other functions, e.g. load handling.
The steering cylinder acts on the wheel spindles. The link arms are
located between steering cylinder and wheel spindles.
Power assisted system, function description

1 Hydraulic oil pump 1 pumps oil to the See the pressure plate on Axial piston pump with variable
priority valve. the left-hand frame beam. displacement, description, page 10:8
2 The priority valve prioritises pressure Checked by control Priority valve, general, page 5:6
feed to the steering valve over the system, error shown with
working hydraulics. The priority valve error code.
also sends a control signal Valve block,
servo pressure.
3 Valve block servo pressure selects the Checked by control Valve block servo pressure, description,
strongest load signal with built-in shuttle system, error shown with page 10:20
valves if other hydraulic functions are error code.
activated while the steering wheel is
turned. The strongest signal is sent as a
control signal to hydraulic oil pump 1.
4 Hydraulic oil pump 1 increases the - Axial piston pump with variable
capacity displacement, description, page 10:8
5 The steering wheel is turned and acts on - Steering wheel, description, page 5:4
the steering valve\qs input shaft.
6 The steering valve sends control signals - Steering valve, description, page 5:8
to control valve, steering.

5:6 5 Steering – Hydraulic oil pump

7 Control valve steering routes pressurised - Control valve steering, description, page
oil to the steering cylinder and sends 5:12
load signals to hydraulic oil pump 1.
8 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:10

machine, page E:4.
5.2.1 Hydraulic oil pump

Hydraulic oil pump, general
Steering is supplied with oil from hydraulic oil pump 1, see Axial piston
pump with variable displacement, description, page 10:8.
5.2.2 Priority valve

Priority valve, general
The priority valve divides the oil flow from hydraulic oil pump 1 so that
there is always oil to the steering valve. Residual flow goes to the
working hydraulics.
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
priority valve and steering valve via a separate line.
The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signal's pressure.
1. Adjusting screw, control pressure (under

rubber plug)
2. Load signal steering left (L)
3. Measuring outlet control pressure (PM)
4. Connection steering cylinder (CL)
5. Connection steering cylinder (CR)
6. Load signal steering right (R)
7. Tank return from steering valve (TS)
8. Pressure feed to steering valve (PS)
9. Tank return (T)
10. Pressure supply from hydraulic pump 1 (P)
11. Pressure feed to control valve lift/lower and
tilt (EF)
12. Load signal to servo valve load handling and
steering (LS)

5 Steering – Priority valve 5:7
Steering pressure, checking
NOTE
B Safety.
operating temperature, 50 °C.
a The oil temperature can be checked with Operating menu,
transmission and hydraulics.
014520
Transmission and hydraulics operating menu

3 Connect a pressure gauge (0 – 25 MPa) to the measuring outlet

for control pressure.
4 Start the engine and increase engine speed to approx. 1200 rpm.
Measuring outlet control pressure
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.
6 Adjust the hydraulic pressure if necessary. The adjusting screw is

located under a rubber plug on Control valve steering.
7 Turn off the engine and turn off the system voltage.
measuring outlet.
Adjusting screw

5:8 5 Steering – Steering valve
Priority valve, replacement

See Control valve steering, replacement, page 5:13.
5.2.3 Steering valve

Steering valve, description
The control valve is fitted on the underside of the cab floor and is
connected to the steering wheel via the steering wheel shaft. The
control valve is a pilot control valve that gives a signal with low pressure
and low flow (load signal) to the control valve for steering.
The control valve for steering acts as a pilot-controlled directional

control valve. The control valve steering also has a built-in priority
valve that gives priority to oil to the steering function. For control valve
steering, see Control valve steering, description, page 5:12.
1. Tank return (T)

4. Pressure feed (P)
Steering valve, replacement
NOTE
B Safety.

3 Remove the six screws securing the lower plastic steering wheel
shaft cover.
Remove the plastic cover.

5 Steering – Steering valve 5:9
4 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
from contaminants.
5 Secure the control valve on the underside so that it does not fall
when the attaching bolts inside the cab are loosened.
1. Tank return (T)

4. Pressure feed (P)
6 Remove the screws securing the control valve to the cab floor.
7 Remove the control valve by pulling it downward.
8 Transfer the connection adapters to the new control valve.
9 Position the new control valve in place under the cab and secure
it so that it does not fall when the attaching bolts inside the cab
are fitted.
10 Fit the control valve's attaching bolts.
11 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE
correctly.
at idle speed.
13 Test the steering a couple of times.
14 Check that the control valve's connections are sealed tightly.

5:10 5 Steering – Steering cylinder
5.2.4 Steering cylinder

Steering cylinder, description
The steering cylinder acts on the wheels via the link arms. The steering
cylinder is a double-acting hydraulic cylinder.
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front suspension
6. Steering cylinder
7. Rear suspension
Steering cylinder, replacement
NOTE
B Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
NOTE
4 Detach the link arms from the steering cylinder.

5 Mark up and detach the hydraulic hoses from the steering cylinder.
2
1 NOTE
from contaminants.
015700
1. Link arm mounting

2. Hydraulic connection

5 Steering – Steering axle cradle 5:11
6 Remove the steering cylinder's attaching bolts.

7 Replace the steering cylinder. Lift the steering cylinder aside.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes for the attaching
bolts are lined up directly opposite the holes in the steering axle.
9 Fit and lubricate the steering cylinder attaching bolts. Tighten the
bolts crosswise in steps until 680 Nm is achieved.
10 Fit the link arms to the steering cylinder.
11 Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

manual.
Hydraulic cylinders, repairs

See Hydraulic cylinders, repairs, page 10:31.
5.2.5 Steering axle cradle

Steering axle cradle, general
See Steering axle cradle, description, page 6:5.
5.2.6 Link arm

Link arm, description
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels
then they must be replaced.
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front suspension
7. Rear suspension

5:12 5 Steering – Wheel spindle
5.2.7 Wheel spindle

Wheel spindle, general
See Wheel hub, description, page 6:11.
5.2.8 Wheel hub

Wheel hub, general
See Wheel spindle, description, page 6:7.

Pipes and hoses, general
5.2.14 Control valve steering

Control valve steering, description
Valve slide, steering
The control valve is a proportional valve controlled by load signals from

the steering valve. This means that both the size and direction of flow
from the valve can be adjusted and the valve also sends control signals
to hydraulic oil pump 1. The load signals control a spring-centred valve
slide that controls the pressure and flow for the current direction to
the steering cylinder.
Valve slide, steering
The valve slide controls the direction and steering angle by controlling
the hydraulic pressure to the steering cylinder.
The valve slide is controlled by servo signals from the steering valve.
1. Adjusting screw, control pressure (under

rubber plug)
3. Measuring outlet control pressure (PM)
4. Connection steering cylinder (CL)
5. Connection steering cylinder (CR)
7. Tank return from steering valve (TS)
8. Pressure feed to steering valve (PS)
9. Tank return (T)
10. Pressure supply from hydraulic pump 1 (P)
11. Pressure feed to control valve lift/lower and
tilt (EF)
12. Load signal to servo valve load handling and
steering (LS)

5 Steering – Control valve steering 5:13
Control valve steering, replacement
NOTE
B Safety.

NOTE
3 Mark up the hydraulic hoses and detach the hoses from the priority
valve.
NOTE
from contaminants.
4 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from contaminants.
5 Undo the screws and remove the control valve's mounting plate
from the body.
6 Undo the screws and remove the control valve from the mounting
plate.
7 Fit the new control valve on the attaching plate.
8 Transfer parts to the new control valve.
NOTE
correctly.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.

5:14 5 Steering – Valve block servo pressure, general
9 Fit the valve in the machine.

10 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
correctly.
11 Connect the hydraulic hoses to the priority valve.
NOTE
correctly.
hydraulic system.
NOTE
the lock ring.

14 Check the function.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
manual.
16 Check the steering pressure, see Steering pressure, checking,
page 5:7.
5.2.22 Valve block servo pressure, general

Valve block servo pressure, general
See Valve block servo pressure, description, page 10:20.

6:1
6 Suspension
Contents 6 Suspension
6 Suspension ........................................................................................................ 6:3
6.2 Suspension ......................................................................................................6:3
6.2.1 Steering axle cradle ....................................................................................6:5
6.2.2 Wheel spindle..............................................................................................6:7
6.2.3 Wheel hub ................................................................................................. 6:11
6.3 Tyres and rims ...............................................................................................6:15
6.3.1 Tyres .........................................................................................................6:16
6.3.2 Rim ............................................................................................................6:17
6.3.3 Nut, washer and clamp .............................................................................6:17
6.3.4 Tyre pressure monitoring ..........................................................................6:18

6:2

6 Suspension – Suspension 6:3
6 Suspension
Suspension, description
The machine's suspension consists of its tyres (with associated wheel
rim and screw), steering axle with hubs, wheel spindles and the
steering axle's suspension in the frame. The drive axle belongs to the
driveline/axle, see section 3 Driveline/Axle, group 3.3 Drive axle.
6.2 Suspension
Suspension, description
The steering axle cradle is attached into the frame with two bushings,
one in the front edge and one in the rear edge of the steering axle
cradle. Two wheel spindles are fitted in the steering axle cradle on
bearing-mounted axles. The wheel spindle is pivoted in order to
facilitate steering. Bearing-mounted wheel hubs are fitted on the wheel
spindles where the wheels are mounted.
Suspension refers to:

• Steering axle cradle
1. Wheel hub • Wheel spindle
2. Wheel spindle • Wheel hub
3. Link arm
4. Steering axle
5. Front suspension
7. Rear suspension
Bushing steering axle mounting, changing
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.

3 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine's
stability.
4 Support under the steering axle so that it cannot fall over.

6:4 6 Suspension – Suspension
5 Attach hoisting equipment to the rear of the machine and take up

the slack so that the steering axle's mountings are unloaded.
NOTE
Do not lift so much that the wheels are off the ground.
6 Remove the shafts holding the steering axle.

7 Lift the machine up so that the frame is lifted away from the axle.
8 Support the machine under the frame.
9 Move the steering axle so that the mountings are accessible.
NOTE
If necessary, disconnect the cable harness for the sensors on
the steering axle.
Steering axle mounts

1. Eccentric bushing
2. Shaft
10 Remove the washers that hold the bushing in place.

11 Press out the bushing.
12 Clean the bearing surfaces on the steering axle.
The illustration shows front attachment.
13 Press in the new bushing in accordance with the figure. Lubricate

the bushing with grease in order to simplify installation.
14 Fit the washers that hold the bushing in place.
Use locking fluid and tighten the bolts to a torque of 65 Nm.
15 Move the steering axle into place under the frame.
Bushing, steering axle

6 Suspension – Steering axle cradle 6:5
16 Turn the eccentric bushings in the frame so that the axle holes in
the steering axle and the frame are aligned directly on front of
each other.
17 Lubricate and install the front and rear axles at the mounting for
the steering axle.
18 Remove the lifting equipment from the machine.
19 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they are
fitted in the exact same location as before. The stability of the
Steering axle mounts machine is affected if the counterweights are changed.
2. Shaft
6.2.1 Steering axle cradle

Steering axle cradle, description
The steering axle is pendulum suspended with a double-acting steering
cylinder. The design comprises a minimum of moving parts to minimise
service points and simplify maintenance. The frame suspension
comprises maintenance-free parts.
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front suspension
7. Rear suspension
Steering axle cradle, replacement
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.
1 Clean the steering axle and the surrounding area.

2 Stop the engine and turn the start key to position I.

6:6 6 Suspension – Steering axle cradle
5 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machine's
stability.
6 Connect the lifting equipment to the rear section of the machine.

7 Tension the lifting equipment, do not lift so high that the wheels
start to hang.
8 Support the machine's rear section.
9 Remove the wheels, it facilitates replacement.
10 Detach the hydraulic hoses from the steering cylinder.
NOTE
from contaminants.
11 Remove the shafts holding the steering axle.

12 Lift the machine up so that the frame is lifted away from the axle.
13 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
Steering axle mounts uncontrollably.
2. Shaft 14 Adjust the support so that the machine is secured in the new
position.
15 Lift the steering axle into place under the frame.
16 Remove the support under the frame.
17 Lower the rear of the machine.
18 Fit the pins at the steering axle mountings.
19 Connect the hydraulic hoses to the steering cylinder.
NOTE
correctly.
20 Remove the lifting equipment from the machine.

21 Fit the counterweights.
NOTE
Steering axle mounts
Make sure that all counterweights are refitted and that they are
1. Eccentric bushing fitted in the exact same location as before. The stability of the
machine is affected if the counterweights are changed.
2. Shaft
22 Fit the steering wheel and retighten in accordance with the
instructions, see Maintenance Manual.

6 Suspension – Wheel spindle 6:7
6.2.2 Wheel spindle

Wheel spindle, description
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
1. Wheel spindle
2. Stuffing box
3. Spindle bolt
4. Nut
5. Spindle bolt bearing
6. Support ring
Spindle bolt bearing, replacement

1 Clean the wheel spindle and its surrounding area.
2 Lift the machine under the steering axle by the relevant wheel.
Support the steering axle in a safe way.
3 Remove the steering wheel in question.

6:8 6 Suspension – Wheel spindle
4 Detach the link arm from the wheel spindle.

Remove the lock screw and then remove the axle. Move the link
arm aside.
5 Position a lifting strap inside the hub to secure the spindle.
6 Remove the covers at the spindle bolt's upper and lower bearing.
7 Remove the grease between the cover and spindle bolt.
8 Adjust the lifting equipment to relieve the load on the wheel spindle.
1. Cover (upper)
2. Shaft, link arm
3. Cover (lower)
9 Bend up the locking washer's tabs, remove the nuts for the spindle
bolt's upper bearing. Note the location of the washers.
Nut upper bearing
10 Remove the nut for the spindle bolt's lower bearing and remove
the washers and bearing. Note the location of the washers.
NOTE
The spindle bolt is suspended in the upper bearing and cannot
fall down.
11 Remove the spindle bolt and the upper bearing upwards.

12 Remove the wheel spindle.
Place the wheel spindle on a soft surface.
Nut lower bearing.

6 Suspension – Wheel spindle 6:9
13 Replace the bearing races and stuffing boxes in the steering axle.
Coat the bearing races thoroughly with lubricating grease before
assembly.
NOTE
Clean the surfaces of the steering axle before the new parts
are fitted.
IMPORTANT
Stuffing box location
Turn the stuffing boxes with the sealing lip facing the
wheel spindle.
14 Lift the wheel spindle into place on the steering axle.
15 Fit the spindle bolt.

Apply lubricating grease onto the spindle bolt and press it into
place.
NOTE
Exercise caution that the bearing races and stuffing boxes are
not damaged.
16 Lubricate the support ring for the lower bearing with lubricating
grease and fit it onto the spindle bolt.
NOTE
Exercise caution that the stuffing box is not damaged.
Spindle bolt
17 Fit the lower bearing with washers and nuts.

Coat the bearing races and the nut thoroughly with lubricating
grease.
NOTE
Do not tighten the nut.
Lower bearing

6:10 6 Suspension – Wheel spindle
18 Fit the upper bearing with washers and nuts.

Coat the bearing races and the nut thoroughly with lubricating
grease.
NOTE
Do not tighten the nuts.
19 Tighten the lower bearing to a torque of 700-720 Nm (oiled screw).

20 Tighten the upper bearing to a torque of 900-1100 Nm. (Oiled
screw).
21 Turn the wheel spindle back and forth a few times to even out the
grease. Check that resistance is uniform.
Upper bearing
22 Fit the split pin on the lower bearing's nut.
Nut lower bearing
23 Lubricate the lock nut with lubricating grease. Fit the locking
washer and lock nut to the upper bearing. Tighten the nut to a
torque of 500 Nm.
24 Fold the locking washer so that the position of the nuts becomes
fixed to each other.
25 Fit the upper and lower covers.
26 Lubricate the upper and lower bearings of the spindle bolt with
lubricating grease.
Nut lower bearing
27 Connect the link arm to the wheel spindle.

Lubricate the link arm bearings with lubricating grease.
29 Remove the support and lower the steering wheel.
30 Test-operate the machine and test the steering. Check also that
the machine feels stable when driving straight ahead.

6 Suspension – Wheel hub 6:11
6.2.3 Wheel hub

Wheel hub, description
The wheel hub holds the wheel in place and allows the wheel to rotate.
1. Hub nut with locking washer

2. Outer wheel bearing
3. Hub
4. Inner wheel bearing
5. Seal
6. Support ring

6:12 6 Suspension – Wheel hub
Wheel bearing, replacement

1 Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.
2 Remove the steering wheel in question.
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe off grease from hub cap and hub nut. Handle it as
environmentally hazardous waste.
6 Secure the hub with a lifting strap.
7 Bend up the locking washer's tabs, remove the lock nut and
locking 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 tap directly on
the bearings.
NOTE
Fit the outer races with the larger diameter outward.

6 Suspension – Wheel hub 6:13
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the seal
does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.
17 Fit the inner bearing's inner race and rollers on the wheel spindle.
Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".
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.

6:14 6 Suspension – Wheel hub
22 Torque the bearing nut as follows.

A. Lubricate the thread and the side of the nut facing the bearing
with oil (SAE 80W/140).
B. Tighten the nut to a torque of 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) and
then further to engage the locking washer in the closest groove.
Lock the bearing nut and lock nut with the locking washer.
25 Fill the bearing cap with grease and fit it.
26 Grease the wheel bearing with grease through the grease nipple.
Lift the seal ring's lip with a small screwdriver to facilitate the
escape of air. Grease until grease comes out by the seal.
28 Remove the support and lower the steering wheel.

6 Suspension – Tyres and rims 6:15
6.3 Tyres and rims

Tyres and rims, safety
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Wheels (tyre + rim) must only be handled pressurised
after inspection and approval, as well as inflated to
full pressure, by certified personnel.
Deflate the tyres before removing. Otherwise the lock
ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air must always be released through the valve. If
this is not possible - loosen the valve in the rim are
release the air. If this does not work, break off, cut or
saw off the valve pipe. If it is not possible to release
the air via the valve connection, the tyre must be
emptied by drilling a hole in the tyre's tread. Use a drill
bit of a max. Ø 5 mm. Damaged tyres may explode.
Never stand in front of the tyre when deflating or
inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It is not permitted to mix rim components between
rims. The parts are adapted during manufacture.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres, and rims are dimensioned and selected
for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec.

6:16 6 Suspension – Tyres
CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturer's or other
approved instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely
inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,
pieces of wood, metal filings, etc.
Check if the tyre wear is abnormal, this may be
indicative of mechanical problems. Take action
immediately to repair any defects and change damaged
tyres.
Tyres and rims, description

The tyres are the point of contact between the machine and the ground,
the tyres absorb unevenness and act as suspension.
The drive axle is subjected to major forces during operation, if the
rolling circumference of the drive wheels is different then the stress on
the drive axle increases. It is important that the tyres on the drive axle
are the same model, type and make and have equal wear and the
correct air pressure.
6.3.1 Tyres
Tyres, description
The tyres are the point of contact between the machine and the ground,
and they absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each tyre's
rolling circumference differs, the stresses on the drive axle increase.
For this reason it is important that the tyres on the drive axle have
equal wear and correct air pressure.
Spare and replacement tyres must be from a manufacturer approved
by Cargotec.
Tyre, change
DANGER
Changing tyres is high-risk work.
Extreme danger!
Let service personnel change tyres, they have the
competence and authority to handle tyres!

6 Suspension – Rim 6:17
The rims must be checked when tyres are changed, see Maintenance
manual section 6 Suspension.
6.3.2 Rim
Rim, description
The rim is split to make it possible to fit a tyre. The rim consists of
the following parts.
• Rim
• Rim bead seat
• Rim flange
• Lock ring
1. Rim
2. Lock ring
3. Rim flange
4. Tapered wheel rim
5. Wheel nut
6. Wheel bolt
6.3.3 Nut, washer and clamp

Nut, washer and clamp, description
The rim is attached to the wheel hub with nuts.
As an option, the rim can be equipped with nut protection.
Wheel bolt, replacement

1 Machine in service position, see section B Safety.
2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel, see Maintenance manual.

6:18 6 Suspension – Tyre pressure monitoring
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.
6.3.4 Tyre pressure monitoring

Tyre pressure monitoring, description
The tyre pressure monitoring system monitors the air pressure in all
tyres. The system is an independent system which communicates with
the machine's control system and gives warnings in the event of tyre
pressure that is high or low. The warnings are shown on the display in
the machine's cab.
The tyre pressure monitoring system comprises the following parts.

• Sensor tyre pressure
The tyre pressure sensor is screwed onto the nipple on the valve
extender on the tyres. There is a sensor on each tyre. The sensor
detects the air pressure in the tyre and sends this information at
a predetermined interval to Control unit tyre pressure monitoring,
via Antenna tyre pressure monitoring. The sensor has a built-in
battery which cannot be replaced, but the sensor is replaced with
a new one when the battery is discharged.
• Antenna tyre pressure monitoring
Antenna tyre pressure monitoring is connected to Control unit tyre
pressure monitoring and receives the signals from Sensor tyre
pressure. The antenna is fitted together with Control unit tyre
pressure monitoring on the frame in the engine compartment.
• Control unit tyre pressure monitoring
1. Sensor tyre pressure Control unit tyre pressure monitoring receives signals from Sensor
tyre pressure via Antenna tyre pressure monitoring. The control
2. Control unit tyre pressure monitoring with unit communicates with the machine's control system. The control
antenna unit is fitted together with Antenna unit tyre pressure monitoring on
the frame in the engine compartment.
Sensor tyre pressure, replacement

For replacement of Sensor tyre pressure, see Maintenance manual.

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .................................................................................................... 7:3
7.1.1 Control lever ................................................................................................7:5
7.1.2 Switch load securing, automatic/manual locking.......................................7:13
7.1.3 Switch, automatic spreading .....................................................................7:14
7.1.5 Switch stop at 30' or 35' ............................................................................7:14
7.2 Lifting/lowering ...............................................................................................7:15
7.2.1 Hydraulic oil pump.....................................................................................7:18
7.2.4 Accumulator servo circuit ..........................................................................7:18
7.2.5 Control valve, lift and tilt ............................................................................7:19
7.2.7 Lift cylinder ................................................................................................7:20
7.2.8 Sensor hydraulic pressure lift cylinder.......................................................7:20
7.2.9 Mast ..........................................................................................................7:22
7.2.10 Sensor lifting height...................................................................................7:35
7.2.11 Lifting carriage...........................................................................................7:38
7.2.13 Pipes and hoses........................................................................................7:42
7.2.14 Hydraulic oil filter .......................................................................................7:42
7.2.15 Accumulator damping ...............................................................................7:42
7.2.16 Side lift attachment....................................................................................7:45
7.4 Side shift ........................................................................................................7:48
7.4.3 Control valve, attachment .........................................................................7:50
7.4.7 Pipes and hoses........................................................................................7:51
7.5 Spreading.......................................................................................................7:52
7.5.3 Control valve, attachment .........................................................................7:60
7.5.7 Buzzer, automatic spreading 20'-40' .........................................................7:61
7.5.8 Pipes and hoses........................................................................................7:61
7.7 Tilt ..................................................................................................................7:62
7.7.5 Control valve, lift and tilt ............................................................................7:64
7.7.6 Load holding valve ....................................................................................7:65
7.7.7 Tilt cylinder ................................................................................................7:65
7.7.8 Mast ..........................................................................................................7:65
7.7.9 Pipes and hoses........................................................................................7:66
7.9 Load carrier....................................................................................................7:67
7.9.1 Twistlocks ..................................................................................................7:67
7.10 Other functions...............................................................................................7:72
7.10.2 Weight indicator.........................................................................................7:72
7.10.3 Container counter......................................................................................7:72

7:2

7 Load handling – Load handling 7:3
7 Load handling
Load handling, general
The load handling function means e.g. to lift, lower, side shift, tilt and
secure the load.
To hold the load secured, the machine is equipped with a twistlocks

attachment.
The load handling functions are controlled with:

• Linear levers.
• Control lever (EGO) .
• Control lever (Cobra) .
Load handling is divided into different subfunctions:

• Lift/lower.
• Side shift.
• Spreading (positioning).
• Automatic spreading 20' - 40' .
• Extra stop, spreading .
• Tilt
• Mechanical levelling (spring-loaded lifting heads)

• Twistlocks.

7:4 7 Load handling – Load handling
Position sensor, checking and adjustment

The machine has several position sensors in the following locations.
1. Sensor end position lift (B7211), see Sensor end position lift,
2. Sensor contact (B7202LE, B7202RI, B7202UL, B7202UR).
3. Sensor spreading, 30'-stop (B7770LE, B7770RI).
4. Sensor spreading, damping end position (B7690LE, B7690RI).
Position sensor overview
Spacing check
2 Check that the sensor in question is free of damage and dirt.
3 Check that the distance between the sensor and the indicator is
5±1 mm.
C-C
5±1 mm 4 Adjust when needed.

009632
5±1 mm
Adjusting, position sensor - indicator

7 Load handling – Controls and instruments 7:5

7.1.1 Control lever
Linear levers, description
The linear levers are used to control the machine's load handling
functions. The levers send voltage signals to Control unit KCU (D7901).
Lifting/lowering
Lifting/lowering is controlled by moving the lever (position 1) forward
(lower) or backward (lift). See Lifting/lowering, function description,
page 7:16.
The signal can be checked with the diagnostic menu, see 7.1 Controls
and Instr 1/XX DIAGNOSE, page 8:39.
Tilt
Tilt is controlled by moving the lever (position 2) forward (tilt forward) or
backward (tilt backward). See Tilt, function description, page 7:62.
Side shift
1. Lift, lower
2. Tilt Side shift is controlled by moving the lever forward (position 3) or
backward (right). See Side shift, function description, page 7:48.
3. Side shift
Spreading (Shift) The signal can be checked with the diagnostic menu, see 7.1 Controls
4. Spare
5. Selecting direction of travel Spreading
6. Opening twistlocks/lock lugs Spreading is controlled by depressing the shift button (position 8) and
7. Spare moving the lever (position 3) forward (out) or backward (in). See
Spreading, function description, page 7:52.
8. Shift button
9. Spare The signal can be checked with the diagnostic menu, see 7.1 Controls
Opening the twistlocks
Switch open twistlocks (position 6) opens twistlocks if the conditions for
this are met. See Twistlocks, function description, page 7:67.

7:6 7 Load handling – Control lever
Linear lever, replacement

2 Remove the panel's screws.
3 Pry off the hydraulic control's rating plate and unscrew the screw in
hydraulic control.
4 Remove the screws which secure the hydraulic control. Use a
magnetic screwdriver if possible.
5 Remove the hydraulic control and gaiter.
1 2 3
1. Panel screws
2. Screws for the hydraulic control
3. Rating plate
6 Turnover the panel and disconnect the contact.

7 Remove the hydraulic control.
015775
Contact

7 Load handling – Control lever 7:7

If the machine is equipped with a travel direction selector and
switch, transfer these to the new hydraulic control.
Wrap around two turns of electrical tape, 4 mm below the travel
direction selector groove. Fit the travel direction selector so that its
2 groove fits in the hydraulic control's hole.
1
3 CAUTION
The plastic parts of the panels may be damaged if the
screws are tightened too hard.
Product damage.
Exercise caution when tightening, do not tighten the
screws too hard.
016576
1. Travel direction selector

2. Electrical tape
3. Switch

Control lever (EGO), description

Lifting/lowering
Control lever (S8150) is used to control the machine's load handling

functions. The lever sends voltage signals to Control unit KCU (D7901).
Lifting/lowering
Lifting/lowering is controlled by moving the control lever (position
1) forward (lower) or backward (lift). See Lifting/lowering, function
Tilt
Tilt is controlled by moving the control lever (position 1) right (tilt out) or
left (tilt in). See Tilt, function description, page 7:62.
The signal from the control lever can be checked with the diagnostic
menu, see 7.1 Controls and Instr 5/XX DIAGNOSE, page 8:40.
Side shift
1. Lift, lower, tilt in and tilt out (whole lever) When the thumb joystick (position 2) is moved downward then side
2. Side shift shift left is activated, and when the thumb joystick (position 2) is moved
Spreading (shift) upward then side shift right is activated. See Side shift, function
3. Selecting direction of travel
4. Spare The signal from the thumb joystick can be checked with the diagnostic
5. Spare
6. Shift button Spreading
7. Opening twistlocks/lock lugs If the shift button (position 6) is depressed and the thumb joystick
8. Horn (position 2) is moved forward, spreading out is activated, and when
the thumb joystick (position 2) is moved backward, spreading in is
activated. See Spreading, function description, page 7:52.
The signal from the thumb joystick can be checked with the diagnostic
Shift button
The shift button changes the function of other buttons on the control
lever.
this are met. See Twistlocks, function description, page 7:67 or .
Horn
Switch horn (S8500-2) (position 8) activates the horn.

Control lever (EGO), adjusting the hand grip

2 Pull down the control lever's gaiter so that the bracket is accessible
3 Hold the base (2) firmly with a wrench and undo the lock nut (1).
CAUTION
Do not loosen the nut without counterhold.
Risk of product damage!
Always counterhold the base when the lock nut is
loosened or tightened.
4 Rotate the control lever to the desired position.

5 Hold the base (2) firmly with a wrench and tighten the lock nut (1).
1. Lock nut
2. Base
Control lever (EGO), replacement

Screws

3 Turn the panel round and undo the control lever's nuts.
4 Remove the control lever from the panel.
5 Connect the new control lever in the same way as the old one.
6 Fit the new control lever on the panel.
Nuts
7 Fit the upper section of the panel.
CAUTION
Exercise caution when the upper section of the panel
is fitted.
The panel may be damaged.
Position the cable harness in the panel so that the
upper section of the panel can be aligned correctly
without the cable harness being trapped.
Screws

Control lever (Cobra), description

Lifting/lowering
1 2 The control lever (S815) is used to control the boom and attachment.
3 The lever sends voltage signals to Control unit KFU (D7901).
The control lever has up to four potentiometer-controlled functions

4 and up to six off and on functions.
5 Lifting/lowering
7
Lifting/lowering is controlled by moving the whole control lever forward
6 (lower) or backward (lift). See Lifting/lowering, function description,
page 7:16.
8
Tilt
000442
Tilt is controlled by moving the whole control lever right (tilt out) or left
(tilt in). See Tilt, function description, page 7:62.
1. No function
The signal from the control lever can be checked with the diagnostic
2. No function
3. No function
Side shift or spreading
4. Side shift right (S815-T1.2)
5. Side shift left (S815-T1.1) When switch (position 4) is pressed down side shift right is activated,
and when switch (position 5) is pressed down side shift left is activated.
6. Opening of twistlocks (S815-T2) at full
See Side shift, function description, page 7:48.
alignment
7. Tilt (S815-P4) If the pistol trigger (position 8) is pressed in at the same time as side
8. Shift-button (S815-T4): changes the function shift right (position 4), spreading out is activated. If the pistol trigger
for side shift to spreading out (S815-T1.2) and (position 8) is pressed in at the same time as side shift left (position 5),
spreading in (S815-T1.1) spreading in is activated. See Spreading, function description, page
7:52.
The signal can be checked with the diagnostic menu, see .

this are met. See Twistlocks, function description, page 7:67 or .
Shift button
The shift button (pistol trigger) (position 8) changes the function of
other buttons on the control lever.

Control lever (Cobra), replacement

Screws
3 Turn the panel round and undo the control lever's attaching bolts.
4 Unplug the connector from the control lever.
5 Remove the control lever from the panel.
6 Fit the new control lever on the panel.
7 Plug in the connector for the control lever.
Connector and attaching bolts
8 Fit the upper section of the panel.
CAUTION
is fitted.
Screws

7 Load handling – Switch load securing, automatic/manual locking 7:13
7.1.2 Switch load securing, automatic/manual

locking
Switch load securing, description
Switch (S1003) for locking the load. The switch is spring-loaded in
position 2.
Position 1 – The load is locked automatically when contact with the

load is made. The parking brake must be released.
Position 0 – Load locking not activated.
Position 2 – The load is locked manually. Button spring-returns.
Twistlocks are opened with the switch on the control lever, see Linear
levers, description, page 7:5 or Control lever (EGO), description, page
7:8.
The switch is supplied with voltage by, and sends a voltage signals to
Control unit (D7902).
The signal can be checked with the diagnostic menu, see 7.9 Load
Carrier 3/XX DIAGNOSE, page 8:47.
Switch right-hand dashboard panel centre section,

replacement
2 Remove the screws.
3 Carefully lift the panel and remove contacts.
4 Detach the connector from the switch.

5 Replace the switch.
CAUTION
is fitted.

7:14 7 Load handling – Switch, automatic spreading
7.1.3 Switch, automatic spreading

Switch automatic spreading, description
Switch automatic spreading, (S1012-2) activates automatic spreading.

When the switch is in position 1, spreading automatically moves to
the next position (20, 30 or 40 feet) if spreading is activated with the
control lever. This is on condition that the parking brake is released
and the doors are closed.
The switch is supplied with voltage from, and sends a voltage signal to
Control unit (D7902) when the switch is activated.
The signal can be checked with the diagnostic menu, see 7.5 Spreading
7/XX DIAGNOSE, page 8:43.
WARNING
Risk of crushing and damage to the product!
Automatic spreading is stopped by activating
spreading in the opposite direction, or by deactivating
the function with the switch, or by applying the parking
brake.

replacement
See Switch right-hand dashboard panel centre section, replacement,
page 7:13.
7.1.5 Switch stop at 30' or 35'

Switch extra stop spreading, description
Switch extra stop spreading (S1004) activates extra stop for the
spreading function. When the switch is in position 1, the function for
spreading is changed from 20'–40' to extra stop (normally at 30' or 35').
If the switch for automatic spreading (S1012-2) is activated at the same

time as this switch then the function is changed to automatic stop at
the next extra stop.
The switch is supplied with voltage by, and sends a voltage signals to
Control unit (D7902).

replacement
See Switch right-hand dashboard panel centre section, replacement,
page 7:13.

7 Load handling – Lifting/lowering 7:15
7.2 Lifting/lowering
Lifting/lowering, description
Lifting/lowering means the mast's parts are moved up and down so that
the lifting carriage is lifted and lowered. During lifting, the inner mast is
raised with the lift cylinders. The chain, which is attached to the carriage
(and in the outer frame), runs over chain wheels in the top of the mast.
In this way the carriage is lifted at the same time as the inner mast.
During lifting, there is an automatic linear increase in engine speed

when the lifting lever is deflected. The engine speeds are adjustable,
see 7.2 Lifting Lowering 16/XX INITIATE, page 8:106 and 7.2 Lifting
Lowering 17/XX INITIATE, page 8:107.
To absorb and dampen pressure surges that arise when driving

on rough surfaces, the machine can be equipped with a piston
accumulator which is connected with a male stud branch tee between
the control valve and the lift cylinders. This way the harmful impact on
the hydraulic system and mechanical parts is reduced, while operator
comfort is improved.

7:16 7 Load handling – Lifting/lowering
Lifting/lowering, function description

Control breaker Disengaged Control breaker voltage, function description, page
11:19.
Sensor, operator- Activated Sensor operator in seat, description, page 9:17.
in-seat

1 The lifting/lowering control lever Lift: U = 0.5–2.0 V Linear levers, description, page 7:5
(R8070-1) sends a voltage signal Zero position: U = 2.0-3.0 D1: 7.1 Controls and Instr 1/XX DIAGNOSE,
proportional to lever movement to the V page 8:39
KPU control unit (D7902).
Lower: U = 3.0–4.5 V
1 Control lever (S8150-Y) sends a voltage Control lever (EGO), description, page 7:8
0.5 V is the fastest lifting
signal to Control unit KPU (D7902) D1: Diagnostic menu, see 7.1 Controls and
speed and 4.5 V is the
proportional to lever movement. Instr 5/XX DIAGNOSE, page 8:40
fastest lowering speed.
Lower voltage than 0.5 V
and higher voltage than
4.5 V is used to detect
and controls.
2 The KPU control unit (D7902) sends the Checked by control 11.5.3.2 Control unit KPU (D7902), page
request to lift mast or lower mast on the system, error shown with 11:27
CAN bus. error code.
3 Control unit KFU (D7971) sends a - 11.5.3.4 Control unit KFU (D7971), page
current signal to Control unit, engine 11:31
(D7940) for increase of engine speed.
4 Control unit, engine (D7940) increases Checked by control 11.5.3.6 Control unit, engine (D7940), page
the engine speed. system, error shown with 11:33
error code.

7 Load handling – Lifting/lowering 7:17

5 Control unit KFU (D7971) activates the Lift start current: 320 mA 11.5.3.4 Control unit KFU (D7971), page
solenoid valve for mast lift (Y6005) or the Lift stop current: 540 mA 11:31
solenoid valve for mast lower (Y6004). D5: 7.2 Lifting Lowering 1/XX DIAGNOSE,
Lower the start current:
330 mA page 8:41 and 7.2 Lifting Lowering 2/XX
Lower the stop current:
550 mA
6 Solenoid valve mast lift (Y6005) or - Control valve, lift and tilt, description, page
Solenoid valve mast lower (Y6004) 7:19
routes servo pressure in proportion to D5: 7.2 Lifting Lowering 1/XX DIAGNOSE,
the control current in the lift slide in page 8:41 and 7.2 Lifting Lowering 2/XX
control valve, load handling. DIAGNOSE, page 8:42.
7 The control valve's lift slide changes - Control valve, lift and tilt, description, page
position and pressurises the lift cylinders 7:19
and sends a load signal to the hydraulic
oil pump 2 and the shuttle valve for
lift/tilt.
8 The pressure reducer in control valve, See the pressure plate on Valve block servo pressure, description,
load handling, limits a part of the the left-hand frame beam. page 10:20
pressure and routes it onward to the Accumulator servo circuit, description, page
service circuit and accumulator servo 10:22
pressure.
9 Shuttle valve lift/tilt sends a lift signal - Shuttle valve, page 10:21
onward to hydraulic oil pump 1.
10 Hydraulic oil pump 2 pumps oil from the See pressure plate on Axial piston pump with variable
hydraulic oil tank to control valve, load left-hand front mudguard. displacement, description, page 10:8
handling.
hydraulic oil tank to the priority valve. left-hand front mudguard. displacement, description, page 10:8
12 The priority valve leads supply pressure See pressure plate on Priority valve, general, page 5:6
to the control valve for load handling. left-hand front mudguard.
13 Pressurised oil passes via control valve, See pressure plate on Control valve, lift and tilt, description, page
load handling, to the load control valves. left-hand front mudguard. 7:19
14 The load control valves in the lift - Lift cylinder, description, page 7:20
cylinders open and route pressure
onward.
15 The lift cylinders raises or lowers the - Lift cylinder, description, page 7:20
inner mast in relation to the outer mast.
16 Damping Position sensor: Sensor end position lift, description, page
When the lifting carriage is approx. 0.4 Sensor directly opposite 7:35
m from an end position then damping is indicator plate: U = 24 V 11.5.3.8 Control unit KAU (D7911), page
activated. Analogue sensor: 11:36
Position sensor: UB7228/3 = 0.5–4.5 V D16: Diagnostic menu, see 7.2 Lifting
Sensor end position lift (B7211) Lowering 11/XX DIAGNOSE, page 8:42 or
sends a voltage signal to Control unit 7.2 Lifting Lowering 13/XX DIAGNOSE,
KAU (D7911) when the inner mast page 8:42
approaches the end position.
Analogue sensor:
Sensor lifting height (B7228) sends
a voltage signal proportional to lifting
carriage position to Control unit KAU
(D7911).

7:18 7 Load handling – Hydraulic oil pump

17 When the signal from Sensor lifting Checked by control Sensor end position lift, description, page
height (B7228) indicates that the lifting system, error shown with 7:35
carriage approaches one of the end error code. 11.5.3.8 Control unit KAU (D7911), page
positions, Control unit KAU (D7911) 11:36
sends damping lift on the CAN bus.
D16: Diagnostic menu, see 7.2 Lifting
Lowering 11/XX DIAGNOSE, page 8:42 or
7.2 Lifting Lowering 13/XX DIAGNOSE,
page 8:42
18 Control unit KFU (D7971) reduces the Checked by control 11.5.3.4 Control unit KFU (D7971), page
control current to Solenoid valve lift mast system, error shown with 11:31
(Y6005) or Solenoid valve lower mast error code. D5: 7.2 Lifting Lowering 1/XX DIAGNOSE,
(Y6004). page 8:41 and 7.2 Lifting Lowering 2/XX
DIAGNOSE, page 8:42
19 The lift or lower speed decreases. - Lift cylinder, description, page 7:20
20 Hydraulic oil filters clean the oil. - Hydraulic oil filter, description, page 10:29.
21 Shock absorption - Accumulator damping, description, page
The piston accumulator is connected to 7:42
the lift cylinders and provides a damping
function in the cylinder.
Hydraulic diagram, see Hydraulic diagram, basic machine, page E:4.

See Axial piston pump with variable displacement, description, page
10:8.
7.2.4 Accumulator servo circuit

Accumulator servo circuit, general
See Accumulator servo circuit, description, page 10:22.

7 Load handling – Control valve, lift and tilt 7:19
7.2.5 Control valve, lift and tilt

Control valve, lift and tilt, description
Lift slide
page 7:64.
The control valve controls the speed and direction of lift and tilt.
The valve has two sections, one for the lift function and one for the
tilt function. The sections have many similarities, but are described
separately under the respective function. For tilt, see Control valve, lift
and tilt, description, page 7:64. Electric solenoid 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 also sends control signals to the variable
pumps.
1. Solenoid valve, lift (Y6005)
Electrically controlled pressure reducing valves (solenoid valves)
2. Solenoid valve, lower (Y6004) convert electric current into a low hydraulic pressure that is proportional
3. Solenoid valve, tilt in (Y6011) to the current, so-called servo pressure. The servo pressure acts on
4. Solenoid valve, tilt out (Y6010) the spring-centred control slide in the control valve for the function in
question and thereby controls the main flow.
5. Connection return to tank (T3)
6. Connection, feed from priority valve (P) The speed of the function is controlled by means of the flow being
regulated in proportion to the lever movement.
7. Connection, feed from hydraulic oil pump (P)
8. Connection, piston side, left lift cylinder Lift slide
9. Connection, piston side, right lift cylinder The lift slide controls the direction and flow of the oil to the lift cylinder.
10. Connection, rod side, tilt cylinder Solenoid valve, lift
11. Connection, piston side, tilt cylinder
The valve is controlled electrically by Solenoid valve, lift (Y6005), which
is activated by Control unit KFU (D7971). The servo valve directs servo
pressure to the lift slide which is proportional to the control current to
the solenoid valve.
The signals can be checked with the diagnostic menu, see 7.2 Lifting
Lowering 1/XX DIAGNOSE, page 8:41.
Solenoid valve, lower
The valve is controlled electrically by Solenoid valve, lower (Y6004),
which is activated by Control unit KFU (D7971). The servo valve
directs servo pressure to the lift slide which is proportional to the control
current to the solenoid valve.
The signals can be checked with the diagnostic menu, see 7.2 Lifting
Lowering 2/XX DIAGNOSE, page 8:42.
Control valve, lift and tilt, replacement

See Main valve, replacement, page 10:24.

7:20 7 Load handling – Lift cylinder
7.2.7 Lift cylinder

Lift cylinder, description
The lift cylinders lift and lower the inner mast which runs in the outer
mast. The lower part of the lift cylinders is fastened with nuts to the
outer mast, while its upper part is fastened with washer and bolt to the
inner mast, one on the right and one on the left side of the mast.
The lift cylinders are connected in parallel and fed from control valve,
lift and tilt, see Control valve, lift and tilt, description, page 7:19.
On the piston side there is a built-in load control valve. The load control
valve consists of a restrictor and a non-return valve. The non-return
valve routes oil past the restrictor when lifting and forces the oil to pass
through the restrictor when lowering. This limits the lowering speed.

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.
7.2.8 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, description
Sensor, hydraulic pressure lift cylinder (B7726-1) measures the
pressure in the lift cylinders and is located on the left lift cylinder.
Pressure is measured to determine whether quick-lift can be activated.

A sensor measures the pressure on the left-hand lift cylinder.
The sensor is supplied with power by, and sends a voltage signal
proportional to the hydraulic oil pressure to Control unit KFU (D7971).
The signal can be checked with diagnostic menu, 8.2 Monitoring 3/XX

7 Load handling – Sensor hydraulic pressure lift cylinder 7:21
Sensor, hydraulic pressure lift cylinder, replacement
NOTE
B Safety.

3 Disconnect the cable harness from the sensor for hydraulic
pressure lift cylinder.
4 Remove the sensor for hydraulic pressure lift cylinder.
NOTE
from contaminants.
5 Fit the new sensor.
NOTE
Sensor hydraulic pressure lift cylinder correctly.
6 Connect the cable harness to the sensor for hydraulic pressure.

7 Clamp the cable harness as before.
8 Turn on the main electric power and start the engine.
9 Activate the lift carefully.
CAUTION
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
10 Check that there are no leaks at hydraulic connections and that

lifting/lowering works properly.
manual.
12 Check pressure and signals with the diagnostic menu, 8.2
Monitoring 3/XX DIAGNOSE, page 8:52.

7:22 7 Load handling – Mast
7.2.9 Mast
Mast, description
The mast is the free-visibility version. The lifting carriage runs in the
1 mast, and in turn it secures the side lift attachment.
The lower part of the mast is fastened to the frame with two shafts in
2 both of the double lugs on the front of the frame. The mast is also
fastened in the frame with two tilt cylinders.
The mast consists of an outer mast and an inner mast manufactured

in high-strength steel with a minimum number of welds to provide
3
maximum strength. The inner mast runs in the outer mast and is raised
and lowered with the lift cylinders. Between the inner and outer masts
are mast wheels and slide plates that guide the inner mast in the outer
mast and reduce the friction between the mast parts.
4 The lower part of the lift cylinders is fastened to the outer mast, while
their upper part is fastened to the inner mast. When the oil is forced
into the lift cylinders, the cylinders' piston rods are forced out and the
inner mast is lifted. The chains, which are attached into the lifting
carriage (and in the outer mast), run over chain wheels in the top of the
inner mast. In this way, the lifting carriage is also raised at the same
time as the inner mast is raised.
Hydraulic hoses and cables for the lifting carriage and side lift
attachment functions run along the left-hand side.
CAUTION
The mast and its component parts are tested under
009918
harsh operating conditions and environments to

ensure a long and trouble-free service life.
1. Inner mast Despite these efforts, problems can arise due
2. Lifting eye to neglected maintenance, improper handling,
malfunction or damage to a mast wheel, mast or
3. Outer mast lifting carriage. For example, lamination or pitting
4. Lift cylinder could occur on the mast beam flange. This most often
occurs on the inner mast, but could also occur on the
outer mast.
Repairs to the mast may only by performed on the
flanges on the outer and inner mast beams according
to special instructions, see Flanges on outer and inner
mast beam, repair, page 7:28.

7 Load handling – Mast 7:23
Mast, removal
NOTE
B Safety.
NOTE
It is possible to remove the lifting carriage and the side lift
attachment as one unit.
1 Remove the side lift attachment, see Side lift attachment,

removing, page 7:45.
2 Remove the lifting carriage, see Lifting carriage, removing, page
7:38.
3 Connect the lifting equipment to the outer lifting lugs at the top of
the mast in a secure manner.
4 Start the engine and tilt the mast fully forward.
009974
8 Mark up and disconnect the hydraulic connections of the lift

cylinders.
NOTE
from contaminants.
9 Mark up and detach the electrical connections on the mast.

Undo the connectors and protect the terminals by lubricating them
with contact grease. Then loosely insert the connectors.

10 Fasten one of the tilt cylinders in the lifting equipment (overhead

crane).
11 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. Turn off the engine.
Save the circlips. Refit the shaft in the tilt cylinder.
Lower the cylinder onto a block of wood. Then slacken and remove
the lifting equipment (overhead crane).
Repeat the procedure for the other cylinder.
12 Undo the nuts and bolts and remove the shafts which attach the
mast into the frame.
009979
13 Release the mast from the chassis.
WARNING
The mast may swing out when it is loosened from the
machine.
Risk of personal injury!
Stand in the mast!
009983

14 Lift aside the mast.
009985
15 Place the mast on the ground and detach the lifting equipment
(overhead crane).
009975

Mast, fitting
NOTE
B Safety.

4 Connect lifting equipment to the mast in a secure manner so the
mast does not tip when lifted.
009975
5 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, the
shaft/bearing must be replacement.
NOTE
The mast is attached to the machine's frame with strong shafts
which run in maintenance-free bearings.
It is extremely important that bearing surfaces are absolutely
clean when the mast is installed.
The shafts and bearings mentioned above must NEVER be
009977
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 outer lifting lugs in a secure manner.
009976

7 Suspend the mast vertically. Align the mast and position the shafts
in their respective mast mountings.
009978
8 Fasten the shafts with bolts and lock nuts.
9 Start the engine and tilt the mast fully forward.
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 loosening the screws and turning
the piston with a hook spanner. Tighten the screws to 136 Nm.
Fit the shafts and lock with circlips.
009996

15 Lubricate the connectors with contact grease and plug them

together.
16 Remove the plugs and connect the hydraulic hoses to the lift
cylinders.
17 Turn on the power supply and start the engine.
19 Check the mast functions.
20 Fit the lifting carriage, see Lifting carriage, installing, page 7:39.
21 Fit the side lift attachment, see Side lift attachment, installing,
page 7:46.
Flanges on outer and inner mast beam, repair
NOTE
B Safety.
If the surface of the flanges has started to break down into small flakes,
this can be repaired so that the mast can still be used. This is rectified
by first grinding down the affected surfaces and then "running-in" the
surface layer.
7:38.
3 Remove the mast, see Mast, removal, page 7:23.
4 Separate the outer mast and inner mast.
5 Clean the mast components.
6 Grind the affected surfaces with a belt sander until the surface is
smooth and bright. Start with grit size 36-40 and finish with 60-80.
Grind in the longitudinal direction of the beam.
Check the internal measurement between the beam's front and
250 mm
rear flange. If the measurement exceeds 252 mm for a beam that

is supposed to be 250 mm, contact Cargotec.
7 Apply a thin layer of slide grease to the sliding surfaces of the
outer mast and reassemble the inner and outer masts.
010127C
8 Apply a thin layer of slide grease to the sliding surfaces of the inner
mast and fit the mast on the machine, see Mast, fitting, page 7:26.
Mast beam size 250 mm. 9 Fit the lifting carriage, see Lifting carriage, installing, page 7:39.
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 correct centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load at
the correct centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
correct centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Cargotec.

7.2.9.1 Inner mast

Slide plates in inner mast, adjusting
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
Mast wheel, adjusting

1 Use a drift to tap out the spring pin (position 4) from the inside.
1
NOTE
Check that the cover washer is centred on the clamping screw.
2
3 2 Screw in the clamping screw (position 5) so that the wheel is
completely locked.
NOTE
4
Rotate the mast wheel while tightening the clamping screw.
5
3 Loosen the clamping screw until the wheel rotates, slightly slowly.
Turn the clamping screw so that the next hole for the spring pin fits.
6 NOTE
7 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

Support rollers/slide plates in the mast, replacement

7:38.
2 If possible, dismantle the mast when it is installed on the machine.
If this is not possible, see Mast, removal, page 7:23 and dismantle
the mast on the ground.
3 Separate the outer mast and inner mast. Applies to Duplex
Standard.
a. Detach the cables, chains and hoses as required to dismantle
the mast. Detach the circlips holding the lift cylinders to the
inner mast.
b. Attach hoisting equipment (overhead crane) to the inner mast
and lift the inner mast away from the outer mast.
c. Place the inner mast on the ground in a safe manner.
4 Check the mast wheels and replace as necessary.
008602
Circlip holding the lift cylinders

5 Use a vernier caliper and measure the distance between the outer
mast beams.
014884
Mast with slide plates
B
008422
Measure the outer mast's internal dimensions (A and

B).
014883
Mast with support rollers

6 Adjust the play.
a. If A and B are equal:
Adjust D to be equal to or max. 0.5 mm smaller than B.
Adjust C to be equal to or max. 0.5 mm smaller than D.
b. If A is greater than B:
Adjust C to be equal to or max. 0.5 mm smaller than D.
c. If A is less than B:
Adjust C to be equal to or max. 0.5 mm smaller than A.
7 Apply a thin layer of slide grease to the inner sliding surfaces of
the outer mast.
8 Lift the inner mast and slide together the inner mast and outer
mast.

7.2.9.2 Outer mast
Slide plates in outer mast, adjusting
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

7.2.9.3 Lifting chains
Lifting chains, description

The lifting chains are of the Fleyer chains type. The lifting chains are
fitted between the lifting carriage and the outer mast and run over chain
wheels on the inner mast. When the inner mast is raised, the lifting
chains raise the lifting carriage.
Lifting chains, replacement
WARNING
The lifting chain is heavy.
Risk of crushing. The chain is difficult to handle.
Handle with caution and be very careful when the
chain is removed from the chain wheel. Serious
personal injury and damage to the vehicle can result
from carelessness.
1 Support the lifting carriage and lower the carriage so the chains
are slack.
3 Release the lifting chain from the load unit.
Remove the cotter pin and shaft from each side of the load carrier.
4 Connect lifting equipment to the chain in a secure manner.
Undo the chain attachment from the chain tensioner and lay the
chain down.
5 Fit a new chain.
008424
6 Tension the chain with the chain tightener. Check that the chains
are tensioned equally.
7 Adjust the lifting carriage's lower position so that the carriage
sides cannot run against the bottom plate of the outer mast. Then
measure the ground clearance of the lifting carriage. The distance
must be equal on the right and left-hand sides with a tolerance of 5
mm. Adjust further with the chain tensioner if necessary.
008425

7.2.9.4 Chain wheels and hose wheels
Chain wheels and hose wheels, description

The chain wheels and hose wheels hold the chains and hoses extended
in the correct position. They are equipped with two roller bearings.
Chain wheels, replacement

2 Raise the mast.
3 Position a support under the lifting carriage and lower the mast
again. Chains and hoses are now slackened.
4 Connect lifting equipment to the chain in a secure manner.
Undo the chain attachment from the chain tensioner and lay the
chain down.
5 Remove the hose guide that prevents the hoses from becoming
derailed.
1 6 Lift the hose off the hose wheel.
7 Undo the circlip and remove the hose wheel.
4
008426
1. Hose guide and attaching bolts

2. Hoses
3. Circlip
4. Hose wheel
8 Undo the attaching bolt that locks the shaft.

9 Pull the shaft out and remove the sprocket.
NOTE
The sprocket will fall down when the shaft is loosened!
10 Install a new sprocket and re-install the shaft.
NOTE
Lubricate the shaft with sliding grease.
11 Lock the shaft with the attaching bolt.

12 Install the hose wheel.
13 Install the circlip.
14 Grease the sprocket.
15 Put the hoses back and install the hose guide.

7 Load handling – Sensor lifting height 7:35
Hose wheels, replacement

2 Raise the mast.
3 Position a support under the lifting carriage and lower the mast
again. Chains and hoses are now slackened.
4 Remove the hose guide that prevents the hoses from becoming
derailed.
1 5 Lift the hose off the hose wheel.
6 Undo the circlip and remove the hose wheel.
2 NOTE
Lubricate the shaft with sliding grease.
3 7 Install a new hose wheel.
8 Install a circlip.
4 9 Put the hoses back and install the hose guide.
008426
1. Hose guide and attaching bolt

2. Hoses
3. Circlip
4. Hose wheel
7.2.10 Sensor lifting height

Sensor end position lift, description
Sensor end position lift (B7211) detects a lug up and down on the
mast and activates damping during lifting when the sensor passes
the lug. The position sensor is used to reduce lifting speed when the
mast approaches an end position.
Sensor end position lift (B7211) is supplied with voltage by, and sends
signals to Control unit KFU (D7971). The signal can be checked with
the diagnostic menu, see 7.2 Lifting Lowering 13/XX DIAGNOSE,
page 8:42.
For checking and adjusting, see Position sensor, checking and

adjustment, page 7:4.
Sensor lifting height, description
In the cases where the machine has a function that is dependent on

the height of the attachment, Sensor lifting height (B7228) is used
instead of the position sensor.
Sensor lifting height (B7228) is supplied with voltage by, and sends a
voltage signal proportional to lifting carriage position to Control unit
KAU (D7911). The signal can be checked with the diagnostic menu,
see 7.2 Lifting Lowering 11/XX DIAGNOSE, page 8:42.

7:36 7 Load handling – Sensor lifting height
Sensor lifting height, replacement
1 Raise the attachment so that the sensor is accessible from the

rear of the mast.
2 Release the cable from the outer mast.
3 Unplug the connector from the sensor.
4 Replace the sensor.
5 Plug in the connector to the sensor.
6 Connect the cable to the outer mast.
7 Turn on the main electric power and turn the start key to position I.
8 Calibrate the sensor, see Sensor lifting height, calibration , page
7:36.
Sensor lifting height, calibration
1 In order to select the function to calibrate, navigate first to the

014981
2 Enter service code with or . Confirm each digit with .

NOTE
015625
3 Select 7. LOAD HANDLING by scrolling with or and confirm

with .

7 Load handling – Sensor lifting height 7:37
4 Select 7.2 Lifting and lowering by scrolling with or and

confirm with .
6 Lower the attachment to the lowest position. Press to save

this value.
7 Select CALIBRATE 2 by scrolling with .
8 Raise the attachment to its top position. Press to save this

value.
9 Exit calibration by scrolling out with .

7:38 7 Load handling – Lifting carriage
7.2.11 Lifting carriage

Lifting carriage, description
The lifting carriage holds the side lift attachment and runs along the
inner mast with slide plates and mast wheels. The attachment can be
shifted sideways ±600 mm with a hydraulic cylinder that sits between
the attachment and lifting carriage.
Also located on the lifting carriage are Control unit KAU (D7911), control
valve for attachment and buzzer for automatic spreading 20'-40' ( )
The lifting carriage holds, via hydraulic cylinders, the side lift attachment
and runs along the inner mast with slide plates and mast wheels.
The following functions are controlled via the lifting carriage cylinders:
• Side shift - the attachment can be shifted to the side ± 600 mm.
• Mechanical levelling - the attachment has 0–250 mm end position
levelling.
The lifting carriage also houses the control valve for the hydraulic
functions of the lifting carriage and side lift attachment.
See also Attachment control valve, description, page 7:50 and .
1. Side shift cylinder

2. Control valve, attachment
3. Slide plates.
4. Mast wheels
Lifting carriage, removing
NOTE
B Safety.
1 Remove the side lift attachment, see Side lift attachment,

removing, page 7:45.
2 Connect lifting equipment to the lifting carriage in a secure manner.
3 Disconnect the main power supply.
4 Detach the wiring for the lifting carriage. Unplug the connectors
and protect the terminals by lubricating them with contact grease.
Then loosely insert the connectors.

7 Load handling – Lifting carriage 7:39
5 Mark up and disconnect the carriage's hydraulic connections. Let

the oil run out.
NOTE
from contaminants.
6 Mark up and disconnect the carriage's hydraulic connections in the

front panel. Let the oil run out.
NOTE
from contaminants.
7 Raise the carriage with the lifting equipment (overhead crane) to

slacken the chains.
8 Undo the nuts and remove the chain tensioners.

9 Start the engine and tilt the mast rearwards.
10 Raise the mast enough for the carriage to release from the mast.
11 Lower the mast again.
12 Lift aside the lifting carriage. Put it on blocks and supports to
prevent damage to the cylinders.
13 Detach the lifting equipment (overhead crane).
Lifting carriage, installing
NOTE
B 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 the carriage fastens in the inner mast. Stop the
mast in a position where the chains can be attached to the carriage.
Fit the chain tensioners and adjust and fasten with the nuts.
4 Lower the carriage as far as possible.

7:40 7 Load handling – Lifting carriage
8 Remove the plugs and connect the mast's hydraulic hoses to the
connections in the front panel.
9 Remove the plugs and connect the mast's hydraulic hoses.
10 Connect the cable harness to the lifting carriage.

Lubricate the connectors with contact grease and plug them
together
11 Fit the side lift attachment, see Side lift attachment, installing,
page 7:46.
14 Check the lifting carriage functions.

Slide plates in lifting carriage, adjusting and, if

necessary, replacing
7:38.
NOTE
Minor adjustment to the clearance between the lifting carriage
and inner mast is possible without removing the lifting carriage.
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
013593
Measure the interior width of the inner mast (A and B)
4 Use a sliding calliper to measure the external measurements

between the lifting carriage's slide plates.
Measure the exterior measurements between the

lifting carriage's slide plates (C and D).

7:42 7 Load handling – Pipes and hoses
5 Adjust lifting carriage clearance by removing the screws and

adding or removing shims.
a. If the width at A and B is the same:
Adjust C and D to be equal to or max. 0.5 mm more than A.
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 C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm less than B.
6 Lubricate the inner sliding surfaces of the inner mast with a thin
7 Fit the lifting carriage, see Lifting carriage, installing, page 7:39.
8 Raise the lifting carriage all the way up and check that the slide
plates do not pinch too hard against the sliding surfaces.
1. Screws
2. Shims
Mast wheel, adjusting

For mast wheel adjustment, see Mast wheel, adjusting, page 7:29.

7.2.14 Hydraulic oil filter

Hydraulic oil filter, general
See Hydraulic oil filter, description, page 10:29.
7.2.15 Accumulator damping

Accumulator damping, description
The piston accumulator is connected to the lift cylinders and provides

a damping function in the cylinder, e.g. when driving on an uneven
surface, which can create pressure spikes in the hydraulic system.
NOTE
Handling the accumulator requires special equipment and training.

7 Load handling – Accumulator damping 7:43
Accumulator damping, replacement
NOTE
B Safety.
NOTE

3 Disconnect the hydraulic hose from the accumulator.
NOTE
from contaminants.
4 Remove the accumulator attaching bolts.

5 Remove the accumulator.
6 Charge the new accumulator. As standard, it must be charged
with 4 MPa preload pressure. The pressure level can be adjusted
to produce the best damping according to the customer's load
conditions, see Gas pre-charge pressure in the accumulator for lift
cylinder damping, check, page 7:43.
7 Transfer the connection adapter to the new accumulator.
8 Fit the new accumulator.
9 Connect the hydraulic hose to the accumulator.
NOTE
correctly.
10 Test the lifting and lower a couple of times.

11 Check that the accumulator's connection is sealed tightly.
Gas pre-charge pressure in the accumulator for lift

cylinder damping, check
NOTE
B Safety.
NOTE

2 Fit a measuring outlet in the lift cylinder or in the lifting circuit.
3 Connect a pressure gauge in the measuring outlet.
4 Lift the load for which the damping shall be optimised.
5 Read the pressure in the lift cylinder with the pressure gauge.

7:44 7 Load handling – Accumulator damping
1 6 Read the recommended gas precharge pressure in the graph.

7 Lower the load so that the pressure in the lift cylinders is unloaded.
100 MPa
85 MPa 9 Connect the gas filling equipment to the connection on the
70 MPa accumulator. Adjust the gas precharge pressure in the accumulator
to the recommended pressure.
55 MPa
40 MPa NOTE
019513
25 MPa Use only pure nitrogen when filling.
10 MPa
2
20 MPa 80 MPa 140 MPa 200 MPa
1. Gas precharge pressure

2. Pressure in lift cylinder

7 Load handling – Side lift attachment 7:45
7.2.16 Side lift attachment

Side lift attachment, general
The side lift attachment is secured on the machine's lifting carriage.

and instructions regarding the attachment's components and systems,
refer to the relevant supplier documentation.
Side lift attachment, removing
NOTE
B Safety.
NOTE
It is possible to remove the lifting carriage and the side lift
attachment as one unit.
1 Park the machine with the mast vertical and the attachment in
its lowest position.
3 Connect lifting equipment (overhead crane) to the attachment in
a secure manner.
4 Start the engine and lift slightly with the lifting equipment (overhead
crane). Let the machine stand with the ignition on for a short while.
6 Detach the side shift cylinder from the lifting carriage.

Remove the cylinder's shaft from the bracket on the lifting carriage.
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 lifting carriage. Turn off the engine.
Save the circlips. Refit the shaft in the cylinder.
7 Secure the side shift cylinder in the attachment using tensioning
straps.
10 Mark up and detach the hydraulic connections from the side lift
attachment and the side shift cylinder.
NOTE
from contaminants.

7:46 7 Load handling – Side lift attachment
11 Detach the cable harness for the attachment. The connectors are
located underneath the top plate of the lifting carriage. They are
accessed from the rear of the lifting carriage.
Unplug the connectors and protect the terminals by lubricating
them with contact grease. Then loosely insert the connectors.
Remove the cable harness clamping ring.
12 Loosen the attachment's mounting unit in the lifting carriage.

13 Lift aside the side lift attachment. Position so as not to damage
the twistlocks/lock lugs.
Side lift attachment, installing
NOTE
B Safety.
1 Park the machine with the mast vertical.

2 Lower the lifting carriage to its lowest position.
6 Lift the side lift attachment into place.
Lifting points, side lift attachment

7 Fit the lifting carriage's front panels in order to secure the side lift
attachment in position.
8 Check that the side lift attachment runs correctly in the lifting
carriage and that the slide plates do not pinch too hard against
the sliding surfaces.
9 Clean and apply a layer of lubricating grease to the side shift

cylinder shaft prior to installation.
10 Connect the side shift cylinder to the lifting carriage.
Align the side shift cylinder, press in the shaft and secure it with
the lock rings.
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.
11 Attach the cable harness for the attachment to the attachment's

control unit.
Lubricate the connectors with contact grease and plug them
together.
Fasten the cable harness with clamps.
12 Remove plugs and connect hydraulic hoses for the side lift
attachment and side shift cylinder using the markings as a guide.
15 Check the functions of the side lift attachment.
manual.

7:48 7 Load handling – Side shift
7.4 Side shift

Side shift, description
Side shift means repositioning the attachment laterally.
Control valve attachment pressurises the side shift cylinder that
pushes/pulls the attachment's main beam in relation to the lifting
carriage.
Side shift, function description

Control breaker Disengaged Control breaker voltage, function description, page 11:19.
Sensor, operator-in- Activated Sensor operator in seat, description, page 9:17.
seat

1 The side shift control lever (R8070-3) Left: U = 0.5–2.0 V Linear levers, description, page 7:5.
sends a voltage signal proportional to Zero position: U = 2.0-3.0 D1: 7.1 Controls and Instr 2/XX DIAGNOSE,
lever movement to the KPU control unit V page 8:40
(D7902).
Right: U = 3.0–4.5 V
0.5 V is the highest
speed left and 4.5 V is
the highest speed right.
Lower voltage than 0.5 V
and higher voltage than
4.5 V is used to detect
and controls.

7 Load handling – Hydraulic oil pump 7:49

2 KPU control unit (D7902) sends the Checked by control 11.5.3.2 Control unit KPU (D7902), page
request side shift left or side shift right system, error shown with 11:27
3 Control unit KFU (D7971) activates - 11.5.3.4 Control unit KFU (D7971), page
Solenoid valve engagement of 11:31.
hydraulics for top lift (Y6003). D3: Diagnostic menu, see 10.4 Pumps 1/XX
DIAGNOSE, page 8:76
4 Solenoid valve, engagement of U = 24 V Solenoid valve, engagement of hydraulics
hydraulics for top lift (Y6003) opens and for top lift, page 10:20
sends a load signal to the shuttle valve. D3: Diagnostic menu, see 10.4 Pumps 1/XX
DIAGNOSE, page 8:76
5 Shuttle valve lift/tilt sends a load signal - Shuttle valve, page 10:21
8 The main valve routes supply pressure - Main valve, description, page 10:23
to the control valve for the attachment.
9 Control unit KAU (D7911) activates I = 330–570 mA 11.5.3.8 Control unit KAU (D7911), page
Solenoid valve side shift left (Y6020) or 11:36
Solenoid valve side shift right (Y6021). Attachment control valve, description, page
7:50
D9: Diagnostic menu, see 7.4 Side Shift
3/XX DIAGNOSE, page 8:43 or 7.4 Side
Shift 4/XX DIAGNOSE, page 8:43
10 Solenoid valve side shift left (Y6020) or - Attachment control valve, description, page
Solenoid valve side shift right (Y6021) 7:50
pressurises the side shift slide in control D9: Diagnostic menu, see 7.4 Side Shift
valve attachment. 3/XX DIAGNOSE, page 8:43 or 7.4 Side
Shift 4/XX DIAGNOSE, page 8:43
11 The control valve's side shift slide - Attachment control valve, description, page
changes position and pressurises the 7:50
side shift cylinder.
12 The side shift cylinder pushes the main - Side lift attachment, general, page 7:50.
beam sideways in relation to the side
shift frame.
Hydraulic diagram, see Hydraulic diagram, attachment, page E:6.

10:8.

7:50 7 Load handling – Control valve, attachment
7.4.3 Control valve, attachment

Attachment control valve, description
Side shift slide
Side shift is controlled by a separate section in control valve attachment.
Control valve attachment controls the hydraulic functions on the

attachment. Electric servo valves control the flow from the valve.
The control valve is an electro-hydraulically controlled, proportional and

pressure-compensated directional control valve. Electrically controlled
servo valves convert current to servo pressure. The servo pressure
controls the spring-centred valve slides that control pressure and flow
for the function in question. The valve slides have a flow limit so that
several functions can be used simultaneously. This enables them to
control the main flow.
The control valve has a built-in supply of pilot pressure. This means
that the valve has a built-in pressure reduction that converts feed
pressure to servo pressure for the various functions. The supply of pilot
pressure 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:

• Side shift
• Spreading
• Twistlocks/lock lugs
Side shift slide
1. Solenoid valve, side shift right (Y6021)
The side shift slide controls the direction and flow of oil to the side
2. Connection to rod side, side shift cylinder shift cylinders.
3. Connection to piston side, side shift cylinder
Servo valve, side shift left
4. Solenoid valve, side shift left (Y6020)
5. Measuring outlet, feed pressure Servo valve side shift left is controlled electrically by Solenoid valve
side shift left (Y6020) which is activated by Control unit KAU (D7911).
6. Connection, feed from hydraulic oil pump (P) The servo valve directs servo pressure to the side shift slide which is
7. Connection return to tank (T) proportional to the control current to the solenoid valve.
The signal can be checked with the diagnostic menu, see 7.4 Side
Shift 4/XX DIAGNOSE, page 8:43.
Servo valve, side shift right
Servo valve side shift right is controlled electrically by Solenoid valve
side shift right (Y6021) which is activated by Control unit KAU (D7911).
The servo valve directs servo pressure to the side shift slide which is
proportional to the control current to the solenoid valve.
The signal can be checked with the diagnostic menu, see 7.4 Side
Shift 3/XX DIAGNOSE, page 8:43.

The side shift cylinder is a part of the attachment and is located
between lifting carriage and attachment. The cylinder moves the
attachment laterally in relation to the lifting carriage.



See Lifting carriage, description, page 7:38.



7:52 7 Load handling – Spreading
7.5 Spreading
Spreading, description
Spreading means that the width between twistlocks/lifting hooks is
changed. Spreading has 20-foot and 40-foot stops; stops at other
distances are available as options, such as 30-foot stop.
Control valve, attachment pressurises the spreading cylinders

individually, and the spreading cylinders retract and extend the
spreading booms.
Spreading is controlled by control lever (S8150) or control lever

(R8070-4). The following inductive position sensors indicate the
position of the spreader units:
• Sensors end position 20' and 40' (B7690RI and B7690LE) indicate
the end position for 20' and 40-foot containers.
• For the 30-foot stop option there are two extra sensors, sensors
end position 30' (B7770RI and B7770LE).
The signals can be checked with the diagnostic menu, see 7.5
Spreading 7/XX DIAGNOSE, page 8:43.
Spreading, function description

Control breaker Disengaged Control breaker voltage, function description, page 11:19.
Sensor, operator-in- Activated Sensor operator in seat, description, page 9:17.
seat
Twistlocks Unlocked or bypass Twistlocks, function description, page 7:67
activated Bypass, description, page 8:6

7 Load handling – Spreading 7:53

1 Switch shift-button (S1991) and Control Shift button: U = 24 V Linear levers, description, page 7:5.
lever spreading (R8070-3) send a Spreading in: U = 0.5–2.0 D1: Diagnostic menu, see 7.1 Controls and
voltage signal proportional to lever V Instr 2/XX DIAGNOSE, page 8:40
movement to Control unit KPU (D7902).
Zero position: U = 2.0-3.0
1 Switch shift button (S1991) and Control V Control lever (EGO), description, page 7:8
lever (S8150-ThumbX) send a voltage D1: Diagnostic menu, see 7.1 Controls and
Spreading out: U =
signal to Control unit KPU (D7902). Instr 6/XX DIAGNOSE, page 8:41 and 7.1
3.0–4.5 V
Controls and Instr 7/XX DIAGNOSE, page
0.5 V is the highest speed
8:41.
in and 4.5 V is the highest
speed out. Lower voltage
than 0.5 V and higher
voltage than 4.5 V is used
to detect faults in cable
2 KPU control unit (D7902) sends the Checked by control 11.5.3.2 Control unit KPU (D7902), page
spreading inward or spreading outward system, error shown with 11:27.
request on the CAN bus. error code.
3 Control unit KFU (D7971) activates - 11.5.3.4 Control unit KFU (D7971), page
Solenoid valve engagement of 11:31.
hydraulics for top lift (Y6003). D3: Diagnostic menu, see 10.4 Pumps 1/XX
DIAGNOSE, page 8:76
4 Solenoid valve, engagement of U = 24 V Solenoid valve, engagement of hydraulics
hydraulics for top lift (Y6003) opens and for top lift, page 10:20
DIAGNOSE, page 8:76
5 Shuttle valve lift/tilt sends a load signal - Shuttle valve, page 10:21.
Solenoid valve spreading left inwards 11:36
(Y6019-LE) or Solenoid valve spreading Attachment control valve, description, page
right outwards (Y6018-RI). 7:50
D10: Diagnostic menu, see 7.5 Spreading
12/XX DIAGNOSE, page 8:44 and 7.5
10 Solenoid valve spreading left inwards - Attachment control valve, description, page
(Y6019-LE) or Solenoid valve spreading 7:60
right outwards (Y6018-RI) pressurises D10: 7.5 Spreading 12/XX DIAGNOSE,
the side shift slide in control valve, page 8:44 and 7.5 Spreading 13/XX
attachment. DIAGNOSE, page 8:44.
left spreading cylinder.
12 The spreading cylinder pushes left - Side lift attachment, general, page 7:61
twistlocks/load hook outwards or pulls
them inwards.


Solenoid valve spreading right inwards 11:36
(Y6019-RI) or Solenoid valve spreading Attachment control valve, description, page
right outwards (Y6018-RI). 7:60
14/XX DIAGNOSE, page 8:45 and 7.5
14 Solenoid valve spreading right inwards - Attachment control valve, description, page
(Y6019-RI) or Solenoid valve spreading 7:60
right outwards (Y6018-RI) pressurises D13: Diagnostic menu, see 7.5 Spreading
the side shift slide in control valve, 14/XX DIAGNOSE, page 8:45 and 7.5
attachment. Spreading 15/XX DIAGNOSE, page 8:45.
right spreading cylinder.
16 The spreading cylinder pushes right - Side lift attachment, general, page 7:61
twistlocks/load hook outwards or pulls
them inwards.
17 Sensor, end position 20'-40' left Sensor directly opposite Position sensor, checking and adjustment,
(B7690-LE) sends a voltage signal to indicator plate: U > 24 V page 7:4
Control unit KAU (D7911). 11.5.3.8 Control unit KAU (D7911), page
11:36
18 Sensor, end position 20'-40' right Sensor directly opposite Side lift attachment, general, page 7:61
(B7690-RI) sends a voltage signal to indicator plate: U = 24 V 11.5.3.8 Control unit KAU (D7911), page
Control unit KAU (D7911). 11:36
19 Control unit KAU (D7911) reduces - 11.5.3.8 Control unit KAU (D7911), page
the control current to Solenoid valves 11:36
spreading out or in. Attachment control valve, description, page
The control valve's spreading slides 7:60
change position and reduce the flow to
the spreader cylinders.
20 Spreader speed decreases. - Side lift attachment, general, page 7:61

Spreading 30-foot stop, description
30-foot stop is an option for spreading that is activated with Switch

stop at 30' or 35'. When 30-foot stop is activated the spreading stops
at 30 feet. At 30-foot stop there is a position sensor for controlling
the function.
Spreading 30' stop, function description

Control breaker Disengaged Control breaker voltage, function description, page 11:19
Sensor, operator-in- Not activated (no operator in Sensor operator in seat, description, page 9:17
seat seat)
Twistlocks Unlocked or bypass activated Twistlocks, function description, page 7:67
Bypass, description, page 8:6
Overload system Passive Overload system, description, page 8:6

1 Switch, stop at 30'-35' (S1004) sends Switch off: Switch extra stop spreading, description ,
a voltage signal to Control unit KPU US1004:4 = 0 V page 7:14
(D7902). D1: Diagnostic menu, see 7.5 Spreading
Switch on:
US1004:4 = 24V
2 Switch shift-button (TBD) and Control U = 0-5 V DC Linear levers, description, page 7:5.
lever spreading (R8070-3) send a D1: 7.1 Controls and Instr 2/XX
voltage signal proportional to lever DIAGNOSE, page 8:40.
movement to Control unit KPU (D7902).
2 Switch shift button (S1991) and Control Shift button: U = 24 V Control lever (EGO), description, page 7:8
lever (S8150-ThumbX) send a voltage In: U = 0.5–2.0 V D2: Diagnostic menu, see 7.1 Controls and
signal to Control unit KPU (D7902). Instr 6/XX DIAGNOSE, page 8:41 and 7.1
Zero position: U = 2.0-3.0
V Controls and Instr 7/XX DIAGNOSE, page
8:41.
Out: U = 3.0–4.5 V
spreading 30' on the CAN bus. system, error shown 11:27
with error code.


4 Spreading left is activated in the same - Spreading, function description, page 7:52
way as in normal spreading, steps D4: Diagnostic menu, see 7.5 Spreading
10–13. 12/XX DIAGNOSE, page 8:44 or 7.5
Spreading 13/XX DIAGNOSE, page 8:44
5 Spreading right is activated in the same - Spreading, function description, page 7:52
way as in normal spreading, steps D5: Diagnostic menu, see 7.5 Spreading
14–17. 14/XX DIAGNOSE, page 8:45 or 7.5
Spreading 15/XX DIAGNOSE, page 8:45
6 When the left spreader beam Sensor directly opposite Side lift attachment, general, page 7:61
approaches the 30' position, Sensor, indicator plate: U = 24 V D6: Diagnostic menu, see 7.5 Spreading
position 30' left (B7770-LE) sends a 9/XX DIAGNOSE, page 8:44
voltage signal to Control unit KAU
(D7911).
7 Control unit KAU (D7911) dampens the - Spreading, function description, page 7:52
speed in the same way as in normal
spreading, steps 20–21.
8 When the left spreader beam is in the Sensor directly opposite Side lift attachment, general, page 7:61
30' position, Sensor, end position 20'-40' indicator plate: U = 24 V D8: Diagnostic menu, see 7.5 Spreading
(B7690-LE) sends a voltage signal to 9/XX DIAGNOSE, page 8:44
Control unit KAU (D7911).
9 Control unit KAU (D7911) cuts off the U=0V 11.5.3.8 Control unit KAU (D7911), page
current to Servo valve spreading out left 11:36
(Y6018-LE) or Servo valve spreading in Attachment control valve, description, page
left (Y6019-LE). 7:60
10 When the right spreader beam Sensor directly opposite Position sensor, checking and adjustment,
approaches the 30' position, Sensor, indicator plate: U = 24 V page 7:4
position 30' right (B7770-RI) sends D10: Diagnostic menu, see 7.5 Spreading
a voltage signal to Control unit KAU 9/XX DIAGNOSE, page 8:44
(D7911).
11 Control unit KAU (D7911) dampens the - Spreading, function description, page 7:52
speed in the same way as in normal
spreading, steps 20–21.
12 When the right spreader beam is in the Sensor directly opposite Side lift attachment, general, page 7:61
30' position, Sensor, end position 20'-40' indicator plate: U = 24 V D12 Diagnostic menu, see 7.5 Spreading
(B7690-RI) sends a voltage signal to 9/XX DIAGNOSE, page 8:44
13 Control unit KAU (D7911) cuts off U=0V 11.5.3.8 Control unit KAU (D7911), page
the current to Servo valve spreading 11:36
out right (Y6018-RE) or Servo valve Attachment control valve, description, page
spreading in right (Y6019-LE). 7:60

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

with Switch, automatic spreading 20'-40'. When the switch is activated,
spreading automatically moves to the next end position when spreading
is activated with Control lever (S8150). During automatic spreading the
buzzer on the attachment sounds.
If the machine is also equipped with 30' or 35'-stop and this is activated,
then spreading stops at this stop. Activate spreading again in order
to go to the next position.
Event menu automatic spreading 20'–40'
Automatic spreading functions both during spreading in and spreading
out.
Automatic spreading 20-40 foot, function

description

Sensor, operator-in- Not activated (no operator in Sensor operator in seat, description, page 9:17
seat seat)
Twistlocks Unlocked or bypass activated Twistlocks, function description, page 7:67
Bypass, description, page 8:6
Doors Closed Doors, description, page 9:77
Parking brake Released Parking brake system, function description, page 4:31

1 Switch, automatic spreading 20'-40' Switch off: Switch automatic spreading, description, page
(S1012-2) sends a voltage signal to US1012-2:4 = 0 V 7:14
Control unit KPU (D7902). D2: Diagnostic menu, see section 7.5 Spreading
Switch on:
US1012-2:4 = 24V
2 Switch shift-button, Control lever U = 0-5 V DC Linear levers, description, page 7:5.
spreading (R8070-3), sends a D1: 7.1 Controls and Instr 2/XX DIAGNOSE,
voltage signal proportional to lever page 8:40.
movement to Control unit KPU
(D7902).


2 Switch shift button (S1991) and Shift button: U = 24 V Control lever (EGO), description, page 7:8
Control lever (S8150-ThumbX) In: U = 0.5–2.0 V D2: Diagnostic menu, see 7.1 Controls and Instr
send a voltage signal to Control unit 6/XX DIAGNOSE, page 8:41 and 7.1 Controls
KPU (D7902). Zero position: U = 2.0-3.0
V and Instr 7/XX DIAGNOSE, page 8:41.
Out: U = 3.0–4.5 V
3 Control unit KPU (D7902) sends Checked by control 11.5.3.2 Control unit KPU (D7902), page 11:27
"automatic spreading out" or system, error shown
"automatic spreading in" on the with error code.
CAN bus.
4 Spreading left is activated in the - Spreading, function description, page 7:52
same way as in normal spreading, D4: Diagnostic menu, see 7.5 Spreading 12/XX
steps 10–13. DIAGNOSE, page 8:44 or 7.5 Spreading 13/XX
DIAGNOSE, page 8:44
5 Spreading right is activated in the - Spreading, function description, page 7:52
same way as in normal spreading, D5: Diagnostic menu, see 7.5 Spreading 14/XX
steps 14–17. DIAGNOSE, page 8:45 or 7.5 Spreading 15/XX
DIAGNOSE, page 8:45
6 Control unit KAU (D7911) activates Buzzer active: U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:36
Buzzer, automatic spreading Buzzer automatic spreading 20'-40', description,
(H9003). page 7:61
D6: Diagnostic menu, see 7.5 Spreading 16/XX
DIAGNOSE, page 8:45
7 Buzzer automatic spreading Buzzer active: U = 24 V Buzzer automatic spreading 20'-40', description,
(H9003) generates acoustic page 7:61
warning signal. D6: Diagnostic menu, see 7.5 Spreading 16/XX
DIAGNOSE, page 8:45
8 When automatic spreading is - 11.5.3.3 Control unit, KID (D7950), page 11:29
active, the KID control unit (D7950)
activates the Automatic Spreading
event menu.
9 When the left spreader beam Sensor directly opposite Side lift attachment, general, page 7:61
approaches the 30' position, indicator plate: U = 24 V D5: Diagnostic menu, see 7.5 Spreading 9/XX
Sensor, position 30' left (B7770-LE) DIAGNOSE, page 8:44
sends a voltage signal to Control
unit KAU (D7911).
10 Control unit KAU (D7911) dampens - 11.5.3.8 Control unit KAU (D7911), page 11:36
the speed in the same way as in
normal spreading, steps 20–21.
11 When the left spreader beam is Sensor directly opposite Side lift attachment, general, page 7:61
in the 20' position, 30' position or indicator plate: U = 24 V D11: Diagnostic menu, see 7.5 Spreading 9/XX
40' position, Sensor, end position DIAGNOSE, page 8:44
20'-40' (B7690-LE) sends a voltage
signal to Control unit KAU (D7911).
12 Control unit KAU (D7911) cuts I = 0 mA 11.5.3.8 Control unit KAU (D7911), page 11:36
off the control current to Solenoid
valve spreading out (Y6018-LE)
or Solenoid valve spreading in
(Y6019-LE).
13 When the right spreader beam Sensor directly opposite Side lift attachment, general, page 7:61
approaches the 30' position, indicator plate: U = 24 V D13: Diagnostic menu, see 7.5 Spreading 9/XX
Sensor, position 30' right (B7770-RI) DIAGNOSE, page 8:44
sends a voltage signal to Control
unit KAU (D7911).
14 Control unit KAU (D7911) dampens - 11.5.3.8 Control unit KAU (D7911), page 11:36
the speed in the same way as in
normal spreading, steps 20–21.

7 Load handling – Hydraulic oil pump 7:59

15 When the right spreader beam is Sensor directly opposite Side lift attachment, general, page 7:61
in the 20' position, 30' position or indicator plate: U = 24 V D15: Diagnostic menu, see 7.5 Spreading 9/XX
40' position, Sensor, end position DIAGNOSE, page 8:44
20'-40' (B7690-RI) sends a voltage
signal to Control unit KAU (D7911).
16 Control unit KAU (D7911) cuts I = 0 mA 11.5.3.8 Control unit KAU (D7911), page 11:36
off the control current to Solenoid Attachment control valve, description, page 7:60
valve spreading out (Y6018-RE)
or Solenoid valve spreading in
(Y6019-RE).

10:8.

7:60 7 Load handling – Control valve, attachment

Servo valve, spreading out
Spreading is controlled by a separate section in control valve,

attachment. For a general description of the valve and component
locations, see Attachment control valve, description, page 7:50.
For more information on spreading, see Spreading, function description,

page 7:52.
Servo valve, spreading out
Servo valve spreading out is controlled electrically by Solenoid valve
spreading out (Y6018), which is activated by Control unit KAU (D7911).
The servo valve directs servo pressure to the spreading slide which is
12/XX DIAGNOSE, page 8:44 and 7.5 Spreading 13/XX DIAGNOSE,
page 8:44.
Servo valve, spreading in
Servo valve spreading in is controlled electrically by Solenoid valve
spreading in (Y6019), which is activated by Control unit KAU (D7911).
The servo valve directs servo pressure to the spreading slide which is
14/XX DIAGNOSE, page 8:45 and 7.5 Spreading 15/XX DIAGNOSE,
1. Solenoid valve spreading in right (Y6019R)
page 8:45.
2. Connection to rod side spreading cylinder
3. Solenoid valve spreading in left (Y6019L)
4. Connection to rod side left spreading cylinder
5. Solenoid valve spreading out left (Y6018L)
6. Connection to piston side, left spreading
cylinder
7. Solenoid valve spreading out right (Y6018R)
8. Connection to piston side, right spreading
cylinder
9. Measuring outlet, feed pressure
11. Connection return to tank (T)


Sensor side lift attachment
The following sensors are fitted on the side lift attachment, and
they send signals to the machine to inform about the status of the
attachment's different functions:
• Sensor end position 20'-40'
• Sensor position 30'
Other components, side lift attachment
The following major components are also fitted on the side lift
attachment:
• Spreading cylinder
• Spreader beams
• Side shift frame

See Lifting carriage, description, page 7:38.
7.5.7 Buzzer, automatic spreading 20'-40'

Buzzer automatic spreading 20'-40', description
The buzzer for automatic spreading 20'-40' (H9003) is fitted in the lifting
carriage on machines with automatic spreading 20'-40'. The buzzer is
activated during automatic spreading movement.



7:62 7 Load handling – Tilt
7.7 Tilt
Tilt, description
Tilt means the angling of the mast in relation to the machine. Control
valve, lift/lower and tilt, pressurises the tilt cylinders, which angle the
mast in relation to the machine. Tilt is controlled by control lever (linear
lever) tilt or control lever.
During tilt in, there is an automatic linear increase in engine speed

when the tilt lever is deflected. The engine speeds are adjustable,
see 7.2 Lifting Lowering 16/XX INITIATE, page 8:106 and 7.2 Lifting
Lowering 17/XX INITIATE, page 8:107.
Tilt, function description

Control breaker Disengaged Control breaker voltage, function description, page
11:19.
Sensor, operator- Activated Sensor operator in seat, description, page 9:17.
in-seat

7 Load handling – Tilt 7:63

1 The tilt control lever (R8070-2) sends Tilt in: U = 0.5–2.0 V Linear levers, description, page 7:5
a voltage signal proportional to lever Zero position: U = 2.0-3.0 D1: 7.1 Controls and Instr 1/XX DIAGNOSE,
movement to the KPU control unit V page 8:39
(D7902).
Tilt out: U = 3.0–4.5 V
0.5 V is the highest speed
in and 4.5 V is the highest
speed out. Lower voltage
than 0.5 V and higher
voltage than 4.5 V is used
to detect faults in cable
2 The KPU control unit (D7902) transmits Checked by control 11.5.3.2 Control unit KPU (D7902), page
a request for tilt out or tilt in on the CAN system, error shown with 11:27
bus. error code.
3 Control unit KFU (D7971) sends a - 11.5.3.4 Control unit KFU (D7971), page
request to Control unit, engine (D7940) 11:31
for increase of engine speed.
4 Control unit, engine (D7940) increases Checked by control 11.5.3.6 Control unit, engine (D7940), page
the engine speed. system, error shown with 11:33
error code.
5 Control unit KFU (D7971) activates the I = 340–490 mA 11.5.3.4 Control unit KFU (D7971), page
solenoid valve for tilt out (Y6010) or the 11:31
solenoid valve for tilt in (Y6011). D5: 7.7 Tilt 1/XX DIAGNOSE, page 8:46
and 7.7 Tilt 2/XX DIAGNOSE, page 8:46.
6 Solenoid valve, tilt out (Y6010) or - Control valve, lift and tilt, description, page
solenoid valve, tilt in (Y6011) allocates 7:19
servo pressure in proportion to the D5: 7.7 Tilt 1/XX DIAGNOSE, page 8:46
control current in the lift slide in control and 7.7 Tilt 2/XX DIAGNOSE, page 8:46.
valve, load handling.
7 The control valve's lift slide changes - Control valve, lift and tilt, description, page
position and pressurises the tilt cylinders 7:19
and sends a load signal to hydraulic oil
pump 2 and the shuttle valve for lift/tilt.
8 The pressure reducer in control valve, See the pressure plate on Valve block servo pressure, description,
load handling, limits a part of the the left-hand frame beam. page 10:20
pressure and routes it onward to the Accumulator servo circuit, description, page
service circuit and accumulator servo 10:22
pressure.
9 Shuttle valve lift/tilt sends a lift signal - Shuttle valve, page 10:21
hydraulic oil tank to control valve, load left-hand front mudguard. displacement, description, page 10:8
handling.
hydraulic oil tank to the priority valve left-hand front mudguard. displacement, description, page 10:8
and the pressure reducer.
13 Pressurised oil passes via control valve, See pressure plate on Control valve, lift and tilt, description, page
load handling, to the load holding valves. left-hand front mudguard. 7:19
14 The load holding valve opens and routes - Load holding valve, description, page 7:65
pressure onward to the lift cylinders.
15 The tilt cylinders tilt the mast outor tilt - Tilt cylinder, description, page 7:65
the mast in.
Hydraulic diagram, see Hydraulic diagram, basic machine, page E:4.

7:64 7 Load handling – Hydraulic oil pump

10:8.
7.7.5 Control valve, lift and tilt

Control valve, lift and tilt, description
Tilt slide
page 7:64.
Tilt slide
When the solenoid valves are activated, the tilt slide 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, solenoid valve tilt out is controlled
electrically by Solenoid valve tilt out (Y6010) which is activated by
Control unit KFU (D7971). The solenoid valve directs servo pressure to
the tilt slide which is proportional to the control current to the solenoid
valve.
1. Solenoid valve, lift (Y6005)
2. Solenoid valve, lower (Y6004) The signal can be checked with the diagnostic menu, see 7.7 Tilt 2/XX
3. Solenoid valve, tilt in (Y6011)
4. Solenoid valve, tilt out (Y6010) Solenoid valve tilt in
5. Connection return to tank (T3) On machines with electric servo, solenoid valve tilt in is controlled
6. Connection, feed from priority valve (P) electrically by Solenoid valve tilt in (Y6011) which is activated by Control
unit KFU (D7971). The solenoid valve directs servo pressure to the tilt
slide which is proportional to the control current to the solenoid valve.
8. Connection, piston side, left lift cylinder
The signal can be checked with the diagnostic menu, see 7.7 Tilt 1/XX
9. Connection, piston side, right lift cylinder
10. Connection, rod side, tilt cylinder
11. Connection, piston side, tilt cylinder

7 Load handling – Load holding valve 7:65
7.7.6 Load holding valve

Load holding valve, description
Load holding valves are located on the tilt cylinders by the hydraulic
connection to the rod side. The load holding valve prevents the tilt
cylinders from moving faster than the supplied pressure from control
valve, load handling. This prevents unwanted tilting forward that can
occur with heavy loads and or high lifting. The load holding valve also
makes the tilt movement more controlled.
009929
Load holding valve
7.7.7 Tilt cylinder

Tilt cylinder, description
The tilt cylinders are located between the mast and the frame and
angle the mast in relation to the machine.
1. Tilt cylinder
2. Mast
3. Lower mast mounting in frame

See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.
7.7.8 Mast
Mast, description
See Mast, description, page 7:22.

7:66 7 Load handling – Pipes and hoses



7 Load handling – Load carrier 7:67
7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, description
The container is held in place on the side lift attachment by two
twistlocks.
Twistlocks are controlled by Switch, twistlocks. A section of Control

valve, attachment pressurises two parallel-connected hydraulic
cylinders, one on each side of side lift attachment. Each hydraulic
cylinder acts on one twistlock. Two position sensors, one on each
twistlock, detect the position and indicate whether twistlocks are open
or locked. Indicator lamps on the side lift attachment and in the cab
show the status of the twistlocks.
A contact pin and a sensor by each twistlock indicate when the

attachment is in contact with the container. This is used to control
when the twistlocks can be activated. An indicator light on the side lift
attachment and 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 in order to activate the
twistlocks.
Twistlocks, function description

Sensor, operator-in-seat Not activated Sensor operator in seat, description, page 9:17
Contact Full contact or bypass Bypass, description, page 8:6
activated

7:68 7 Load handling – Twistlocks

1 Switch, lock twistlocks (S1003) U = 24 V Switch load securing, description, page 7:13
(automatic mode) sends a voltage signal D1: Diagnostic menu, see 7.9 Load Carrier
to Control unit KPU (D7902). 3/XX DIAGNOSE, page 8:47
2 Switch open twistlocks (S8070-1) in the U = 24 V Control lever (EGO), description, page 7:8
control lever sends a voltage signal to D2: Diagnostic menu, see 7.1 Controls and
Control unit KPU (D7902) for opening Instr 7/XX DIAGNOSE, page 8:41
the twistlocks.
2 Switch open twistlocks (S1020) in the
control lever sends a voltage signal to
Control unit KPU (D7902) for opening
the twistlocks.
3 Sensor contact left (B7202LE), Sensor Sensor directly opposite Side lift attachment, general, page 7:70
contact right (B7202RI) send voltage indicator plate: U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:36
signals to Control unit KAU (D7911).
D3: Diagnostic menu, see 7.9 Load Carrier
4 Control unit KAU (D7911) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:36
on the CAN bus. system, error shown
with error code.
5 Control unit KID (D7950) activates Event - 11.5.3.3 Control unit, KID (D7950), page 11:29
menu, contact.
6 Control unit KAU (D7911) activates U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:36
Indicator light, contact (H5640-1) on the D6: Diagnostic menu, see 7.9 Load Carrier
boom's light panel. 10/XX DIAGNOSE, page 8:48
7 Indicator light contact (H5640-1) U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier
illuminates. 10/XX DIAGNOSE, page 8:48
8 Control unit KCU (D7901) activates U = 24 V 11.5.3.1 Control unit KCU (D7901), page
Indicator light contact (H5640-2) in the 11:25
cab's light panel. D8: Diagnostic menu, see 7.9 Load Carrier
9 Indicator light contact (H5640-2) in the D8: Diagnostic menu, see 7.9 Load Carrier
cab's light panel illuminates. 14/XX DIAGNOSE, page 8:49
10 Control unit KPU (D7902) sends "open Checked by control 11.5.3.2 Control unit KPU (D7902), page
twistlocks" or "lock twistlocks" on the system, error shown 11:27
CAN bus. with error code.
11 Control unit KFU (D7971) activates U = 24 V 11.5.3.4 Control unit KFU (D7971), page 11:31
Solenoid valve engagement of D11: Diagnostic menu, see 10.4 Pumps 1/XX
hydraulics for top lift (Y6003). DIAGNOSE, page 8:76
12 Solenoid valve, engagement of - Solenoid valve, engagement of hydraulics for
hydraulics for top lift (Y6003) opens and top lift, page 10:20
DIAGNOSE, page 8:76
13 Shuttle valve lift/tilt sends a load signal - Shuttle valve, page 10:21.
14 Hydraulic oil pump 1 pumps oil from the See pressure plate Axial piston pump with variable displacement,
hydraulic oil tank to the priority valve. on left-hand front description, page 10:8
mudguard.
15 The priority valve leads supply pressure See pressure plate Priority valve, general, page 5:6
to the control valve for load handling. on left-hand front
mudguard.
17 Control unit KAU (D7911) activates U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:36
Solenoid valve "open twistlocks" D17: Diagnostic menu, see 7.9 Load Carrier
(Y6039) or Solenoid valve "lock 6/XX DIAGNOSE, page 8:47 or 7.9 Load
twistlocks" (Y6040). Carrier 7/XX DIAGNOSE, page 8:47

7 Load handling – Twistlocks 7:69

18 Solenoid valve open twistlocks (Y6039) - Attachment control valve, description, page
or Solenoid valve lock twistlocks (Y6040) 7:70
pressurises the twistlock slide with servo D17: Diagnostic menu, see 7.9 Load Carrier
pressure in control valve, attachment. 6/XX DIAGNOSE, page 8:47 or 7.9 Load
Carrier 7/XX DIAGNOSE, page 8:47
19 The control valve's twistlock slide valve - Attachment control valve, description, page
lock cylinders.
20 The lock cylinders rotate the twistlocks. - Side lift attachment, general, page 7:70
21 Sensor, twistlocks left (B7205-LE) and Sensor directly opposite Side lift attachment, general, page 7:70
Sensor twistlocks right (B7205-RI) send indicator plate: U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:36
a signal to Control unit KAU (D7911).
D21: Diagnostic menu, see 7.9 Load Carrier
115/XX DIAGNOSE, page 8:50 and 7.9 Load
22 Control unit KAU (D7911) supplies U = 24 V 11.5.3.8 Control unit KAU (D7911), page 11:36
voltage to Indicator light unlocked D6: Diagnostic menu, see 7.9 Load Carrier
twistlocks (H5620-1) or Indicator light 8/XX DIAGNOSE, page 8:47 or 7.9 Load
locked twistlocks (H5630-1) on the Carrier 10/XX DIAGNOSE, page 8:48
attachment's light panel.
23 Indicator light unlocked twistlocks U = 24 V D6: Diagnostic menu, see 7.9 Load Carrier
(H5620-1) or Indicator light locked 8/XX DIAGNOSE, page 8:47 or 7.9 Load
twistlocks (H5630-1) on the attachment's Carrier 10/XX DIAGNOSE, page 8:48
light panel illuminates.
24 Control unit KAU (D7911) sends Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:36
information about "twistlocks unlocked" system, error shown
or "twistlocks locked" on the CAN bus. with error code.
25 Control unit KCU (D7901) supplies U = 24 V 11.5.3.1 Control unit KCU (D7901), page
voltage to Indicator light unlocked 11:25
twistlocks (H5620-2) or Indicator light D8: Diagnostic menu, see 7.9 Load Carrier
locked twistlocks (H5630-2) on the cab's 12/XX DIAGNOSE, page 8:48 or 7.9 Load
light panel. Carrier 13/XX DIAGNOSE, page 8:49
26 Indicator light unlocked twistlocks U = 24 V D8: Diagnostic menu, see 7.9 Load Carrier
(H5620-2) or Indicator light locked 12/XX DIAGNOSE, page 8:48 or 7.9 Load
twistlocks (H5630-2) in the cab's light Carrier 13/XX DIAGNOSE, page 8:49
panel illuminates.
27 Control unit KID (D7950) activates Event Checked by control 11.5.3.3 Control unit, KID (D7950), page 11:29
menu, twistlocks. system, error shown
with error code.
7.9.1.1 Hydraulic oil pump

10:8.

7:70 7 Load handling – Twistlocks
7.9.1.2 Control valve, attachment

Twistlocks slide, description
The twistlocks function is controlled by a separate section in the

attachment's control valve. For a general description of the valve and
component locations, see Attachment control valve, description, page
7:50.
Twistlocks slide, description
The valve slide controls the direction of the lock cylinder. The valve
slide is controlled by Solenoid valve lock twistlocks (Y6040) and
Solenoid valve open twistlocks (Y6039).
Solenoid valve lock twistlocks, description
Solenoid valve lock twistlocks routes pressure to the twistlock slide so
that the slide opens and pressurises the lock cylinders.
Solenoid valve lock twistlocks (Y6040) is activated by Control unit KAU

(D7911). The solenoid valve directs servo pressure to the twistlock
slide.
The signal can be checked with the diagnostic menu, see 7.9 Load
Solenoid valve open twistlocks, description
Solenoid valve open twistlocks routes pressure to the twistlock slide so
1. Solenoid valve lock twistlock/lock lug (Y6040) that the slide opens and pressurises the lock cylinders.
2. Connection to piston side, lock cylinders Solenoid valve open twistlocks (Y6039) is activated by Control unit
3. Connection to rod side, lock cylinders KAU (D7911). The solenoid valve directs servo pressure to the
twistlock slide.
4. Solenoid valve, open twistlock/lock lug (Y6039)
5. Measuring outlet, feed pressure The signal can be checked with the diagnostic menu, see 7.9 Load
7. Connection return to tank (T)
7.9.1.6 Side lift attachment

Sensor side lift attachment
The following sensors are fitted on the side lift attachment, and
they send signals to the machine to inform about the status of the
attachment's different functions:
• Sensor contact
• Sensor twistlocks
• Sensor lifting head
Other components, side lift attachment
The following major components are also fitted on the side lift
attachment:
• Twistlock cylinders
• Twistlocks

7 Load handling – Twistlocks 7:71
7.9.1.10 Pipes and hoses

7.9.1.11 Relief valve, attachment
Relief valve attachment, description

See section 10 Common hydraulics, group 10.2.3 Relief valve
attachment.
7.9.1.12 Main valve
Main valve, description

See Main valve, description, page 10:23.
7.9.1.13 Hydraulic oil filter


7:72 7 Load handling – Other functions
7.10 Other functions

7.10.2 Weight indicator
Weight indicator, general
See Weight indicator, description, page 8:16.
7.10.3 Container counter

Container counter, general
See Container counter, description, page 8:16.

8:1
8 Control system
Contents 8 Control system

8 Control system .................................................................................................. 8:3
8.1.2 Information display ......................................................................................8:4
8.2 Monitoring ........................................................................................................8:6
8.2.1 Overload system .........................................................................................8:6
8.2.2 Bypass ........................................................................................................8:6
8.2.4 Height limitation...........................................................................................8:7
8.2.5 Speed limitation...........................................................................................8:8
8.2.6 Service indicator..........................................................................................8:8
8.2.8 Height warning ..........................................................................................8:10
8.2.11 Load sensor .............................................................................................. 8:11
8.2.12 Statistics ....................................................................................................8:15
8.2.13 Weight indicator.........................................................................................8:16
8.2.14 Container counter......................................................................................8:16
8.4 Diagnostics ....................................................................................................8:18
8.4.1 Engine .......................................................................................................8:21
8.4.2 Transmission .............................................................................................8:28
8.4.4 Brakes .......................................................................................................8:34
8.4.6 Suspension ...............................................................................................8:36
8.4.7 Load handling............................................................................................8:39
8.4.8 Control system ..........................................................................................8:51
8.4.9 Frame, body, cab and accessories............................................................8:56
8.4.10 Common hydraulics...................................................................................8:76
8.4.11 Common electrics......................................................................................8:77
8.4.13 Pin diagnostics ..........................................................................................8:90
8.5 Setup..............................................................................................................8:92
8.5.1 Engine .......................................................................................................8:95
8.5.2 Transmission ...........................................................................................8:100
8.5.6 Suspension .............................................................................................8:103
8.5.7 Load handling..........................................................................................8:103
8.5.8 Control system ........................................................................................ 8:116
8.5.9 Frame, body, cab and accessories..........................................................8:123
8.5.11 Common electrics....................................................................................8:127

8:2

8 Control system – Control system 8:3
8 Control system
Control system, general
In many cases, the machine's functions are controlled electrically. The
signals that control the machine are monitored to warn the operator
or limit the machine's functions in the event of certain dangerous
situations or if there are malfunctions in the machine.
The control system function is divided into the following functions:

• Instruments and controls
• Monitoring
• Error codes, machine (described together with error codes from
other systems under section D Error codes)
• Diagnostics
• Setup
Instruments and controls describes the information display in the cab,

which is the interface to the control system.
Monitoring describes the machine's various monitoring functions that

warn the operator or limit the machine's functions in the event of
potentially dangerous situations.
Error codes advises the operator and mechanic when faults are
detected by the control system.
Diagnostics describes the control system’s diagnostic menus.

The diagnostics menus form a tool for performing service and
troubleshooting from the information display.
Settings describes the control system’s initiation menus. The initiation

menus form a tool for making settings and adapting machine functions
from the information display.

8:4 8 Control system – Controls and instruments

8.1.2 Information display
Navigation of menus, description
Information is presented on the display (position a). The function keys
a (positions c - e) are used to navigate in the display menus and confirm
selections.
Navigation in and to menus and settings in the menus for Diagnostics,

Initiation and Calibration is performed in the same way for all functions.
The Pop-up row for the key function changes in appearance and
function depending on the menu. The different functions are explained
below.
Confirm.
Select the highlighted function.
Activate the output manually.
Save a value.
Change the arrow function from the left/right arrows to
up/down arrows.
The symbol is only shown in menus where settings
are possible.
016040
b c d e Exit menu.
Cancel setting.
a. Display
Increase/decrease a signal value.
b. Pop-up for button function
Step up/step down in a list.
c. ENTER/YES/ON/SAVE/EDIT/MAN
d. Navigate menus/adjust values , , or Go to next menu/back to previous menu.
e. EXIT/NO/OFF//LEAVE
Navigation in and to menus and settings can also be done using the
wheel for navigation on the right control panel, rear part, and the keys
to confirm and cancel.
After logging into the service menus, the buttons for adjusting the
right-hand control panel can also be used to navigate in the menus
instead of the buttons on the display.
1. Forward/back corresponds to and or

and depending on what is shown on the
display
2. Key confirm
3. Key cancel
4. Wheel for navigation

8 Control system – Information display 8:5
Navigation to a menu, work instruction

To navigate to a menu, do as follows:
1 Navigate to the service menu using or .
2 Confirm with or cancel with .
014981

8:6 8 Control system – Monitoring
8.2 Monitoring
8.2.1 Overload system
Overload system, description
The machine's load sensor continuously measures the weight of the

load, see 8.2.11 Load sensor, page 8:11. The weight from the load
detector and the lifting height are used for various overload warnings.
Part of the overload system is a warning system, OLS (Over Load

System). The system is used for stationary load handling, so that the
capacity and stability of the machine in the forward direction are not
put at risk. The system is used for stationary load handling, so that the
Display of current load in the main menu stability of the machine in the forward direction is not put at risk. OLS is
not designed to control lateral stability or stability when operating. Nor
does the system take inclined ground conditions into account. Current
load is shown in the main menu with a bar on the right.
The bar's areas have different colours depending on how much of the
capacity is utilised in the current load position:
Blue green = 0-80 % of the max. load in current load position.
Yellow = 80-90 % of the max. load in current load position.
Red = 90-100 % of the max. load in current load position.
In the event of high load on the steering axle, machine speed is limited
dynamically depending on load, see Speed limitation, description, page
8:8.
Lift and tilt in are blocked in the event of overload. The load can always
be lowered and tilted out in order to back out of the overload situation.
When the overload system blocks the functions, the following occurs:
• the buzzer in the cab sounds (indication to operator)
• the event menu, adapted to the overloaded function (lift or tilt), is
shown in the display (indication to the operator).
8.2.2 Bypass
Bypass, description
Bypass is activated using the bypass switch by the safety system
(S1005).
012733
Position 0, normal function.

0 1
Switch, bypass Position 1, bypass of the safety system permits the following:
The Bypass warning lamp illuminates when bypass of safety locks

is activated.
DANGER
Bypassing the safety systems results in a risk of
tipping. Use at your own risk.
Risk of fatal accidents and property damage!
Only use the bypass of safety systems in emergency
situations.

8 Control system – Height limitation 8:7
Bypass with code lock
As an option, bypass can be equipped with a code lock which means

that a code must be entered via the display when bypass of certain
functions is required. The functions that can have a code lock are
divided into five groups Service technicians can activate or disable the
code lock for each group individually.
By pass with key
As an option, the bypass can be equipped with a key lock, which means
that a key must first be inserted in the lock (S1005-2) and then turned
to bypass certain functions when required. Functions that can have a
key lock are divided into five groups. A service technician can activate
or disengage the key lock for each group individually.
8.2.4 Height limitation

Height limitation, description
The height limitation prevents the machine lifting higher than a set
height (position A) without the operator being informed.
The height limitation is controlled by the control system with a

signal from Sensor, lifting height (B7228), see Sensor lifting height,
description, page 7:35. When the sensor indicates that the permitted
height has been reached, the lift is blocked and the event menu for
height limitation is also activated.
The load can be operated beyond the set limit by activating bypass,
see Bypass, description, page 8:6.

8:8 8 Control system – Speed limitation
8.2.5 Speed limitation

Speed limitation, description
Speed limitation prevents the machine's speed from exceeding the

preset value by limiting gear position and engine speed.
Machine speed is also limited by certain events in order to reduce

the risk of damage, e.g. in the event of: faults in the transmission,
high brake oil temperature, lifting loads near the machine's maximum
capacity, bypass activated. In most of these cases the event menu is
shown for the function that limits the speed, such as the event menu
Event menu, general speed warning for high brake temperature.
Some functions cannot be activated above certain speeds in order to

reduce the risk of inappropriate use of the machine. If the operator tries
to activate such a function above the speed limit then the event menu,
general speed warning, is shown.
Machine speed is limited when:

• The control breaker is activated.
• The configuration ID numbers of the control units are incorrect.
Maximum speed is 10 km/h.
• The hydraulic oil temperature is too high.
• The accumulator pressure for the brake function is too low.
Maximum speed is 10 km/h.
• Lifting the load above a certain lifting height.
• Lifting the load above a certain weight.
The speed limitation is set using the initiation menu, see menu 8.2
Monitoring 1/XX INITIATE, page 8:118.
8.2.6 Service indicator

Service indicator, description
The service indicator counts down to the next scheduled service and
informs the operator when it is time for service with an event menu.
After service is completed the service indicator should be reset to zero.
015443
Event menu service
Service indicator, resetting

See Maintenance manual.

8 Control system – Service indicator 8:9
Service indicator, changing the service interval

See also Initiation, work instructions, page 8:93 for a general
explanation of how settings are made.
2 Navigate to the service menu with or and confirm with .
014981
3 Enter diagnostic code 1111 to set with or and confirm with .

015625
4 Select 8. CONTROL SYSTEM by scrolling with or and

confirm with .
015624
5 Select 8.2 Monitoring by scrolling with or and confirm with .

015629

8:10 8 Control system – Height warning
6 Select INITIATE by scrolling with or and confirm with .
015735
7 Select Service time interval by scrolling with or .
See also 8.2 Monitoring 3/XX INITIATE, page 8:118 for setting
the service interval.
8 Press once for EDIT and adjust the interval time with or .
Press once for SAVE in order to save the set value or press
to cancel the entry.
9 Select Service time pop up hours by scrolling with or .

See also 8.2 Monitoring 5/XX INITIATE, page 8:119 for setting how
long before the service interval expires that a warning is shown
to the operator.
10 Press once for EDIT and adjust the time with or .
Press once for SAVE in order to save the set value or press
to cancel the entry.
11 Exit Initiation by scrolling out with .
8.2.8 Height warning

Height limitation, description
Height warning warns when the set maximum lifting height is reached.
Height warning is adjustable according to customer requirements.
The warning includes both a symbol that appears on the display and
a sound signal.
The height limitation is controlled by the control system with a signal

from Sensor, lifting height (B7228). When the sensor indicates that the
permitted height has been reached, the event menu for height warning
is activated.

8 Control system – Load sensor 8:11
8.2.11 Load sensor

Load sensors, description
Load sensors use a pressure sensor in the lift cylinder to calculate
the load. The weight of the load is calculated as a function of the
pressure in the lift cylinders. This information is used for several of
the machine's subsystems, e.g.:
• Overload system
• Weight indicator
• Load counter
Load sensors, function description

1 Sensor, hydraulic pressure lift cylinder U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder,
(B7226-1) sends voltage signals description, page 8:14
proportional to the hydraulic pressure D1: Diagnostic menu, see 8.2 Monitoring
in the lift cylinders to Control unit KFU 3/XX DIAGNOSE, page 8:52
(D7971).
2 Control unit KFU (D7971) calculates and Checked by control 11.5.3.4 Control unit KFU (D7971), page
sends the weight on the CAN bus. system, error shown with 11:31
The weight is calculated from error code.
machine-unique calibration data in
the control unit and the sensor value for
hydraulic pressure in the lift cylinders.
3 Control unit KID (D7950) shows weight - 11.5.3.3 Control unit, KID (D7950), page
information in the display. 11:29

8:12 8 Control system – Load sensor
Load sensor, calibration
DANGER
Do not leave the machine during calibration. The
machine may start to move.
1 Operate the lifting carriage up and down a few times to remove

any mechanical tension. Make sure that the mast is vertical.
2 Operate the machine for a few minutes before calibration in order
to achieve operating temperature in the engine and hydraulic oil.
3 Stop the machine on level ground and apply the parking brake.
4 In order to select the function to calibrate, navigate first to the
014981
5 Enter the code for calibration with or . Confirm each digit

with .
NOTE
015625
6 Select 8. CONTROL SYSTEM by scrolling with or and

confirm with .
015624
7 Select 8.2 Monitoring by scrolling with or and confirm with .

015629

8 Control system – Load sensor 8:13
015628
Duplex standard mast
9 Calibration for machine with Duplex standard mast.
a) Operate the lifting carriage up and lower it slowly to approx. 1
metre above the ground. Press .
b) Continue with calibration according to Calibration for increased
accuracy of the scales, page 8:13.
Mast with load cell in chain tightener.

10 Calibration for machine with mast with chain tightener.
a) Operate the lifting carriage up and lower it slowly to approx. 1
metre above the ground. Press .
b) Continue with calibration according to Calibration for increased
accuracy of the scales, page 8:13.
Calibration for increased accuracy of the scales

11 Calibration for increased accuracy of the scales.
a) Perform the calibration without load and with hydraulic oil at
maintained operating temperature.
b) Run the engine at high engine speed.
c) Operate the lifting control to maximum deflection.
d) When the four bottom rows show 1 and the value in the first row
starts to become stabilised, stop the manoeuvre.
e) Press to save the new value.

8:14 8 Control system – Load sensor

b) Run the engine at idle speed.
c) Operate the lifting control to maximum deflection.

b) Raise the lifting carriage to maximum height.
c) Run the engine at idle speed.
d) Operate to maximum deflection to lower the lifting carriage.
e) When the three bottom rows show 1 and the value in the first row
f) Press to save the new value.

b) Run the engine at idle speed.
c) Operate the lifting control to 10% of maximum deflection. When
you reach 10%, there is a 1 in the row for lifting.
Maintain this position on the lifting control for the rest of the
manoeuvre.
15 Exit calibration by scrolling out with .
8.2.11.1 Sensor hydraulic pressure lift cylinder
Sensor hydraulic pressure lift cylinder, description

The lift cylinder pressure sensor (B7226-1) measures the pressure on
the piston side of the lift cylinders.
The sensor is located in the hydraulic block inside the frame or on the
lift cylinder on the inlet for lifting movement at the lower end.
The sensor is supplied with power by, and sends a voltage signal
proportional to the hydraulic oil pressure to Control unit KFU (D7971).
The signals can be checked with diagnostic menu 8.2 Monitoring 3/XX

8 Control system – Statistics 8:15
8.2.12 Statistics
Trip computer, description
1 2 The trip computer shows fuel consumption, speed and load calculator.
016518
1. Fuel consumption
2. Speed
3. Load counter
Statistics menus, description
Data regarding operating time, fuel consumption, mileage and lifting

can be read on the statistics menus.
The following symbols are used in these menus.
Statistics Total value, cannot be

reset
Resettable values
Statistics on operating Operating times engine
times
Operating times
transmission
Operating times
hydraulic pump
Operating times idling
Statistics on fuel Used quantity of fuel l/h
consumption/total
quantity fuel used Used quantity of fuel
l/100 km
Used quantity of fuel
l/each
Statistics on mileage km
Lift statistics Load quantity/h

8:16 8 Control system – Weight indicator
8.2.13 Weight indicator

Weight indicator, description
The weight indicator shows the weight of the raised load. The weight
indicator uses the load sensor's sensor signals in order to calculate the
weight of the lifted load, see Load sensors, description, page 8:11. The
weight is shown in the main menu on the display.
Load weight is shown in the main menu, more detailed weight

information is shown in Operating menu scale and the menus for
statistics and operating time. For information on menus and handling,
see Operator's manual.
Scales, weighing and load totalling

1 Grab the load.
1 4
2 Perform a lift movement and then lower the load slowly about 30
2 cm.
5
3 Select Operating menu, scale / . Confirm with .
3 6 4 Select tarring with / .
Switch between to tare (current weight displayed) and not to tare
(0 shown).
Confirm with .
016095
5 Select load weight with / .

The value of the load weight can be added to the total weight
1. Tare symbol with .
2. Total symbol 6 Select total weight with /
3. Reset symbol The value of the total weight can be reset by .
4. Tare weight 7 Leave the menu with .
5. Load weight (net weight)
6. Sum weight (gross weight)
8.2.13.1 Sensor hydraulic pressure lift cylinder
Sensor hydraulic pressure lift cylinder, general

See Sensor hydraulic pressure lift cylinder, description, page 7:20.
8.2.14 Container counter

Container counter, description
The container counter counts the number of lifted containers. The
counter has two counters that can be reset separately.
The container counter counts lifting when contact disappears with

locked twistlocks or lock lugs, and twistlocks or lock lugs are not
opened within 8 seconds.
a. Counter 1
b. Counter 2

8 Control system – Container counter 8:17
Container counter, function description


1 The attachment is positioned over - Lifting/lowering, function description, page 7:16
a container with the functions 7.2 D1: Diagnostic menu, 7.1 Controls and Instr
Lifting/lowering. 5/XX DIAGNOSE, page 8:40
2 Sensor, contact left (B7202-LE), Sensor, Sensor directly Side lift attachment, general, page 7:70
contact right (B7202-RI) send voltage opposite indicator D2: Diagnostic menu, see 7.9 Load Carrier
signals to Control unit KAU (D7911). plate: U = 24 V 92/XX DIAGNOSE, page 8:49 or
3 Control unit KAU (D7911) sends contact Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:36
on the CAN bus. system, error shown
with error code.
4 Twistlocks are rotated to the locked - Twistlocks, function description, page 7:67
position and are closed with the 7.9.1
Twistlocks function.
5 Sensor, twistlocks left (B7205-LE) and U = 0.5-4.5 V Side lift attachment, general, page 7:70
Sensor twistlocks right (B7205-RI) send D5: Diagnostic menu, see 7.9 Load Carrier
a voltage signal proportional to the 115/XX DIAGNOSE, page 8:50 and 7.9 Load
position to Control unit KAU (D7911). Carrier 116/XX DIAGNOSE, page 8:50.
6 Control unit KAU (D7911) sends locked Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:36
twistlocks on the CAN bus. system, error shown
with error code.
7 The container is lifted with the function - Lifting/lowering, function description, page 7:16
7.2 Lifting/lowering.
8 Sensor, contact left (B7202-LE) and U=0V Side lift attachment, general, page 7:70
Sensor, contact right (B7202-RI) stop D2: Diagnostic menu, see 7.9 Load Carrier
sending voltage signals to Control unit 92/XX DIAGNOSE, page 8:49 or
KAU (D7911).
9 Control unit KAU (D7911) sends no Checked by control 11.5.3.8 Control unit KAU (D7911), page 11:36
contact on the CAN bus. system, error shown
with error code.
10 If the twistlocks remain locked for 8 - 11.5.3.1 Control unit KCU (D7901), page 11:25
seconds then Control unit KCU (D7901)
adds one lift to the container counter.
11 Control unit KID (D7950) updates the Checked by control 11.5.3.3 Control unit, KID (D7950), page 11:29
display in Operating menu load counter. system, error shown
with error code.

8:18 8 Control system – Diagnostics
8.4 Diagnostics
Diagnostics, general
Diagnostics are performed via menus in the display. Diagnostics is a
tool in order to perform service and troubleshooting.
The machine has built-in functions for troubleshooting called diagnostic

test. The diagnostic test consists of several menus shown on the
display. The menus are grouped for faster access. Diagnostic tests
show how the control units interpret input signals as well as which
signals that the control units send. The diagnostic tests are grouped in
accordance with the function groups in the manuals.
Diagnostics are divided into the following groups:

• Engine, 8.4.1 Engine, page 8:21.
• Transmission, 8.4.2 Transmission, page 8:28.
• Brakes, 8.4.4 Brakes, page 8:34.
• Suspension, 8.4.6 Suspension, page 8:36
• Load handling, 8.4.7 Load handling, page 8:39.
• Control system, 8.4.8 Control system, page 8:51.
• Frame, body, cab and accessories, 8.4.9 Frame, body, cab and
accessories, page 8:56.
• Common hydraulics, 8.4.10 Common hydraulics, page 8:76.
• Common electrics, 8.4.11 Common electrics, page 8:77.
• Pin diagnostics, 8.4.13 Pin diagnostics, page 8:90.
All diagnostic menus are listed below, except those for pin diagnostics.
The menus for pin diagnosis work in the same way for each
input/output, so only the principle is described. Certain menus refer
to options that are only shown on the display if the machine has the
option in question.
Navigation diagnostic menus, work instructions

1 Park the machine.
014981
3 Enter diagnostic code 1111 with or and confirm with .

015625

8 Control system – Diagnostics 8:19
4 Select the function with or and confirm with .
Symbol Function
1. Engine
2. Transmission
3. Power transmission
4. Brakes
015623
5. Steering
6. Suspension
7. Load handling
8. Control system
9. Frame, body, cab and accessories
10. Common Hydraulics
11. Common electrics
Pin diagnosis
5 Select group by scrolling with or and confirm with .

015627
6 Select DIAGNOSE with or and confirm with .

016048
7 Each menu group consists of a sequence of menus. The first

menu for the selected group opens in the display. Use the arrow
keys or to move to the desired menu.
8 Use the function key MAN to manually control the output shown
in the menu. For a description of the menu screen, see Menu
example, description, page 8:20.
All signal values in the menu figures are examples and may
differ from the values shown in an actual machine.
NOTE
Example of first menu in group Current values can only be adjusted within specific limits.

8:20 8 Control system – Diagnostics
Menu example, description
1 All diagnostic menu, except for the pin diagnostics, are explained
2 3
separately.
– Menu group, enter the group, 2.8 Control System, whose signals
provides a basis for diagnosis. The menus are subdivided into the
same function groups as the manuals.
8 – Sequence number, 2/XX, enter the page number and total number
4 of menus in the menu loop. As the number of menus is dependent
on how the machine is equipped, state the number of menus here
with XX.
– Diagnose indicates in the menu example that diagnosis is the
015873
selected setting function. Other settings functions are Initiate for
7 5 setting and Calibrate for calibration.
6
– Variables, such as row 1 Current gear position, describe the
1. Menu group function/component that the signal/measurement comes from.
Each menu can contain 1-6 rows, where each row describes a
2. Sequence number variable with an associated signal value.
3. Selected setting function – Signal value, 0, is the current value for Current gear position.
4. Signal values All signal values in the menu figures in this manual are
5. Function key LEAVE/Cancel examples and may differ from the values in a real machine.
6. Arrow keys The following icons are used to explain further the signal values:
7. Function key Manual mode/Edit mode denotes a saved value.
8. Variables denotes an output value from an output from a control unit.
denotes an input value which is measured by a control unit.
Explanation of pin status codes

Variables of the pin status type can have the following values:
Code Explanation
OK There is no error
O.C Open circuit
S.C Short circuit
O.C/S.C Open or short circuit
Other Other error
CfgErr Configuration error

8 Control system – Engine 8:21
8.4.1 Engine
8.4.1.1 Diagnostic menus Controls and instruments
engine
1.1 Controls & Instr 1/XX DIAGNOSE
Row 1 shows signal A from the accelerator pedal (R6900).
Row 2 shows the value on row 1 converted into % of the total possible
value.
Row 3 shows signal B from the accelerator pedal (R6900).
Row 4 shows the value on row 3 converted into % of the total possible
value.
Row 5 shows the requested pedal outcome in %.
Row 6 shows the requested speed to the engine via the accelerator
pedal.

Row 1 shows the requested engine speed.
It is possible to set the engine speed on row 1, Requested engine
speed (TSC1). See Navigation of menus, description, page 8:4
for an explanation how settings are made.
Row 2 shows the true engine speed from the engine via CAN bus
(EEC1).
8.4.1.2 Diagnostic menus Fuel system

1.2 Fuel System 1/XX DIAGNOSE
Row 1 shows the signal from the fuel level sensor (B7570).
Row 2 shows the amount of fuel in %.
Row 3 shows the amount of fuel in litres.
1.2 Fuel System 2/XX DIAGNOSE

Row 1 shows the current fuel consumption.
Row 2 shows the average fuel consumption since the engine was
started.
This value is reset every time the engine is started.
Row 3 shows the average fuel consumption.
Row 4 shows resetting of the value for average fuel consumption.

It is possible to reset average fuel consumption. Change to 0 in row
4, Reset average fuel consumption. See Navigation of menus,
description, page 8:4 for an explanation how settings are made.

8:22 8 Control system – Engine
8.4.1.3 Diagnostic menus Exhaust cleaning
1.3 Aux Exhaust Clean 1/XX Diagnose
Row 1 shows the signal from sensor, exhaust back pressure (B7572).
Row 2 shows current exhaust back pressure as a percentage of

permitted maximum pressure.
Row 3 shows highest measured exhaust back pressure as a

percentage of permitted maximum pressure.
Row 4 shows engine speed limitation due to exhaust back pressure.
8.4.1.6 Diagnostic menus Air intake and exhaust outlet
1.6 Intake Exhaust 3/XX DIAGNOSE

Row 1 shows the input intake temperature.
Row 2 shows the input pressure.
1.6 Intake Exhaust 4/XX DIAGNOSE
Row 1 describes signals for the emission control system.
Row 2 shows fuel level in AdBlue tank in %.
Row 3 shows temperature in AdBlue tank.
Row 4 shows the status for the exhaust cleaning system.

3 = Reduced engine power.
4 = Advance warning of serious error for AdBlue additive.
5 = Serious error for AdBlue additive.
6 = Temporary disengagement of AdBlue additive.
Row 5 shows setting for fixed warning for low AdBlue level.
0 = No flashing.
1 = Fixed warning.
Row 6 shows setting for flashing warning for low AdBlue level.
0 = No flashing.
1 = Flashing warning (1 Hz).

8.4.1.7 Diagnostic menus Cooling system

1.7 Cooling system 4/XX DIAGNOSE
Row 1 describes Visco clutch (M6580).
Row 2 shows the requested pulse length.
It is possible to set the pulse length on row 2, Requested duty
cycle. See Navigation of menus, description, page 8:4 for an
explanation how settings are made.
Row 3 shows the required voltage in relation to the battery voltage.
Row 4 shows the true current.
Row 5 shows the pin status. See Explanation of pin status codes, page
8:20 for an explanation of pin status.
Row 6 shows the calculated impedance.

Row 1 shows need of drive for the engine cooling fan. 100% means
that fan rotation speed = engine rpm.
It is possible to set the drive need in row 1, Cool. required. See
Navigation of menus, description, page 8:4 for an explanation how
settings are made.
Row 2 shows the requested rotation speed.
Row 3 shows requested pulse length for Visco clutch (M6580).
Row 4 shows measured frequency from Visco clutch (M6580).
Row 5 shows the cooling fan's calculated rpm based on measured
frequency.
Row 6 shows engine speed.

Row 1 describes Cooling fan intercooler (M6590).
Row 3 shows the required voltage in relation to the battery voltage.

Row 1 shows need of drive for Cooling fan intercooler (M6590).
It is possible to set the drive need in row 1, Cool. required. See
settings are made.
Row 2 shows requested pulse length for Cooling fan intercooler
(M6590).
Row 3 shows actual pulse length for Cooling fan intercooler (M6590).
Row 5 shows the cooling fan's calculated rpm based on pulse length.
Row 6 shows status for Cooling fan intercooler left (M6590-LE).
Row 6 shows status for Cooling fan intercooler right (M6590-RI).


Row 1 shows outside temperature.
Row 2 shows the engine's coolant temperature.
Row3 shows the transmission's oil temperature.
Row 4 shows the intake temperature.
Row 5 shows the engine's turbo pressure.

Row 1 describes cooling fan, intercooler.
Row 2 shows fan reversing request.
It is possible to activate fan reversing on row 2, Fan reversing
request. See Navigation of menus, description, page 8:4 for an
0 = normal, anticlockwise as seen from the rear of the truck.
1 = reverse.
Row 3 shows whether the fan reversing procedure is activated
0 = Not activated.
1 = fan turning activated.
Row 4 shows requested pulse length for Cooling fan intercooler

(M6590).
Row 5 shows the cooling fan's calculated rpm based on pulse length.
Positive value indicates rpm in normal direction, negative value
indicates rpm with turned direction

Applies to Volvo TAD572VE and TAD871VE.
Row 1 shows outside temperature (sensor for engine).
Row 2 shows the engine's coolant temperature.
Row3 shows the transmission's oil temperature.
Row 4 shows charge air temperature after the intercooler.
Row 5 shows the intake temperature.
Row 6 shows the engine's turbo pressure.
8.4.1.8 Diagnostic menus Lubrication system

1.8 Lubrication 1/XX DIAGNOSE
Row 1 shows the oil pressure.
Row2 shows the oil temperature.

8.4.1.9 Diagnostic menus, Control system, engine
1.9 Control System 1/XX DIAGNOSE

Row 2 shows the true engine speed.
Row 3 shows the true torque in % from the engine (EEC1).
Row 4 shows % load at the current speed (EEC2).
Row 5 shows the nominal friction torque in % from the engine (EEC3).
Row 6 shows the engine's maximum reference torque at a specific

speed (EC1).

Row 1 shows the engine's total operating time in hours.
Row 2 shows the battery voltage in the engine's control computer.
Row 3 shows the alternator's charging status.

0 = not charging
1 = charging

Applies to Volvo
Row 1 shows accelerator pedal position.
Row 2 shows requested engine speed limitation.
Row 3 shows actual engine speed limitation.
Row 4 shows requested torque limitation.

Applies to Cummins
Row 1 shows accelerator pedal position.
Row 2 shows requested engine speed limitation.
Row 3 shows actual engine speed limitation.
Row 4 shows requested torque limitation.

8.4.1.11 Diagnostic menus Start and stop
1.11 Start & Stop 1/XX DIAGNOSE

Applies to Cummins
Row 1 shows the input for the start button (S1051).

0 = start button not active.
1 = start button active.
It is possible to set the output signal for the starter relay on row
2, Starter relay output K3600 C1p43 D7971. See Navigation
of menus, description, page 8:4 for an explanation of how the
settings are made.
0 = starter motor not active.
1 = starter motor active.
Row 3 shows the true current to the relay.
Row 5 shows the input start immobiliser (K3300).

0 = start immobiliser active, engine will not start.
1 = start immobiliser not active.

Applies to Volvo
Row 1 shows the input for the start button (S1051).

0 = start button not activated.
1 = start button activated.
Row 2 shows VP status (applies to Volvo engines)

It is possible to set the output signal to the starter relay on row 2,
Start request on CAN message VP Status. See Navigation of
menus, description, page 8:4 for an explanation how settings are
made.
0 = Not activated to start.
1 = request to start.
Row 3 shows the request to stop the engine.

0 = not stop the starter motor.
1 = stop starter motor.
Row 4 shows the input start immobiliser (K3300).

0 = start immobiliser active, engine will not start
1 = start immobiliser not active


Row 1 shows automatic start and stop function.
Row 2 shows whether automatic start and stop function is available

on the machine.
It is possible to set activate automatic start and stop function in
row 2, Function available. See Navigation of menus, description,
page 8:4 for an explanation how settings are made.
0 = Automatic start and stop function not available.
1 = Automatic start and stop function available.
Row 3 shows whether the conditions for auto-stop are fulfilled

(prepared to auto-start).
0 = Engine not auto-stopped.
1 = Engine auto-stopped.
Row 4 shows status for temperature of engine, transmission, hydraulics

and in the cab.
0 = Temperatures too low for automatic start and stop function.
1 = Temperatures for automatic start and stop function reached.
Row 5 shows status for charge level of batteries.

0 = Charge level too low for automatic start and stop function.
1 = Charge level for automatic start and stop function reached.

Row 1 shows automatic start and stop function.
Row 2 shows whether the engine is running.

0 = Engine stopped.
1 = Engine running.
Row 3 shows whether the parking brake is applied.

0 = Parking brake not applied.
1 = Parking brake applied.
Row 4 shows whether the parking brake is released.

0 = Parking brake not released.
1 = Parking brake released.
Row 5 shows countdown timer to auto-stop. How quick the countdown

is depends on the set time for the auto-stop timer. Long time means
that the counter is counting slowly.

8:28 8 Control system – Transmission

Row 1 shows whether the automatic stop function is available on the
machine. (Automatic stop function means that the engine is switched
off automatically, starting must take place manually.) Automatic stop
function is always active in ECO mode.
It is possible to set activate the automatic stop function in row 2,
Function available. See Navigation of menus, description, page
8:4 for an explanation how settings are made.
0 = Automatic stop function not available.
1 = Automatic stop function available.
Row 2 shows whether the conditions for auto-stop are fulfilled.

0 = Engine not auto-stopped.
1 = Engine auto-stopped.
Row 3 shows status for temperature of engine, transmission, hydraulics

and in the cab.
0 = Temperatures too low for auto-stop.
1 = Temperatures for auto-stop reached.
Row 4 shows status for charge level of batteries.

0 = Charge level too low for auto-stop.
1 = Charge level for auto-stop reached.
Row 5 shows whether the engine has been auto-stopped by means of

the parking brake being applied.
0 = Charge level too low for auto-stop.
1 = Charge level for auto-stop reached.
Row 6 shows countdown timer to auto-stop. How quick the countdown

is depends on the set time for the auto-stop timer. Long time means
that the counter is counting slowly.
8.4.2 Transmission
transmission

Row 1 describes the input signals from the travel direction selector
(S1310 or S1310-2).
Row 2 shows the input parking brake.
Row 3 shows the input forward.
Row 4 shows the input neutral.
Row 5 shows the input centre.
Row 6 shows the input reverse.

8 Control system – Transmission 8:29

Row 1 describes the control system's request to the transmission.
Row 2 shows the request forward.
Row 3 shows the request neutral.
Row 4 shows the request reverse.

Row 1 shows the shifting position.
0 = manual.
1 = automatic.
Row 2 shows the input signal from Switch, automatic/manual shifting

(S1790).
0 = Not activated.
1 = Activated.
Row 3 shows the input signal from Switch, manual shifting down
(S1350-1).
0 = Not activated.
1 = Activated.
Row 4 shows the input signal from Switch, manual shifting up

(S1350-2).
0 = Not activated.
1 = Activated.
Row 5 shows the requested gear, +/- 125.
Row 6 shows the current gear +/- 125.
8.4.2.2 Diagnostic menus Torque converter/clutch
2.2 Torq Conv Clutch 1/XX DIAGNOSE

Row 1 describes declutching (CCO clutch cut off).
Row 2 shows the brake pressure.
Row 3 shows the brake pressure when declutching.
Row 4 shows whether declutching is activated.

0 = drive engaged.
1 = transmission disengaged.
Row 5 shows the transmission's current gear.

0 = neutral.
positive value = forward.
negative value = reverse.

2.2 Torq Conv Clutch 3/XX DIAGNOSE

Applies to Dana LTE144xx
Row 1 describes locking of the torque converter (Lock-Up).
Row 2 shows request for locking the torque converter.

0 = Disengage torque converter.
1 = Lock torque converter (Lock-Up).
Row 3 shows status for locking of drive.

0 = Torque converter disengaged.
1 = Torque converter locked Lock-Up).
Row 4 shows the current gear.

0 = neutral.
positive value = forward.
negative value = reverse.
8.4.2.6 Diagnostic menus Lubrication system
2.6 Lubrication Sys 1/XX DIAGNOSE

Row 1 shows the oil temperature in the transmission.
8.4.2.8 Diagnostic menus Control system,

transmission

Row 1 shows the current gear position. A positive value means a
forward gear is selected, a negative value means a reverse gear is
selected.
Row 2 shows operating mode 0-7.
Row 3 shows whether an error has occurred.

0 = There is no error.
1 = There is an active error, see the error code list and HMI menu
for more detailed information.
Row 4 shows the torque converter's input torque on the engine side
Row 5 shows the torque converter's output torque in the transmission
Row 6 shows the speed ratio turbine speed divided by engine speed. A
value that is lower than 1.0 means acceleration, a value that is greater
than 1.0 means braking.


Row 1 shows whether manual shifting is selected for the transmission.
0 = manual shifting.
1 = Automatic shifting.
Row 2 shows whether the warning from the transmission is active.

0 = Normal operation.
1 = Warning active.
Row 3 shows whether shifting is in progress.

0 = Gear selected.
1 = Shifting in progress.

Row 1 shows rotation speed from Sensor engine speed (B7530).
Row 2 shows rotation speed from Sensor rpm turbine (B7510).
Row 3 shows rotation speed from Sensor rpm inner transfer shaft
(B7520).
Row 4 shows rotation speed from Sensor rpm output shaft (B7580)
Row 5 shows machine speed in km/h.

Row 1 shows CAN bus message TSC1 from Control unit transmission
(D7930).
Row 2 shows status for control request from Control unit transmission
to Control unit engine.
0 = No control.
1 = Rotation speed control.
2 = Torque control.
3 = Rotation speed and torque limitation.
Row 3 shows conditions for control request from Control unit

transmission to Control unit engine.
0 = Response mode, optimised for neutral position and drive
without lock-up.
1 = Stability mode, optimised for neutral position and drive without
lock-up.
2 = Stability mode, optimised for drive with/without lock-up
operating mode 1.
3 = Stability mode, optimised for drive with/without lock-up
operating mode 2.
Row 4 shows priority degree for control request from Control unit
transmission to Control unit engine.
0 = Top priority.
1 = High priority.
2 = Intermediate priority.
3 = Low priority.
Row 5 shows requested rotation speed limit.
Row 6 shows requested torque limit.


Row 1 shows status for pressure sensor drive forward (B7653).
0 = OK.
1 = Error.
Row 2 shows status for pressure sensor drive backward (B7654).

0 = OK.
1 = Error.
Row 3 shows status for pressure sensor gear 1/3 (B7651).

0 = OK.
1 = Error.
Row 4 shows status for pressure sensor gear 2/4 (B7652).

0 = OK.
1 = Error.
Row 5 shows status for temperature sensor sump (B7660).

0 = OK.
1 = Error.
Row 5 shows status for temperature sensor torque converter (B7661).

0 = OK.
1 = Error.

Row 1 shows status for Solenoid valve gear selection 1/3 (Y6075).
0 = Deactivated.
1 = Shifting in progress or gear selected.
Row 2 shows status for Solenoid valve gear selection 2/4 (Y6096).
0 = Deactivated.
Row 3 shows ignition voltage for Control unit, transmission (D7930).

0 - 50000.6 mV = Normal operation.
254000.0 mV = Voltage error.
255000.0 mV = Not available
Row 4 shows battery voltage for Control unit, transmission (D7930).

0.0 – 50000.6 mV = Normal operation.
Row 5 shows voltage feed to the speed sensor from Control unit,
transmission (D7930).
0.0 – 50000.6 mV = Normal operation.


Row 1 shows status for Servo valve drive forward (Y6300).
0 = Deactivated.
Row 2 shows status for Servo valve drive backward (Y6310).

0 = Deactivated.
Row 3 shows status for Servo valve gear 1/3 (Y6067).

0 = Deactivated.
Row 4 shows status for Servo valve gear 2/4 (Y6069).

0 = Deactivated.
Row 5 shows status for Servo valve lock-up (Y6038).

0 = Deactivated.

Row 1 shows pressure from Pressure sensor drive forward (B7653) in
bar.
Row 2 shows pressure from Pressure sensor drive backward (B7654)

in bar.
Row 3 shows pressure from Pressure sensor gear 1/3 (B7651) in bar.
Row 4 shows pressure from Pressure sensor gear 2/4 (B7652) in bar.
Row 5 shows impedance for Sensor oil temperature (B7660) in ohm.
Row 6 shows impedance for Sensor oil temperature torque converter

(B7661) in ohm.

Row 1 shows the temperature from Sensor oil temperature (B7660)
in °C.
Row 2 shows the temperature from Sensor oil temperature torque

converter (B7661) in °C.

8:34 8 Control system – Brakes

Row 1 shows control current for Servo valve drive forward (Y6300)
in mA.
0 – 1012 mA = Normal operation.
1016 = Fault on output.
1020 = Not available.
Row 2 shows control current for Servo valve drive backward (Y6310)
in mA.
Row 3 shows control current for Servo valve gear 1/3 (Y6067) in mA.
Row 4 shows control current for Servo valve gear 2/4 (Y6069) in mA.
Row 5 shows control current for Servo valve lock-up (Y6038) in mA.
8.4.4 Brakes
8.4.4.3 Diagnostic menus Power-assisted brake
system
4.3 Power Assisted 3/XX DIAGNOSE
Row 1 shows the signal from the brake pressure sensor (B7681).
Row 2 shows the brake pressure.
Row 3 shows the signal from accumulator pressure sensor (B7683).
Row 4 shows the accumulator pressure.
4.3 Power Assisted 4/XX DIAGNOSE

Row 1 shows the signal from the accumulator pressure sensor (B7683).
Row 3 shows the requested speed limitation.
Row 4 shows the requested gear limitation.

8 Control system – Brakes 8:35
8.4.4.5 Diagnostic menus Parking brake system

4.5 Park Brake Sys 1/XX DIAGNOSE
Row 1 describes the parking brake system.
Row 2 shows whether the standard travel direction selector (S1310)

is in the parking brake position.
0 = not in position.
1 = in parking brake position.
Row 3 shows whether the travel direction selector (S1310) is in the

centre position.
0 = not in position.
1 = in centre position.
Row 4 shows whether the brake pressure is OK, when the pressure is
so high that the parking brake may be released.
0 = not OK.
1 = OK.

It is possible to release the parking brake on row 4, Parking brake
released. See Navigation of menus, description, page 8:4 for an
0 = not released.
1 = released.

Row 1 shows status for the output to Solenoid valve parking brake
(Y6420).
It is possible to set the signal for the output on row 1, Output
Y6420 C1p17 D7971. See Navigation of menus, description, page
8:4 for an explanation of how the settings are made.
0 = no signal.
1 = signal.
Row 2 shows the digital output current.
Row 3 shows the pin status for the output. See Explanation of pin
status codes, page 8:20 for an explanation of pin status.
Row 4 shows the signal from the parking brake sensor (B7682).
Row 4 shows the pressure for parking brake caliper.

0 = not released.
1 = released.

Row 1 describes the parking brake system.

0 = not released.
1 = released.

8:36 8 Control system – Suspension
8.4.6 Suspension
8.4.6.3 Diagnostic menus Tyres and rims
6.3 Tyres and Rims 1/XX Diagnose
Row 1 describes Sensor tyre pressure left front outer (B9130-1).
Row 2 shows tyre pressure in bar.
Row 3 shows 99 as fixed value, this is not an actual tyre temperature.
Row 4 shows the status for the sensor.

0 = No contact with the control unit.
1 = Data sent.
Row 5 shows the status for the tyre.

0 = OK.
1 = Air leak detected.
2 = Error.
Row 6 shows combined status for tyre and sensor.

0 = OK.
1 = Low battery voltage (replace sensor).
2 = Error.
Row 1 describes Sensor tyre pressure left front inner (B9130-2).

1 = Data sent.

0 = OK.
2 = Error.

0 = OK.
2 = Error.

8 Control system – Suspension 8:37
Row 1 describes Sensor tyre pressure right front inner (B9130-3).

1 = Data sent.

0 = OK.
2 = Error.

0 = OK.
2 = Error.
Row 1 describes Sensor tyre pressure right front outer (B9130-4).

1 = Data sent.

0 = OK.
2 = Error.

0 = OK.
2 = Error.

8:38 8 Control system – Suspension
Row 1 describes Sensor tyre pressure left rear (B9130-5).

1 = Data sent.

0 = OK.
2 = Error.

0 = OK.
2 = Error.
Row 1 describes Sensor tyre pressure right rear (B9130-6).

1 = Data sent.

0 = OK.
2 = Error.

0 = OK.
2 = Error.
Row 1 describes serial number of sensors for tyre pressure monitoring

on front wheels.
Row 2 shows serial number for Sensor tyre pressure left front outer
(A9130-1).
Row 3 shows serial number for Sensor tyre pressure left front inner
(A9130-2).
Row 4 shows serial number for Sensor tyre pressure right front inner
(A9130-3).
Row 5 shows serial number for Sensor tyre pressure right front outer
(A9130-4).

8 Control system – Load handling 8:39
Row 1 describes serial number of sensors for tyre pressure monitoring

on rear wheels.
Row 2 shows serial number for Sensor tyre pressure left rear (A9130-6).
Row 3 shows serial number for Sensor tyre pressure right rear
(A9130-5).
Row 1 shows number of connected sensors for tyre pressure

monitoring.
Row 2 shows message from Control unit tyre pressure monitoring

(A9130).
8.4.7 Load handling

7.1 Controls and Instr 1/XX DIAGNOSE

Applies to linear levers.
The menu shows signals regarding load handling.
Row 1 shows the signal voltage from lever 1 (R8070-1).
Row 2 shows actuation (interpretation of lever position) ±100% from

lever 1.
Row 3 shows the function changing switch on lever 1 (S8070-1).

0 = off.
1 = on.

lever 2.

0 = off.
1 = on.

8:40 8 Control system – Load handling

Applies to linear levers.
The menu shows signals regarding load handling.

lever 3.

0 = off.
1 = on.

lever 4.

0 = off.
1 = on.

Row 1 shows whether the hydraulic functions are activated.
0 = not active.
1 = active.
Row 2 shows the signal from the control breaker (S2500).

0 = not activated.
1 = activated.
Row 3 shows the driver in seat sensor (B2300).

0 = driver not in seat.
1 = driver in seat.
Row 4 shows the signal from the bypass switch (S1005).

0 = not bypassed.
1 = bypassed.
Row 5 shows whether the hydraulic functions are reduced.

0 = not reduced.
1 = reduced.
Reduced hydraulic function means that the value of the levers is
restricted to 50% movement speed.
It is possible to use the reduced hydraulic functions when row 3=0
and row 4=1.

Applies to control lever.
Row 1 describes Control lever (S8150).
Row 2 shows the position on the X-axis with the help of signals from
potentiometer (R8070-2).
Row 3 shows control lever actuation as a percentage.
Row 4 shows the position on the Y-axis with the help of signals from
Row 5 shows control lever actuation as a percentage.


Row 1 describes the thumb control on Control lever (S8150).
Row 2 shows the position on the X-axis with the help of signals from
Row 3 shows thumb lever actuation as a percentage.
Row 4 shows the position on the Y-axis with the help of signals from
Row 5 shows thumb lever actuation as a percentage.

Row 1 describes the buttons on Control lever (S8150).
Row 2 shows signal from Switch shift button (S1991) (alternative

function).
0 = not activated.
1 = activated.
Row 3 shows the signal from Switch, horn (S1490).

0 = not activated
1 = activated
Row 4 shows the signal from Switch, open twistlocks (S1020).

0 = not activated.
1 = activated.
Row 5 shows the signal from Switch, levelling lock (S1037).

0 = not activated.
1 = activated.
Row 6 Not used.

0 = not activated.
1 = activated.
8.4.7.2 Diagnostic menus Lifting/lowering
7.2 Lifting Lowering 1/XX DIAGNOSE

Row 1 shows the output to the lift solenoid valve (Y6005). Output
actual current in % of max. current that is set in Initiation, see 7.2
Lifting Lowering 2/XX INITIATE, page 8:105.
Row 2 shows the requested current.

It is possible to set the current on row 2 manually, Requested
current. See Navigation of menus, description, page 8:4 for an
Row 6 shows the pulse length. Pulse length in % of the battery voltage
is another measure of how much the valve is operated.


Row 1 shows the output to the lower solenoid valve (Y6004). Output
actual current in % of max. current that is set in Initiation, see 7.2
Lifting Lowering 4/XX INITIATE, page 8:106.
Row 6 shows the pulse length.
Row 1 describes controlling blocking valves for the lift cylinders.

Row 2 shows status for activation
0 = blocking valves not activated (lift cylinders blocked).
1 = blocking valves activated (lowering possible).
Row 3 shows actual current to Solenoid valve blocking left (Y6045-LE).
Row 4 shows pin status for the output to Solenoid valve blocking left
(Y6045-LE). See Explanation of pin status codes, page 8:20 for an
explanation of pin status.
Row 5 shows actual current to Solenoid valve blocking left (Y6045-RI).
Row 6 shows pin status for the output to Solenoid valve blocking left
(Y6045-RI). See Explanation of pin status codes, page 8:20 for an
explanation of pin status.
Row 1 shows signal voltage from Sensor lifting height (B7228).

Row 2 shows height to contact position for twistlocks or hooks.
Row 3 shows current total height for the mast.

Row 1 shows status for Sensor end position lift (B7211).

8.4.7.4 Diagnostic menus Side shift
7.4 Side Shift 3/XX DIAGNOSE

Row 1 shows the output to Solenoid valve, side shift right (Y6021).
Output actual current in % of max. current that is set in Initiation, see
7.4 Side Shift 6/XX INITIATE, page 8:107.

7.4 Side Shift 4/XX DIAGNOSE

Row 1 shows the output to Solenoid valve, side shift left (Y6020).
7.4 Side Shift 8/XX INITIATE, page 8:108.

8.4.7.5 Diagnostic menus Spreading
7.5 Spreading 7/XX DIAGNOSE

Row 1 describes switch for the spreading function.
Row 2 shows signal from Switch extra stop spreading (S1004).

0 = Not activated.
1 = Activated.
Row 3 shows the signal from Switch automatic spreading 20'-40'

(S1012-2).
0 = Not activated.
1 = Activated.
Row 4 shows the signal from Switch, spreading (S1012).

0 = Not activated.
1 = activated (spreading in).
Row 5 shows the signal from Switch, spreading (S1012).

0 = Not activated.
1 = activated (spreading out).


Row 1 describes position sensor for the spreading function.
Row 2 shows signal from Sensor end position 20'–40' left (B7690-LE),
controls damping end position and stop extra position .
0 = Not activated.
1 = Activated.
Row 3 shows signal from Sensor extra stop spreading left (B7770-LE),
controls stop end position and damping extra position .
0 = Not activated.
1 = Activated.
Row 4 shows signal from Sensor end position 20'–40' right (B7690-RI),
controls damping end position and stop extra position .
0 = Not activated.
1 = Activated.
Row 5 shows signal from Sensor extra stop spreading right (B7770-RI),
controls stop end position and damping extra position .
0 = Not activated.
1 = Activated.

Row 1 shows the output to Solenoid valve, spreading left out
(Y6018-LE).Output actual current in % of max. current that is set in
Initiation, see 7.5 Spreading 20/XX INITIATE, page 8:109.


Row 1 shows the output to Solenoid valve, spreading left in (Y6019-LE).
7.5 Spreading 23/XX INITIATE, page 8:110.



Row 1 shows the output to Solenoid valve, spreading right out
(Y6018-RI). Output actual current in % of max. current that is set in


Row 1 shows the output to Solenoid valve, spreading right in
(Y6019-RI). Output actual current in % of max. current that is set in


Row 1 describes buzzer for automatic spreading 20'–40'.
Row 2 shows the requested output signal.

It is possible to manually activate the buzzer on row 2, Requested
output. See Navigation of menus, description, page 8:4 for an
0 = Not activated.
1 = activated, buzzer active.
Row 3 shows actual current to Buzzer automatic spreading 20'–40'

(H9003).

8.4.7.7 Diagnostic menus Tilt
7.7 Tilt 1/XX DIAGNOSE

Row 1 shows the output for tilt in solenoid valve (Y6011). Output actual
current in % of max. current that is set in Initiation, see 7.7 Tilt 2/XX
INITIATE, page 8:113.


Row 1 shows the output for tilt out solenoid valve (Y6010). Output
actual current in % of max. current that is set in Initiation, see 7.7 Tilt
4/XX INITIATE, page 8:114.

Row 1 shows the signal from the tilt angle sensor (B7229).
Row 2 shows the true angle.

8.4.7.9 Diagnostic menus Load carrier
7.9 Load Carrier 3/XX DIAGNOSE

Row 1 describes twistlocks.
Row 2 shows the signal from Switch, lock twistlocks (S1003).

0 = Not activated.
1 = Activated.
Row 3 shows signal from Switch open twistlocks (S1002) or Switch

open/clamp function (S1020).
0 = Not activated.
1 = Activated.

Row 1 describes Solenoid valve lock twistlocks (Y6040).
Row 2 shows status for the output.

It is possible to manually activate the solenoid valve on row 2,
Requested output. See Navigation of menus, description, page
0 = Not activated.
1 = activated (open twistlocks).

Row 1 describes Solenoid valve open twistlocks (Y6039).

0 = Not activated.
1 = activated (lock twistlocks).

Row 1 describes Indicator light, locked twistlocks (H5630-1).

It is possible to manually activate the indicator light in row 2,
0 = Not activated.
1 = activated (lamp illuminated).


Row 1 describes Indicator light, open twistlocks (H5620-1).

0 = Not activated.

Row 1 describes Indicator light, contact twistlocks (H5640-1).

0 = Not activated.

Row 1 describes the ground signal to the indicator lights on the
attachment. Ground signal pulse length is controlled in order to
increase and decrease the brightness of the indicator lights.

It is possible to manually set the pulse length on row 2, Requested
duty cycle C2p35 D7911. See Navigation of menus, description,
page 8:4 for an explanation of how the settings are made.
Row 3 shows the requested voltage.

Row 1 describes Indicator light, locked twistlocks (H5630-2).

0 = Not activated.


Row 1 describes Indicator light, open twistlocks (H5620-2).
0 = Not activated.

Row 1 describes Indicator light, contact twistlocks (H5640-2).
0 = Not activated.
Row 1 describes Sensor damping attachment (B7230).

Row 2 shows input signal from Sensor, damping attachment (B7230) in
mV.
Row 3 shows recalculated distance to container in mm.
Row 4 shows status for damping of lower function.
0 = No damping.
1 = Damping active.

Row 1 describes status for sensor contact.
Row 2 shows status for Sensor contact left (B7202-LE):
0 = Not activated.
1 = Activated.
Row 3 shows status for Sensor contact right (B7202-RI):
0 = Not activated.
1 = Activated.
Row 4 shows status for Sensor float position lifting head left
(B7216-LE):
0 = Not activated.
1 = Activated.
Row 5 shows status for Sensor float position lifting head right
(B7216-RI):
0 = Not activated.
1 = Activated.


Row 1 describes sensor twistlocks left.
Row 2 shows the voltage signal from Sensor, twistlocks left (B7205-LE).
Row 3 shows status for the locked position.

0 = Not activated.
1 = activated (twistlock locked).
Row 4 shows status for the open position.

0 = Not activated.
1 = activated (twistlock open).
Row 5 shows current position of twistlocks (angle degrees).

Row 1 describes sensor twistlocks right.
Row 2 shows the voltage signal from Sensor, twistlocks right

(B7205-RI).
Row 3 shows status for the locked position.

0 = Not activated.
Row 4 shows status for the open position.

0 = Not activated.
Row 5 shows current position of twistlocks (angle degrees).

Row 1 describes sensor twistlocks.
Row 2 shows status for locked position twistlocks left rear or left.
0 = Not activated.
Row 2 shows status for open position twistlocks left rear or left.
0 = Not activated.
Row 1 describes sensor twistlocks.
Row 2 shows status for locked position twistlocks right rear or right.
0 = Not activated.
Row 2 shows status for open position twistlocks right rear or right.
0 = Not activated.

8.4.8 Control system


Row 1 describes control of the searchlights in the panels.
Row 2 describes Sensor, ambient brightness (B7252).
Row 3 shows the input signal from Sensor, ambient brightness (B7252).
Row 4 describes the drive-train/wiper control panel (A3700-02).

It is possible to manually control the pulse length (brightness) on
row 5, Requested duty. See Navigation of menus, description,

Row 1 describes control of the function lights in the panels.
Row 4 describes the drive-train/wiper control panel (A3700-02).


Row 1 describes control of the searchlight on the switch.
Row 4 describes output signal to searchlight in switch.


8:52 8 Control system – Control system
8.4.8.2 Diagnostic menus, monitoring

8.2 Monitoring 1/XX DIAGNOSE
Row 1 shows the speed limitation request. The value 99.9 kph means
that there is no speed limitation.
Row 2 shows the gear limitation request.
Row 3 shows the speed limitation request.
Row 4 shows whether speed limitation is activated.

0 = Not activated.
1 = Activated.
Row 4 shows the torque limitation request.
Row 5 shows whether torque limitation is activated.

0 = Not activated.
1 = Activated.

Row 1 shows settings for ECO Drive Mode.
Row 2 shows set ECO mode.

It is possible to manually set ECO mode on row 2 Mode selected.
See Navigation of menus, description, page 8:4 for an explanation
how settings are made.
1 = Maximum output.
2 = Normal.
3 = ECO mode.
Row 3 shows the speed limitation request. It is possible to manually

activate speed limitation only on row 3, Vehicle speed limit request.
See Navigation of menus, description, page 8:4 for an explanation how
settings are made.
Row 1 shows the signal from the hydraulic scales sensor (B7226-1).
Row 2 shows the lift pressure.
Row 3 shows lift area (total cylinder area).
Row 4 shows the ratio in the mast.
Row 5 shows the tare weight, stored value from calibration.
Row 6 shows the load weight.

Row 1 shows the number of hours remaining to the next service
interval.
Row 2 shows the number of hours when restoring a new service

interval.

Row 1 describes the overload system for lifting.
Row 2 shows over which threshold level the alarm system triggers.
Row 3 shows under which threshold level the alarm system stops.
Row 4 shows the true load.
Row 5 shows overloading.

0 = not overloaded.
1 = overloaded.
Row 6 shows the signal regarding cutting lift and tilt in

0 = does not cut.
1 = cuts lift and tilt in.
Row 1 describes the overload system for lifting.
Row 2 shows over which threshold level the alarm system triggers.
Row 3 shows under which threshold level the alarm system stops.
Row 4 shows the true load.
Row 5 shows overloading.

0 = not overloaded.
1 = overloaded.

Row 1 describes the overload system
Row 2 shows over which threshold level the lift system starts.
Row 3 shows over which threshold level the tilt system starts.
Row 4 shows the signal from the sensor which give reduced capacity,
overload protection (B7685).

Row 1 shows the threshold value for lift in the overload system, over
which the system triggers an alarm.
Row 2 shows the threshold value for tilt, over which the system triggers
an alarm.
Row 3 shows the true lift height.
Row 4 shows the height, for reduced capacity level 2.


Row 1 describes the overload system.
Row 2 shows the threshold speed below which the overload system is
active.
Row 4 shows the current vehicle speed.

Row 1 describes hydraulic load sensor.
Row 2 describes pressure sensors.
Row 3 shows the signal from Sensor lift cylinder piston side left
(B7226-1).
Row 4 shows the signal from Sensor lift cylinder rod side left (B7226-3).
Row 5 shows the signal from Sensor lift cylinder piston side right
(B7226-2).
Row 6 shows the signal from Sensor lift cylinder rod side right
(B7226-4).

Row 1 describes hydraulic load sensor.
Row 2 describes pressure sensors.
Row 3 shows the recalculated signal from Sensor lift cylinder piston
side left (B7226-1).
Row 4 shows the recalculated signal from Sensor lift cylinder rod side
left (B7226-3).
Row 5 shows the recalculated signal from Sensor lift cylinder piston
side right (B7226-2).
Row 6 shows the recalculated signal from Sensor lift cylinder rod side
right (B7226-4).
Speed limitation, weight.
Row 1 shows the weight at which speed limitation 1 is activated.
Row 1 shows the weight at which speed limitation 2 is activated.
Row 3 shows the set speed limitation 1.
Row 4 shows the set speed limitation 2.
Row 5 shows the current speed limitation.
Row 6 shows the machine's speed.

Row 1 shows the current weight.
Row 2 shows whether speed limitation 1 is active.

0 = not active.
1 = active.

0 = not active.
1 = active.
Row 1 shows the current weight.

0 = not active.
1 = active.
Hydraulic scales.
Row 1 shows the signal from Sensor lift cylinder left (B7226-1).
Row 2 shows pressure in left-hand lift cylinder.
Row 3 shows load for left-hand lift cylinder.
Row 4 shows the signal from Sensor lift cylinder right (B7226-2).
Row 5 shows pressure in right-hand lift cylinder.
Row 6 shows load for right-hand lift cylinder.
Hydraulic scales. Applies to machines with duplex mast equipped with

position sensor.
Row 1 shows whether the inner mast is in the upper position.

0 = lower position.
1 = upper position.
Row 2 shows the area of the lift cylinders.
Row 3 shows the gear ratio of the lifting mast.
Row 4 shows the saved tare weight.
Row 5 shows the current load.

8:56 8 Control system – Frame, body, cab and accessories
Row 1 shows status for speed limitation for the engine at cold start.
0 = not active.
1 = active.
Row 2 shows the engine speed to which the engine is limited based on
the current coolant temperature.
Row 3 shows the engine speed to which the engine is limited based
on the current transmission oil temperature.
Row 4 shows the engine speed to which the engine is limited based on
the current hydraulic oil temperature.
Row 5 shows the maximum permissible engine speed for the current
temperatures.
Row 1 shows speed limitation depending on drive axle load.
Row 2 shows maximum permitted load for speed limit 1 in kg.
Row 3 shows maximum permitted load for speed limit 2 in kg.
Row 4 shows setting for speed limit 1 in km/h.
Row 5 shows setting for speed limit 2 in km/h.
Row 6 shows current speed limit for machine (the speed can be limited
by other functions in the machine).
8.4.9 Frame, body, cab and accessories

Row 1 shows the signal from the bypass switch (S1005).
0 = Not activated.
1 = Activated.
Row 2 shows bypass active.

It is possible to manually set bypass active on row 2, Override
active. See Navigation of menus, description, page 8:4 for an
0 = Not activated.
1 = activated, bypassed.

Row 1 describes the switch to adjust the steering panel.
Row 2 shows the input for the steering panel up adjustment switch
(S1058-1).
Row 3 shows the input for the steering panel down adjustment switch
(S1058-2).

8 Control system – Frame, body, cab and accessories 8:57

Row 1 describes the adjustment forward/back of the right arm rest.
Row 2 shows the input for right arm rest forward adjustment switch
(S1056-1).
0 = Not activated.
1 = Activated.
Row 3 shows the input for right arm rest back adjustment switch
(S1056-2).
0 =not activated.
1 = Activated.

Row 1 describes the adjustment forward/back of the right arm rest.
Row 2 shows the output for the control motor steering panel
forwards/back (M6941).
0 = not active.
1 = active.
Row 3 shows the direction H-bridge.

It is possible to manually set the H-bridge direction on row 3,
H-bridge direction. See Navigation of menus, description, page
0 = back.
1 = forward.
Row 6 shows the feedback signal for the arm rest length position.

Row 1 describes the height adjustment of the right arm rest.
Row 2 shows the input for right arm rest up adjustment switch
(S1057-1).
Row 3 shows the input for right arm rest down adjustment switch
(S1057-2).


Row 1 describes the height adjustment of the right arm rest.
Row 2 shows the steering motor output, panel up/down (M6942).

0 = not active.
1 = active.
Row 3 shows the direction H-bridge.

It is possible to manually set the H-bridge direction on row 3,
H-bridge direction. See Navigation of menus, description, page
0 = downward.
1 = upward.
Row 6 shows the feedback signal for the arm rest height position.
Row 1 describes key lock for the bypass function.
Row 2 shows the signal from the bypass key switch (S1005-2).
0 = not active.
1 = active.
8.4.9.3 Diagnostic menus Driver's seat
9.3 Seat 1/XX DIAGNOSE

Row 1 shows the input for seatbelt contact (B2250).
0 = seatbelt not fastened.
1 = seatbelt fastened.
Row 2 shows the input for driver in seat contact (B2300).

0 = no driver in seat.
1 = driver in seat.
Row 3 shows an indication that the seatbelt is not fastened.

0 = seatbelt fastened.
1 = seatbelt not fastened.

9.3 Seat 20/XX DIAGNOSE
Row 1 shows Indicator light seat belt (H5991).

0 = Not activated.
1 = activated (seat belt not used).
Row 4 shows the status for the seat belt.
0 = Not activated.
1 = activated (seat belt used).
Row 5 shows status for operator in seat.
0 = Not activated.
1 = activated (operator in seat).
8.4.9.4 Diagnostic menus Air conditioning unit

9.4 Climate System 1/XX DIAGNOSE
Row 1 describes the air conditioning control panel.
Row 2 shows the input for the defroster switch (S1390).
0 = not active.
1 = active.
Row 3 shows the input for the recirculation switch (S1910).
0 = not active.
1 = active.
Row 4 shows the input for the residual heat switch (S1019).
0 = not active.
1 = active.
Row 5 shows the input for the auto air conditioning switch (S1054).
0 = not active.
1 = active.

Row 2 shows the input for the increase fan speed switch (S1180-1).
0 = not active.
1 = increases fan speed.
Row 3 shows the input for the decrease fan speed switch (S1180-2).
0 = not active.
1 = reduce fan speed.
Row 4 shows the input for the increase temperature switch (S1052-1).
0 = not active.
1 = increases temperature.
Row 5 shows the input for the decrease temperature switch (S1052-2).
0 = not active.
1 = lower temperature.


Row 2 shows the input for the roof air distribution switch (S1053-1).
0 = not active.
1 = active.
Row 3 shows the input for the central air distribution switch (S1053-2).
0 = not active.
1 = active.
Row 4 shows the input for the floor air distribution switch (S1053-3).
0 = not active.
1 = active.
Row 5 shows the input for the air conditioning switch (S1120).
0 = not active.
1 = active.

Row 1 describes the temperature sensor.
Row 2 shows input Sensor, ambient temperature (B7740).
Row 3 shows input Sensor, deicing temperature (B7753).
Row 4 shows the input for Sensor, fan temperature (B7752).
Row 5 shows input Sensor, inside temperature (B7751).

Row 1 describes the temperature sensor.
Row 2 shows recalculated signal from Sensor, ambient temperature

(B7740).
Row 3 shows recalculated signal from Sensor, deicing temperature

(B7753).
Row 4 shows recalculated signal from Sensor, fan temperature

(B7752).
Row 5 shows recalculated signal from Sensor, inside temperature

(B7751).

Row 1 describes sensors.
Row 2 shows status for signal from Pressure switch refrigerant (B2460)
within normal interval.
0 = not within the interval.
1 = within the interval.
Row 3 shows status for high-pressure signal from Pressure switch

refrigerant (B2460).
0 = low AC pressure, which results in low fan speed.
1 = AC pressure > 16 bar, which results in max fan speed.
Row 4 shows air filter contact input (B2190).

0 = no signal.
1 = signal, which may indicate a clogged filter.

Row 1 describes temperature control.
Row 2 shows the requested temperature.
Row 3 shows the true temperature from the inside temperature sensor
(B7751).
Row 4 shows the feedback signal for position from Water valve (Y6730).
Row 5 shows recalculated value for position of Water valve (Y6730).

Row 1 describes air distribution control.
Row 2 shows the requested air distribution position 0–6

0= Auto position.
1= Windscreen.
2= Windscreen-Panel.
3= Panel.
4= Panel-Floor.
5= Floor.
6= Floor-Windscreen.
Row 3 shows the true air distribution position.

0= Auto position.
1= Windscreen.
2= Windscreen-Panel.
3= Panel.
4= Panel-Floor.
5= Floor.
6= Floor-Windscreen.
Row 4 shows the feedback signal for position on Damper motor, air
distribution (Y6720).


Row 1 describes signals relating to fan motor (M6570) in the cab.

duty cycle. See Navigation of menus, description, page 8:4 for an

Row 1 describes Actuator motor, recirculation (Y6120).

It is possible to manually set the output signal on row 2, Requested
output (0=recirculate). See Navigation of menus, description,
0 = Recirculated air.
1 = Fresh air.

Row 1 describes Actuator motor, recirculation (Y6120).

Row 1 describes Magnetic clutch, AC compressor (Y6450).

It is possible to manually set the signal on row 2, Requested
0 = Not activated.
1 = Activated.


Row 1 describes opening of Water valve (Y6730).


Row 1 describes closing of Water valve (Y6730).


Row 1 describes opening the Damper motor, air distribution (Y6720).


Row 1 describes closing the Damper motor, air distribution (Y6720).


Row 1 shows the signals from the external heater unit for the cab and
engine heater (E6690).
Row 2 shows whether the function is activated

It is possible to manually activate the function on row 2, Function
Activated. See Navigation of menus, description, page 8:4 for an
0 = Not activated.
1 = Activated.
8.4.9.5 Diagnostic menus Windscreen wipers
9.5 Wiper & Washer Sys 4/XX DIAGNOSE

Row 1 describes the rear windscreen wiper switch.
Row 2 shows the input for the continuous rear windscreen wiper switch
(S1190-RE).
0 = no signal.
1 = switch activated.
Row 3 shows the input for the intermittent rear windscreen wiper switch
(S1520-RE).
0 = no signal.

Row 1 describes Wiper motor rear (M6502).
Row 2 shows output Wiper motor rear (M6502).

It is possible to manually activate the signal on row 2, Output
M6502 C2p17 D7901. See Navigation of menus, description, page
0 = no signal.
1 = signal.
Row 5 describes rear windscreen wiper motor feedback.
Row 6 shows the feedback signal from Wiper motor rear (M6502).
0 = no signal.
1 = signal.


Row 1 describes signals for rear windscreen wiper.
Row 2 shows the input for the washer switch (S1200).
Row 3 shows output Washer motor rear (M6512).

It is possible to manually activate the signal on row 3, Rear washer
motor Out M6512 C2p16 D7901. See Navigation of menus,
description, page 8:4 for an explanation of how the settings are
made.
0 = no signal.
1 = signal.

Row 6 shows status for signal from Contact level, washer fluid (B2991).
0 = no signal.
1 = fluid level OK.

Row 1 describes the front windscreen wiper switch.
Row 2 shows the input for the front windscreen wiper switch
(S1190-FR).
0 = no signal.
1 = signal, switch activated.
Row 3 shows the intermittent front windscreen wiper switch input

(S1520-FR).
0 = no signal.
1 = signal, switch activated.

Row 1 describes the front, left windscreen wipers relay.
Row 2 shows the relay output for front, left windscreen wipers
(K6501-LE).
It is possible to manually activate the signal to row 2, Output
R6501-LE C2p08 D7901. See Navigation of menus, description,
0 = no signal.
1 = signal.
Row 5 shows the feedback input from the front, left wiper motor
(M6501-LE).
0 = no signal.
1 = signal.


Row 1 describes the front, right windscreen wipers relay (K6501-RI).
Row 2 shows the relay output for front, right windscreen wipers.
It is possible to manually activate the signal on row 2, Output
K6501–RI C2p09 D7901. See Navigation of menus, description,
0 = no signal.
1 = signal.
Row 5 shows the feedback input from the front, right wiper motor
(M6501-RI).
0 = no signal.
1 = signal.

Row 1 describes the front windscreen washer (S1200).
Row 2 shows the input for the washer switch.
Row 3 shows the output of the front windscreen washer motor (M6511).
It is possible to manually activate the signal on row 3, Front
washer motor rel. out K6511 C2p10 D7901. See Navigation
settings are made.
0 = no signal.
1 = signal.

Row 6 shows the washer fluid level sensor input (B2991).

0 = no signal.
1 = fluid level OK.

Row 1 describes signals from the roof windscreen wiper switch.
Row 2 shows the input for the continuous front windscreen wiper
switch (S1190-UP).
Row 3 shows the input for the intermittent front windscreen wiper
switch (S1520-UP).


Row 1 describes the roof windscreen wiper motor.
Row 2 shows the output of the roof windscreen wiper motor (M6503).
It is possible to manually activate row 2, Output M6503 C2p19
D7901. See Navigation of menus, description, page 8:4 for an
explanation of how the settings are made.
0 = no signal.
1 = signal, motor running.
Row 5 shows input feedback from roof windscreen wiper motor

(M6503).
0 = no signal.
1 = signal.

Row 1 describes roof washer.
Row 2 shows the roof washer switch input (S1200).

0 = no signal.
Row 3 shows the output of the roof washer motor (M6513).

It is possible to manually activate row 3, Roof washer motor out
0 = no signal.
1 = signal.
Row 6 shows the washer fluid level sensor input (B2991).

0 = no signal.
1 = fluid level OK.
8.4.9.6 Diagnostic menus Lighting
9.6 Lighting Sys 1/XX DIAGNOSE

Row 1 shows the headlights switch input (S1000).
Row 2 describes high beam
Row 3 shows the input for Switch, high beam (S1600).
Row 4 shows the input for Switch, high beam on the arm rest for
joystick/mini-wheel (S1992).
For all row it applies:

0 = no signal.


Row 1 describes the front lights.

0 = no signal.
1 = low beam lamp should be lit.
Row 3 shows the true current in the left low beam lamp (E4000-LE).
Row 5 shows the true current in the right low beam lamp (E4000-RI).

Row 1 describes tail lights.

output.
See Navigation of menus, description, page 8:4 for an explanation
how settings are made.
0 = no signal.
1 = tail light lamp should be lit.
Row 3 shows the true current in the tail light lamp (H4120-LE/RI).

Row 1 describes brake lights.

0 = no signal.
1 = brake light lamp should be lit.
Row 3 shows the true current in the brake light lamp (H4110-LE/RI).


Row 1 describes the direction indicators.
Row 2 shows the multi-function lever right direction indicator input
(S1600:R).
Row 3 shows the multi-function lever left direction indicator input
(S1600:L).
Row 4 shows the input for the direction indicator switch (S1470) on the
arm rest right mini-wheel/joystick control (S1470:1)
Row 5 shows the input for the direction indicator switch (S1470) on the
arm rest left mini-wheel/joystick control (S1470:3).
0 = no signal.

Row 1 describes the direction indicators.
Row 2 shows the requested left output signal.
output left. See Navigation of menus, description, page 8:4 for an
0 = no signal.
1 = left direction indicator lamp should be lit.
Row 3 shows the true current for the left direction indicator lamp
(H4220-FL/RL).

Row 1 describes the direction indicators
Row 2 shows requested output right.
output right. See Navigation of menus, description, page 8:4 for
an explanation how settings are made.
0 = no signal.
1 = right direction indicator lamp should be lit.
Row 3 shows the true current for the right direction indicator lamp
(H4220-FR/RR).

Row 1 describes position lights.
Row 2 shows requested output signal for position lights.
0 = no signal.
1 = position light lamp should be lit.
Row 3 shows actual current in the position light lamp.


Row 1 shows signals for rear work light switch (S1032).

It is possible to set the signal on row 1, Requested output. See
settings are made.
0 = no signal.
1 = rear work light lamp should be lit.
Row 3 shows true current for left rear work light lamp (E4050-LE).
Row 5 shows true current for right rear work light lamp (E4050-RI).
Row 1 shows signals for cab work light switch (S1050-1).

It is possible to set the signal on row 1, Requested output. See
settings are made.
0 = no signal.
1 = work light lamp should be lit.
Row 3 shows the true current for left cab work light lamp (E4042-LE).
Row 5 shows the true current for right cab work light lamp (E4042-RI).

Row 1 shows signals for mast/boom work light switch (S1050-2).

0 = no signal.
1 = the mast/boom work light lamp should be lit.
Row 3 shows the true current for left mast/boom work light lamp
(E4043-LE).
Row 5 shows the true current for right mast/boom work light lamp
(E4043-RI).

Row 1 shows signals for frame work light switch (S1050-4).

0 = no signal
1 = frame work light lamp should be lit
Row 3 shows the true current for frame work light lamp (E4041-1).
Row 5 shows the true current for frame work light lamp (E4041-2).

Row 1 describes cab lighting
Row 2 shows the input for the interior lighting switch (S1160).
Row 3 shows the input for the step lighting switch (S1410).
Row 4 shows the input for the right cab door contact switch (B2660-RI).
Row 5 shows the input for the left cab door contact switch (B2660-LE).

0 = no signal.

Row 1 describes signals for interior lighting lamp (E4340)



Row 1 shows the signals from Switch, work light attachment (S1050-3).
0 = no signal.
1 = working lights attachment illuminated.
Row 3 shows actual current to Working lights on attachment left
(E4044-LE).
Row 5 shows actual current to Working lights on attachment right
(E4044-RI).
Row 1 shows the signals from Switch, work light attachment (S1050-3).
0 = no signal.
1 = working lights attachment illuminated.
Row 3 shows actual current to Working lights on attachment left
(E4044-LF).
Row 5 shows actual current to Working lights on attachment right
(E4044-RF).
Row 1 shows the signals from Switch, work light cab (S1050-1).
0 = no signal.
1 = work light cab illuminated.
Row 3 shows actual current to Work light cab (E4042-1).
Row 5 shows actual current to Work light cab (E4042-2).

8.4.9.7 Diagnostic menus Signal system

9.7 Signalling Sys 1/XX DIAGNOSE
Row 1 describes the horn.
Row 2 shows the multi-function lever horn (S1600:31b).
0 = no signal.
Row 3 shows the input for the right panel horn switch (S8500-2).
0 = no signal.
Row 4 shows the horn output (H8500).
It is possible to manually set the signal on row 4, Output M8500
C2p12 D7901. See Navigation of menus, description, page 8:4 for
an explanation of how the settings are made.
0 = no signal.
1 = horn sounds.

Row 1 describes revolving beacon cab.
Row 2 shows the input for Switch, revolving beacon (S1100).
0 = no signal.
Row 3 shows the output for Revolving beacon (H4282).
It is possible to manually set the signal on row 3, Output H4282
C2p13. See Navigation of menus, description, page 8:4 for an
0 = no signal.
1 = revolving beacon switched on.
Row 1 describes the revolving beacon on the frame.

Row 2 shows the input for the revolving beacon switch (S1100).
0 = no signal.
It is possible to set the signal on row 3, Output H4281 C1p45
0 = no signal.
1 = revolving beacon frame switched on.


Row 1 describes the revolving beacon on the attachment.
Row 2 shows the input for the revolving beacon switch.

0 = no signal.

0 = no signal.
1 = warning beacon attachment illuminates.

Row 1 describes the reversing alarm.
Row 2 shows the request for reversing (H9650).

0 = no signal.
1 = reversing.
Row 3 shows the reversing alarm output (H9650).

0 = no signal.
1 = reversing alarm.

Row 1 describes the hazard warning lights.
Row 2 shows the input for the hazard warning lights switch (S1090).
0 = no signal.
Row 3 shows requested output.

It is possible to set the signal on row 3, Output request. See
settings are made.
0 = no signal.
1 = hazard flashers flash.

8.4.9.14 Diagnostic menus Central lubrication
9.14 Central Lubr 1/XX DIAGNOSE
Row 1 describes central lubrication frame.
Row 2 shows remaining pause time (time until next lubrication cycle).
Row 3 shows the feedback signal from Sensor, central lubrication

(B7242).
0 = not active.
1 = active (lubrication system pressurised).
Row 4 shows the number of performed lubrication cycles.
Row 5 shows the timeout status.

0 = OK.
1 = timeout, central lubrication interrupted.
Row 1 describes central lubrication frame.
Row 2 shows the status for Lubrication motor (M6930).

It is possible to manually start the motor on row 2, Motor on/off
0 = off.
1 = on.
Row 1 describes central lubrication attachment.
Row 2 shows remaining pause time (time until next lubrication cycle).
Row 3 shows the feedback signal from Sensor, central lubrication

(B7242).
0 = not active.
1 = active (lubrication system pressurised).
Row 4 shows the number of performed lubrication cycles.
Row 5 shows the timeout status.

0 = OK.
1 = timeout, central lubrication interrupted.

8:76 8 Control system – Common hydraulics
Row 1 describes central lubrication attachment.
Row 2 shows the status for Lubrication motor (M6930).

It is possible to manually start the motor on row 2, Motor on/off
0 = off.
1 = on.
8.4.10 Common hydraulics

8.4.10.4 Diagnostic menus Pumps
10.4 Pumps 1/XX DIAGNOSE

Row 1 describes activation of hydraulic pressure to attachment.
Row 2 shows status for Solenoid valve engagement of hydraulic

pressure to top lift (Y6003).
Requested output Y6003 C1p15 D7971 KFU. See Navigation
settings are made.
0 = off.
1 = on (attachment pressurised).
8.4.10.6 Diagnostic menus, temperature control,

cleaning and hydraulic oil
10.6 Oil Temp/Clean 1/XX DIAGNOSE

Row 1 shows the input for hydraulic oil temperature sensor (B7760).
Row 2 shows the hydraulic oil temperature.
Row 4 shows the requested gear limitation.

8 Control system – Common electrics 8:77
8.4.11 Common electrics

Row 1 describes signals relating to driving forward.
Row 2 shows the output for Control unit KCU (D7901).

It is possible to manually set the signal on row 2 Output C2p31
D7901 KCU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving forward.

Row 1 describes signals relating to driving backward.
Row 2 shows the output for Control unit KCU (D7901).

It is possible to manually set the signal on row 2 Output C2p32
D7901 KCU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving backward.

Row 1 describes signals relating to driving forward.
Row 2 shows the output for Control unit KFU (D7971).

It is possible to manually set the signal on row 2, Output C1p22
D7971 KFU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving forward.

Row 1 describes signals relating to driving backward.
Row 2 shows the signal from Control unit KFU (D7971).

It is possible to manually set the signal on row 2, Output C1p23
D7971 KFU. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = driving backward.

8:78 8 Control system – Common electrics
8.4.11.4 Diagnostic menus Alternator

11.4 Alternator 1/XX DIAGNOSE
Row 1 shows status for alternator charging voltage (D+).
0 = not charging.
1 = charging.
Row 2 shows the battery voltage.
8.4.11.5 Diagnostic menus Distribution of electricity

11.5 Distr of Electr 1/XX DIAGNOSE
Row 1 describes the voltage feed to and from Control unit KCU
(D7901).
Row 2 shows the battery voltage input (F9968-RD:2).
Row 3 shows the ignition current input.
Row 4 shows the input for the ignition key lock switch (S1500).
0 = no signal.
Row 5 shows the output for voltage feed to sensors and transducers.

Row 1 describes redundant voltage feed (CPU Power) from Control
unit KCU (D7901).
Row 2 shows output redundant voltage feed (CPU Power).
It is possible to manually set the signal for redundant voltage
feed (CPU Power) on row 2, CPU power supply system output
C2p35. See Navigation of menus, description, page 8:4 for an
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KCU (D7901).
Row 2 shows the output for 24 V voltage feed to sensor, control,
pressure switch refrigerant and feedback to wiper motors.
It is possible to manually set the signal on row 2, 24V sensor
power supply cabin, output C2p05. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.


Row 1 describes the voltage feed to and from Control unit KFU (D7971).
Row 2 shows input redundant voltage feed (CPU Power).
Row 3 shows input voltage feed ignition voltage (voltage bolt).
Row 4 shows output for 5 V voltage feed to sensors.

Row 1 describes the voltage feed from Control unit KFU (D7971).
Row 2 shows output for 24 V sensor voltage feed to sensors for central
lubrication and electric heater.
It is possible to manually set the 24V sensor power supply,
output C2p32. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KFU (D7971).
Row 2 shows output for 24 V voltage feed to sensors and switches

mast/boom.
It is possible to manually set on row 2, 24V sensor power supply
mast/boom, output C2p33. See Navigation of menus, description,
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KAU (D7911).
Row 3 shows input voltage feed ignition voltage (voltage bolt).
Row 4 shows output for 5 V voltage feed to sensors.


Row 1 describes the voltage feed from Control unit KAU (D7911).
Row 2 shows output for 24 V voltage feed to sensors and switches.

It is possible to manually set the 24V sensor power supply
output C2p32. See Navigation of menus, description, page 8:4 for
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed from Control unit KAU (D7911).

It is possible to manually set the signal on row 2, 24V sensor
power supply Output C2p33. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KPU (D7902).
Row 3 shows input voltage feed ignition voltage.

Row 1 describes the voltage feed from Control unit KPU (D7902).
Row 2 shows output for 5 V voltage feed to analogue controls and

feedback signals (internally connected to C3p01 and C8p04).
It is possible to manually set the voltage feed to sensors on row 2,
5V ref. power supply output C2p01 (internally connected to
C3p01 and C8p04). See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.
Row 3 shows the output voltage.


Row 2 shows output for 5 V voltage feed to the steering panel, silicone
panel, right-hand dashboard panel front section (climate controls)
and silicone panel, right-hand dashboard panel rear section (lighting
controls), (internally connected to C7p01 and C9p01).
It is possible to manually set the voltage feed to sensors on row 2,
5V ref. power supply Output C6p01 (internally connected to
C7p01 and C9p01). See Navigation of menus, description, page
0 = no signal.
1 = voltage feed.
Row 3 shows the output voltage.

Row 2 shows output for 24 V sensor voltage feed to Switch, control

lever (off/on buttons), output C3p09.
It is possible to manually set the voltage feed on row 2, 24 sensor
power supply (switches, joystick, etc.) Output C3p09. See
Navigation of menus, description, page 8:4 for an explanation of
how the settings are made.
0 = no signal.
1 = voltage feed.

Row 2 shows output for 24 V sensor voltage feed to Switch, output

C4p01.
It is possible to manually set the voltage feed on row 2, 24
sensor power supply Output C4p01. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.

Row 2 shows output for 24 V voltage feed to travel direction selector

and parking brake, sensor steering wheel angle and multi-function
lever, output C5p01.
It is possible to manually set the voltage feed on row 1, 24 sensor
power supply (steering column, etc.) Output C5p01. See
Navigation of menus, description, page 8:4 for an explanation of
how the settings are made.
0 = no signal.
1 = voltage feed.


Row 2 shows output for 24 V voltage feed to Switch control breaker

(S2500), output C8p01.
It is possible to manually set the voltage feed on row 1, 24
sensor power supply Output C8p01. See Navigation of menus,
made.
0 = no signal.
1 = voltage feed.

Row 1 describes the voltage feed to Control unit KID (D7950).
Row 3 shows input voltage feed ignition voltage.
Row 4 shows the output for voltage feed to sensors.

Row 1 shows input from Switch control breaker (S2500)
0 = no signal (control breaker depressed).
1 = breaker activated.

Row 1 describes safe voltage feed (Control breaker voltage) group 1 in

0 = no signal.
1 = voltage feed.
Row 3 shows voltage to Solenoid valve lift (Y6005), Solenoid valve

lower (Y6004), Solenoid valve tilt out (Y6010) and Solenoid valve tilt in
(Y6011) output C1p27–C1p29, C1p33.
Row 4 shows voltage to Solenoid valve blocking left (Y6045-LE),

Solenoid valve blocking right (Y6045-RI), output C1p34–C1p37.
Row 5 shows voltage on output C1p38–C1p41.


Control unit KFU (D7971)

0 = no signal.
1 = voltage feed.
Row 3 shows voltage to output C1p48, C1p50 and Visco clutch

(M6580), output C1p47.

Row 2 shows status for requested output signal to, output C2p35, and
output C2p37.
0 = no signal.
1 = voltage feed.

Row 1 describes safe voltage feed (Control breaker voltage) ground 1
in Control unit KFU (D7971), output C1p10.

0 = no signal.
1 = voltage feed.

in Control unit KFU (D7971), output C1p30.

0 = no signal.
1 = voltage feed.


Row 1 shows the signal from safe voltage feed (Control breaker
voltage) group 1 in Control unit KAU (D7911).
0 = no signal.
1 = voltage feed.
Row 3 shows voltage to Solenoid valve rotation clockwise (Y6008),

Solenoid valve rotation anticlockwise (Y6009), Solenoid valve
spreading out (Y6018) and Solenoid valve spreading in (Y6019), output
C1p27-C1p29, C1p33.
Row 4 shows voltage to Solenoid valve tilt in (Y6011) and Solenoid

valve tilt out (Y6010), output C1p34-C1p37.
Row 5 shows voltage to Solenoid valve side shift left (Y6020), Solenoid
valve side shift right (Y6021), output C1p38–C1p41.


0 = no signal.
1 = voltage feed.
Row 3 shows voltage on, output C1p47-C1p48, C1p50.

Row 1 describes safe voltage feed (Control breaker voltage) group 3
in Control unit KAU (D7911) to indicator lights on the boom, output
C2p35, C2p37.

0 = no signal.
1 = voltage feed.

in Control unit KAU (D7911), output C1p10.

0 = no signal.
1 = voltage feed.


in Control unit KAU (D7911), output C1p30.

0 = no signal.
1 = voltage feed.

Row 1 describes voltage feed from Control unit KAU (D7911) to extra
lifting tool.

It is possible to manually set the signal on row 2, 24V external
attachment Output C2p34. See Navigation of menus, description,
0 = No signal.
1 = Voltage feed.
8.4.11.6 Diagnostic menus Communication
11.6 Communication 1/XX

Row 1 describes the RedCAN system.
Row 2 shows the expected number of nodes.
Row 3 shows the true number of nodes.
Row 4 shows discovered cable errors on the CAN bus.
Row 5 shows the communication mode.

0 = normal.
1 = scanning.
2 = RedCAN locked.
3 = Program downloading.
Row 6 shows scanning of the RedCAN system.

It is possible to manually activate scanning on row 5, Scan
RedCAN system. See Navigation of menus, description, page 8:4
0 = no scanning.
1 = scanning.


Row 1 describes the expected RedCAN system.
Row 2 shows the 1st node number.
Row 3 shows the 2nd node number.
Row 4 shows the 3rd node number.
Row 5 shows the 4th node number.
The 1st node number is the first node in the loop, the 2nd node
number is the second node in the loop, etc. For a description of node
numbering, see 11.6.2 Redundant CAN bus, page 11:42.

Row 1 describes the expected RedCAN system.
The 6th node number is the sixth node in the loop, the 7th node
number is the seventh node in the loop, etc. For a description of node
numbering, see 11.6.2 Redundant CAN bus, page 11:42.

Row 1 describes which nodes actually communicate in the RedCAN
system.
Row 2 shows the 1st node number.
Row 3 shows the 2nd node number.
For a description of node numbering, see 11.6.2 Redundant CAN bus,

page 11:42.

Row 1 describes which nodes actually communicate in the RedCAN
system.

page 11:42.


Row 1 describes the RedCAN system.
Row 2 shows the node number for the node that has detected a cable
error on its normal side.
Row 3 shows the node number for the node that has detected a cable
error on its redundant side.

page 11:42.

Row 1 describes RedCAN nodes, which are not found during start-up
of the CAN bus. For a more detailed explanation, see Redundant CAN
bus, start-up, page 11:43.
Row 2 shows 1st node not found.
Row 3 shows 2nd node not found.
Row 4 shows 3rd node not found.
Row 5 shows 4th node not found.
Row 6 shows 5th node not found.

0 = OK
1= node not found

page 11:42.

Row 1 describes RedCAN, which nodes disappear (unresponsive)
after start-up of the CAN bus. For a more detailed explanation, see
Redundant CAN bus, start-up, page 11:43.
Row 2 shows 1st node disappeared.
Row 3 shows 2nd node disappeared.
Row 4 shows 3rd node disappeared.
Row 5 shows 4th node disappeared.
Row 6 shows 5th node disappeared.

0 = OK.
1 = node disappeared.

page 11:42.


Row 1 describes the RedCAN statistics.
Row 2 shows the number of system scans since start-up. Scanning

is performed in the event of problems delivering messages, a high
number of scans may be due to intermittent faults in the cable harness
or faulty termination resistors.
Row 3 shows the last scan time. A short scanning time means that the
CAN bus is working well.
Row 4 shows scanning of the RedCAN system.

It is possible to manually activate scanning on row 4, Scan
RedCAN system. See Navigation of menus, description, page 8:4
0 = no scanning.
1 = scanning in progress.

Row 1 describes status for the communication for CAN bus drive-train.
Row 2 shows status for Control unit engine (D7940-1).

0 = no contact.
1 = communication OK.
Row 3 shows status for Control unit UDS (D7940-2).

0 = no contact.
Row 4 shows status for Control unit transmission (D7930).

0 = no contact.

Identification of operator.
Row 1 shows whether the ID for the operator is supported.

0 = ID not supported.
1 = ID supported.
Row 2 shows ID number 1.
Row 3 shows ID number 2.


Row 1 shows signal strength (CSQ). (CSQ is a GSM standard for
signal strength.)
Row 2 shows whether GSM is registered on the GSM network.

0 = not registered.
1 = registered.
Row 3 shows whether OTA, communication with "back-office", is OK.

0 = OTA not OK.
1 = OTA OK.
Row 4 shows whether GPS is OK.

0 = GPS not OK.
1 = GPS OK. Position fixed.
Row 5 shows whether MTU Tx OK is OK.

0 = MTU Tx OK, not OK.
1 = GPS MTU Tx OK, OK.

Telematics unit
Row 1 shows type of unit.
Row 2 shows version.

Telematics unit
Row 1 shows serial number.

Row 1 describes communication on CAN bus drive-train.
Row 2 shows status for Control unit engine (D7940-1).

0 = no contact.
Row 3 shows status for Control unit transmission (D7930).

0 = OK.
1 = node disappeared.

8:90 8 Control system – Pin diagnostics
8.4.13 Pin diagnostics

Pin diagnostics, description
The menus for pin diagnostics have the same structure as other
diagnostic menus. See Navigation of menus, description, page 8:4 for
an explanation of how to navigate to and through the menus.
The pin diagnostics are used to quickly diagnose all functions in

the control system. Input signal values from e.g. a lever are shown
in the diagnostic menus. A control unit's output signal current to a
corresponding valve can be shown and with that it is possible to check
whether the software sends a correct signal to control the valve. It can
be quickly determined whether the problem is on the input or output
side and if the control unit is working properly without connecting to
other instruments.
Outputs and inputs are described with respect to the contact and pin,
for example C2p01, which denotes contact 2, pin 1.
Outputs can also be controlled with the right permissions in the

diagnostic system. The variable Request can be activated manually.
Example 1:
It is discovered that there is no input signal from the lift lever, but to
be able to move the machine to the workshop the attachment must
be lifted from the ground. In this situation the lifting can be "force
operated" from the display using service code and wiring diagram.
Example 2:
It is established that everything seems to be OK for lifting, and input

and output signals are as they should be. Despite this lifting does not
work. If the "forced operation" function does not work despite stronger
current than normal to the solenoid valve, then the fault probably lies in
the valve or cables.
1 The following terms are used in pin diagnostic menus.

Actual current indicates the true current.
Digital input indicates digital input.
2 Digital output indicates digital output.
4
Direction indicates the direction.
3 5
Duty cycle indicates the pulse length of an analogue PWM output.
6
Frequency input indicates the frequency input.
016092
H bridge indicates H-bridge for engine control.

Impedance indicates impedance.
1. Example Menu group
Pin status indicates status for input or output, see Explanation
2. Signal from digital input, contact 2 pin 1 of pin status codes, page 8:20.
3. Signals from digital output, contact 2 pin 1 PWM output indicates pulse width modulated output
4. Request for signal to the digital output PVE output indicates PVE output of the Sauer Danfoss type.
5. True current Request indicates the ability to manually set the signal value.
6. Pin status Requested current indicates the requested current.
Requested duty cycle indicates the requested pulse length.
Requested voltage indicates the requested voltage.
Resistance input indicates the resistance measurement input.
Voltage input indicates the voltage input.

8 Control system – Pin diagnostics 8:91
11.7 I/O D7901 KCU 1-48/XX DIAGNOSE

Contains diagnostic menu 1-48 for Control unit KCU (D7901).
11.8 I/O D7902 KPU 1–41/XX DIAGNOSE

Contains diagnostic menu 1-41 for Control unit KPU (D7902).
11.9 I/O D7971 KFU 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KFU (D7971).
11.10 I/O D7950 KID 1–4/XX DIAGNOSE

Contains diagnostic menu 1-4 for Control unit KID (D7950).
11.11 I/O D7911 KAU 1–75/XX DIAGNOSE

Contains diagnostic menu 1-75 for Control unit KAU (D7911).

8:92 8 Control system – Setup
8.5 Setup
Initiation, general
Initiation is performed before using the machine for work and means to
set e.g., start and stop currents, deadband, sensitivity, minimum and
maximum values for the control of different functions.
DANGER
The settings influence the functions. Adjustments
may impair the function.
If uncertain, contact Cargotec Service.
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.
After changes have been made, the ignition must be switched off
and then on for the changes to be saved and start to apply.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
Initiation is available for the following groups:

• Engine, 8.5.1 Engine, page 8:95
8.5.1.1 Initiation menus Controls and instruments engine, page
8:95
8.5.1.2 Initiation menus Fuel system, page 8:96
• Transmission, 8.5.2 Transmission, page 8:100
8.5.2.1 Initiation menus Controls and instruments transmission,
page 8:100
• Suspension, 8.5.6 Suspension, page 8:103
8.5.6.3 Initiation menus Tyres and rims, page 8:103
• Load handling, 8.5.7 Load handling, page 8:103
8.5.7.1 Initiation menus Controls and instruments load handling,
page 8:103
8.5.7.2 Initiation menus Lifting/lowering, page 8:105
8.5.7.4 Initiation menus, Side shift, page 8:107
8.5.7.5 Initiation menus, Spreading, page 8:108
8.5.7.7 Initiation menus, Tilt, page 8:113
• Control system, 8.5.8 Control system, page 8:116
8.5.8.1 Initiation menus Controls and instruments, page 8:116
8.5.8.2 Initiation menus, Monitoring, page 8:118
• Frame, body, cab and accessories, 8.5.9 Frame, body, cab and
accessories, page 8:123
8.5.9.4 Initiation menus, Climate system, page 8:124
8.5.9.5 Initiation menus, Windscreen wipers, page 8:124
8.5.9.6 Initiation menus, Lighting, page 8:125
8.5.9.7 Initiation menus, Signal system, page 8:126
8.5.9.14 Initiation menus, Central lubrication, page 8:127
• Common electrics, 8.5.11 Common electrics, page 8:127
8.5.11.5 Initiation menus, Voltage feed, page 8:128

8 Control system – Setup 8:93
Initiation, work instructions

Navigation to a menu, work instruction
To navigate to a menu for setup or calibration, do as follows:
NOTE
The machine must be stationary with parking brake applied in
order to enable access to the menus.
014981
2 Enter service code with or and confirm with .

NOTE
015625
3 Select the function with or and confirm with .

015624
4 Select group by scrolling with or and confirm with .

015629

8:94 8 Control system – Setup
5 Select INITIATE with or and confirm with
015735
6 Each menu group consists of a sequence of a number of menus.
The first menu for the selected group opens in the display. Use the
arrow keys or to move to the desired menu.
All signal values in the menu figures are examples and may
differ from the values shown in an actual machine.
7 Use the function key EDIT to select adjustment mode for the
menu (the function for the arrow keys is changed from navigating
between the menus to adjusting values).
8 Set the new value in the upper row using or .
Example of first menu in group

NOTE
Current values can only be adjusted within specific limits.
9 Use the function key SAVE to store the set value.
Menu example, description
1 All menus for initiation and calibration are explained separately.

2 3
– The menu group, indicates the group, 1.7 Cooling System, whose
signals need to be initiated.
8 – Sequence number, 1/XX, enter the page number and total number
4 of menus in the menu loop. As the number of menus is dependent
on how the machine is equipped, state the number of menus here
with XX.
– Initiate indicates in the menu example that initiation is the
selected setting function. The other setup function is Calibrate
for calibration.
015883
– Variables, such as row 1 Cooling fan start current, describe the

7 5 function/component that the signal/measurement comes from.
6
Each menu can contain 1-6 rows, where each row describes a
1. Menu group variable with an associated signal value.
2. Sequence number – Signal value, 450.0 mA, is the saved value for Cooling fan start
current.
3. Selected setting function
All signal values in the menu figures in this manual are
4. Signal values examples and may differ from the values in a real machine.
5. Function key LEAVE/Cancel The following icons are used to explain further the signal values:
6. Arrow keys denotes a saved value.
7. Function key Manual mode/Edit mode denotes a value from an output from a control unit.
8. Variables denotes an input value which is measured by a control unit.

8.5.1 Engine
8.5.1.1 Initiation menus Controls and instruments
engine
1.1 Controls & Instr 1/XX INITIATE

1. Read the explanation of initiation menus before making any
changes, see Initiation, general, page 8:92.
For a description of navigation to this menu, see Navigation to a
menu, work instruction, page 8:93
2. Row 1 shows the setting value of the accelerator pedal's deadband
when the pedal is released.
Row 2 shows the saved value of the accelerator pedal's deadband
when the pedal is released.
Row 3 shows the true position of the accelerator pedal.
3. Set the deadband for the accelerator pedal's zero position on row
1, Throttle pedal start deadband. Change the value with /
and store the value with Save .

2. Row 1 shows the setting value of the accelerator pedal's deadband
at full throttle in the setup position.
Row 2 shows the saved value of the accelerator pedal's deadband
when the pedal is at full throttle.
Row 3 shows the true position of the accelerator pedal.
3. Set the deadband for the accelerator pedal's full throttle position on
row 1, Throttle pedal end deadband. Change the value with /
8.5.1.1 Calibration menus Controls and instruments

engine
Calibration of accelerator pedal

Stop the machine on level ground. Apply the parking brake and leave
the ignition turned on.
1.1 Controls & Instr 1/XX CALIBRATE
NOTE
Depress the accelerator pedal normally at least once before starting
calibration.
1. Navigate to 1.1 Controls & Instr 1/XX CALIBRATE, menu 1 with

/ .
2. Row 1 shows the accelerator pedal's top position.
The picture shows an example of the value in mV and
may differ depending on model. Row 5 shows the accelerator pedal's lowered value for signal B.
3. Release the pedal SLOWLY all the way and save the value using
the function key .

1.1 Controls & Instr 2/XX CALIBRATE

1. Navigate to 1.1 Controls & Instr 1/XX CALIBRATE, menu 2 with
/ .
2. Row 1 shows the accelerator pedal's bottom position.
Row 5 shows the accelerator pedal's lowered value for signal B.
3. Press the accelerator pedal right down and save the value using
the function key .
The picture shows an example of the value in mV and

may differ depending on model.
8.5.1.2 Initiation menus Fuel system

2. Row 1 shows the setting value for warning in the event of low
fuel level.
Row 2 shows the stored value for warning in the event of low
fuel level.
3. Set the warning in row 1, Alarm Low fuel level. Change the value
with / and store the value with Save .
8.5.1.7 Initiation menus Cooling system engine

1.7 Cooling System 3/XX INITIATE
Applies to Volvo TAD572VE and Volvo TAD871VE.
menu, work instruction, page 8:93.

2. Row 1 shows the setting value for lock cooling fan at 70% of max.
capacity.
Row 2 shows whether the cooling fan is locked at 70% of max.
capacity.
3. Activate lock cooling fan at 70% in row 1, Lock cooling fan at 70%.
Change the value with / and store the value with Save .
0 = off
1 = on


2. Row 1 shows the setting value for locking of the engine's cooling
fan to a certain rpm in % of the engine's rpm.
Row 2 shows current operating mode for the engine's cooling fan.
0.00 % = Automatic fan control
0.01 — 100.00 % = Locked rpm.
-1.00 % = Locked to the engine speed.
Row 3 shows fan speed.
3. Activate change of lock value for cooling fan row 1, Lock cooling
fan at speed (0–100%) with .

2. Row 1 shows the setting value for locking the speed of the
intercooler cooling fans to a certain rpm in % of maximum rpm.
Row 2 shows current operating mode for the cooling fan.
0.00 % = Automatic fan control
0.01 – 100.00 % = Locked rpm in % of maximum rpm.
-1.00 % = Locked to the engine speed.
Row 3 shows calculated fan speed.
3. Activate change of lock value for cooling fans in row 1, Lock
cooling fan charge air at speed (0–100%) with .
8.5.1.9 Initiation menus Control system, engine
1.9 Control System 1/XX INITIATE

2. Row 1 shows the setting value for the lowest engine speed (idling
speed).
Row 2 shows the saved value for the lowest engine speed.
3. Set lowest engine speed in row 1, Engine min rpm. Change the
value with / and store the value with Save .


2. Row 1 shows the setting value for the highest permitted engine
speed (speed inhibitor).
Row 2 shows the saved value for the highest permitted engine
speed.
3. Set highest permitted engine speed in row 1, Engine max rpm.

2. Row 1 shows the setting value for the engine's ramp time down
(how fast the engine speed is allowed go down to idle). Too short a
time may result in engine stop.
Row 2 shows the saved value for the engine's ramp down time.
3. Set the engine's ramp down time in row 1, Engine request speed
decrease time. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for the engine's ramp up time
(throttle response).
Row 2 shows the saved value for the engine's ramp up time.
3. Set the engine's ramp up time in row 1, Engine request speed
increase time. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for the engine's max. speed in
neutral position for the transmission.
Row 2 shows the stored value for the engine's max. speed in
neutral position for the transmission.
3. Set the engine's max. speed in row 1, Engine max rpm at neutral.


2. Row 1 shows the setting value for request for limitation of the
engine's torque in % of the engine's maximum torque.
Row 2 shows stored value for request for limitation of the engine's
torque.
3. Set the engine's max. speed in row 1, Engine request torque
limit. Change the value with / and store the value with Save
.
8.5.1.11 Initiation menus Start and stop
1.11 Start & Stop 1/XX INITIATE

2. Row 1 shows the setting value for the delay before the engine is
auto-stopped by the automatic start and stop function in seconds.
Row 2 shows the stored value for the delay before the engine is
auto-stopped in seconds.
3. Set the time in row 1, Auto Start & Stop. Change the value with
/ and store the value with Save .

2. Row 1 shows the setting value for the delay before the engine is
auto-stopped by the automatic stop function in seconds.
Row 2 shows the stored value for the delay before the engine is
auto-stopped in seconds.
3. Set the setting in row 1, Auto Start & Stop, light. Change the

2. Row 1 shows the setting value for the drive mode in which the
engine should be auto-stopped by the automatic stop function.
Row 2 shows the stored value for the drive mode in which the
engine should be auto-stopped by the automatic stop function.
3. Set the setting in row 1, Auto Start & Stop, light Available in
mode. Change the value with / and store the value with
Save .


2. Row 1 shows the setting value for preventing start if the operator is
not wearing the seat belt.
Row 2 shows the stored value for preventing start if the operator is
not wearing the seat belt.
3. Enter the setting in row 1, Disable start when no seat belt.
8.5.2 Transmission
Initiation transmission, general
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.

transmission

2. Row 1 shows the setting value for tyre radius correction.
Row 2 shows the saved value for tyre radius correction.
Row 3 shows tyre radius plus correction.
3. Set tyre radius correction on row 1, Tyre rolling radius offset, to
adjust the speedometer with tyre wear. Change the value with /

2. Row 1 shows the setting value for start gear.
Row 2 shows the saved value for start gear.
3. Set start gear in row 1, Transmission start gear. Change the


2. Row 1 shows the setting value for automatic engine speed
reduction when changing travel direction.
Row 2 shows the stored value for automatic engine speed
reduction when changing travel direction.
3. Set automatic engine speed reduction in row 1, Automatic engine
rpm limit at forward/reverse request (1= on). Change the value
0 = No engine speed reduction when changing travel direction.
1 = Automatic reduction of engine speed when changing travel
direction.

2. Row 1 shows the setting value for the lowest engine rpm required
to activate kick-down in the transmission.
Row 2 shows the saved value for rotation speed.
3. Set engine rpm in row 1, Min engine speed needed before
kick down. Change the value with / and store the value
with Save .
4. Switch off the ignition for at least three seconds in order to save
the value.

2. Row 1 shows the setting value for the highest permitted speed
for change of travel direction.
Row 2 shows the saved value for speed.
3. Set engine rpm in row 1, Max vehicle speed Fwd - Rev to
perform a direction change. Change the value with / and
store the value with Save .
the value.

2. Row 1 shows the setting value for the highest permitted engine
speed for change of travel direction.
Row 2 shows the saved value for the engine speed.
3. Set engine rpm in row 1, Max engine speed Fwd - Rev to
perform a direction change. Change the value with / and
the value.

8.5.2.2 Initiation menus, Torque converter and clutch
2.2 Torq Conv Clutch 1/XX INITIATE

2. Row 1 shows the setting value for brake pressure when declutching
the transmission.
Row 2 shows the saved value for brake pressure when declutching
the transmission.
Row 3 shows the true brake pressure.
3. Set brake pressure in row 1, Declutch brake pressure. Change
the value with / and store the value with Save .

2. Row 1 show the accelerator's minimum value for declutching.
Row 2 shows the saved value for the accelerator pedal's minimum
value for declutching.
Row 3 shows the true accelerator pedal in %.
3. Set the accelerator pedal's minimum value for declutch in row 1,
Declutch throttle min percent. Change the value with /

2. Row 1 shows the setting value for operating mode for locking of
the torque converter (lock-up) on the transmission.
Row 2 shows the stored value lock-up.
1 = Automatic lock-up.
2 = Activate lock-up.
3 = Disengage lock-up.
Row 3 shows status for the lock-up function.
0 = Off, no lock-up.
1 = On, lock-up activated.
3. Set the accelerator pedal's minimum value for declutch in row 1,
Lock-Up mode selection. Change the value with / and store
the value with Save .

8 Control system – Suspension 8:103
8.5.6 Suspension
8.5.6.3 Initiation menus Tyres and rims
6.3 Tyres & Rims 1/XX INITIATE

2. Row 1 shows setting value for the tyre pressure monitoring function
in the machine.
Row 2 shows the stored value for the tyre pressure monitoring
function.
0 = Tyre pressure monitoring deactivated.
1 = Tyre pressure monitoring with pressure indication in operating
menu.
menu as well as event menus in the event of incorrect tyre
pressure.
menu as well as event menus and speed limitation in the event
of incorrect tyre pressure.
3. Set the tyre pressure monitoring function in row 1, Tyre Pressure
Monitoring mode. Change the value with / and store the
value with Save .
8.5.7 Load handling

8.5.7.1 Initiation menus Controls and instruments load
handling

2. Row 1 shows the setting value for the lever's deadband in the
centre position.
Row 2 shows the saved value for the lever's deadband in the
centre position.
3. Set lever's deadband on row 1, Lever middle deadband. Change

2. Row 1 shows the setting value for the lever's deadband in the end
position.
Row 2 shows the saved value for the lever's deadband in the end
position.
3. Set lever's deadband on row 1, Lever high/low deadband.


2. Row 1 shows the setting value for Control lever (S8150) deadband
in centre position.
Row 2 shows the stored value for Control lever (S8150) deadband
in centre position.
3. Set Control lever (S8150) deadband on row 1, Joystick middle
deadband. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for Control lever (S8150) deadband
in end position.
Row 2 shows the stored value for Control lever (S8150) deadband
in end position.
3. Set Control lever (S8150) deadband on row 1, Joystick high/low
deadband. Change the value with / and store the value
with Save .

2. Row 1 shows the setting value for the thumb control on Control
lever (S8150) deadband in centre position.
Row 2 shows the stored value for the thumb control on Control
lever (S8150) deadband in centre position.
3. Set the thumb control on Control lever (S8150) deadband on row
1, Thumb joystick middle deadband. Change the value with /

2. Row 1 shows the setting value for the thumb control on Control
lever (S8150) deadband in end position.
Row 2 shows the stored value for the thumb control on Control
lever (S8150) deadband in end position.
3. Set the thumb control on Control lever (S8150) deadband on row
1, Thumb joystick high/low deadband. Change the value with

8.5.7.2 Initiation menus Lifting/lowering
7.2 Lifting Lowering 1/XX INITIATE

2. Row 1 shows the setting value for start current for Solenoid valve
lift (Y6005).
Row 2 shows the saved value for start current.
3. Set start current for Solenoid valve lift (Y6005) on row 1, Start
current lift mast. Change the value with / and store the
value with Save .
The start current is the lowest current that can be actuated. In
practice, it controls how slowly a function can be operated. On
functions with analogue control/activation (controllable), e.g. lift,
this is the current which is triggered when the lever leaves the
zero position.

2. Row 1 shows the setting value for end current for Solenoid valve
lift (Y6005).
Row 2 shows the saved value for end current.
3. Set end current for Solenoid valve lift (Y6005) on row 1, End
current lift mast. Change the value with / and store the
value with Save .
The end current is the highest current that can be actuated. In
practice, it controls how quickly a function can be operated. On
functions with analogue control activation (controllable), e.g. lift,
this is the current which is triggered when the lever is in the end
position.

lower (Y6004).
3. Set start current for Solenoid valve lower (Y6004) on row 1, Start
current lower mast. Change the value with / and store the
value with Save .
zero position.


lower (Y6004).
3. Set end current for Solenoid valve lower (Y6004) on row 1, End
current lower mast. Change the value with / and store the
value with Save .
position.

2. Row 1 shows the setting value for limitation of lifting speed when
the gear is selected. Lifting speed is limited when the machine can
be operated in order to reduce centre of gravity changes.
Row 2 shows the stored value for limitation of lifting speed.
3. Set end current for Solenoid valve lower (Y6004) in row 1, Lift
boom max output when drivetrain is engaged. Change the
position (deadband).

2. Row 1 shows the setting value for engine speed at minimum
deflection of the control lever for lifting without load. The rotation
speed is the lower level for rotation speed increase for the lifting
function for lifting without load. Engine speed affects lifting speed.
3. Set the engine speed on row 1, Boom engine speed request
unloaded, min. Change the value with / and store the value
with Save .


2. Row 1 shows the setting value for engine speed at maximum
deflection of the control lever for lifting without load. The rotation
speed is the upper level for rotation speed increase for the lifting
function for lifting without load. Engine speed affects lifting speed.
3. Set the engine speed on row 1, Boom engine speed request
unloaded, max. Change the value with / and store the value
with Save .
8.5.7.4 Initiation menus, Side shift

7.4 Side Shift 5/XX INITIATE
2. Row 1 shows the setting value for start current to Solenoid valve
side shift right (Y6021).
3. Set start current for Solenoid valve side shift right (Y6021), in row
1, Start current side shift right. Change the value with /
zero position.

2. Row 1 shows the setting value for end current to Solenoid valve
side shift right (Y6021).
3. Set end current for Solenoid valve side shift right (Y6021), in row
1, End current side shift right. Change the value with /
position.


side shift left (Y6020).
3. Set start current for Solenoid valve side shift left (Y6020), on row
1, Start current side shift left. Change the value with /
zero position.

side shift left (Y6020).
3. Set end current for Solenoid valve side shift left (Y6020), on row
1, End current side shift left. Change the value with / and
position.
8.5.7.5 Initiation menus, Spreading
7.5 Spreading 19/XX INITIATE

spreading out left (Y6018-LE).
3. Set start current for Solenoid valve spreading out left (Y6018-LE)
in row 1, Start current spreading out left. Change the value with
zero position.


spreading out left (Y6018-LE).
3. Set end current for Solenoid valve spreading out left (Y6018-LE) in
row 1, End current spreading out left. Change the value with /
position.

2. Row 1 shows the setting value for damping of spreading out left.
Row 2 shows the saved value for damping.
3. Set value for damping of spreading out in row 1, Damp value
spreading out left. Change the value with / and store the
value with Save .
Damping is the percentage by which the control current to the
solenoid valve is reduced approaching the end position. Damping
is used to increase accuracy and reduce mechanical stress on
the machine.

spreading in left (Y6019-LE).
3. Set start current for Solenoid valve spreading in left (Y6019-LE) in
row 1, Start current spreading in left. Change the value with /
zero position.


spreading in left (Y6019-LE).
3. Set end current for Solenoid valve spreading in left (Y6019-LE) in
row 1, End current spreading in left. Change the value with /
position.

2. Row 1 shows the setting value for damping of spreading in left.
3. Set value for damping of spreading in, in row 1, Damp value
spreading in left. Change the value with / and store the
value with Save .
the machine.

spreading out right (Y6018-RI).
3. Set start current for Solenoid valve spreading out right (Y6018-RI)
in row 1, Start current spreading out right. Change the value
zero position.


spreading out right (Y6018-RI).
3. Set end current for Solenoid valve spreading out right (Y6018-RI)
in row 1, End current spreading out right. Change the value with
position.

2. Row 1 shows the setting value for damping of spreading out right.
3. Set value for damping of spreading out in row 1, Damp value
spreading out right. Change the value with / and store the
value with Save .
the machine.

spreading in right (Y6019-RI).
3. Set start current for Solenoid valve spreading in right (Y6019-RI) in
row 1, Start current spreading in right. Change the value with
zero position.


spreading in right (Y6019-RI).
3. Set end current for Solenoid valve spreading in right (Y6019-RI) in
row 1, End current spreading in right. Change the value with
position.

2. Row 1 shows the setting value for damping of spreading in right.
3. Set value for damping of spreading in, in row 1, Damp value
spreading in right. Change the value with / and store the
value with Save .
the machine.

2. Row 1 shows the setting value for whether spreading should be
permitted with locked twistlocks.
Row 2 shows the stored value for whether spreading should be
permitted with locked twistlocks.
3. Set the value for whether spreading should be permitted with
locked twistlocks in row 1, Spreading when locked TW. Change

8.5.7.7 Initiation menus, Tilt
7.7 Tilt 1/XX INITIATE

tilt in (Y6011).
3. Set start current for Solenoid valve tilt in (Y6011) on row 1, Start
current tilt in. Change the value with / and store the value
with Save .
zero position.

tilt in (Y6011).
3. Set end current for Solenoid valve tilt in (Y6011) on row 1, End
current tilt in. Change the value with / and store the value
with Save .
position.

tilt out (Y6010).
3. Set start current for Solenoid valve tilt out (Y6010) on row 1, Start
current tilt out. Change the value with / and store the value
with Save .
zero position.


tilt out (Y6010).
3. Set end current for Solenoid valve tilt out (Y6010) on row 1, End
current tilt out. Change the value with / and store the value
with Save .
position.

2. Row 1 shows the setup value for tilt out, end position.
Row 2 shows the stored value for tilt out, end position.
Row 3 shows the tilt angle.
3. Set tilt angle for end position out on row 1, Tilt out, end position.

2. Row 1 shows the setup value for tilt in, end position.
Row 2 shows the stored value for tilt in, end position.
Row 3 shows the tilt angle.
3. Set tilt angle for end position in on row 1, Tilt in, end position.

2. Row 1 shows the setting value for raising the engine speed at tilt in.
Row 2 shows the stored value for raising the engine speed at tilt in.
3. Set the engine speed at tilt in row 1, Tilt engine speed request.

8.5.7.9 Initiation menus, Load securing
7.9 Load carrier 28/XX INITIATE

2. Row 1 shows setting value for the distance to the load when
the speed of the lower function shall be dampened at top lift on
machines with container damping.
Row 2 shows the saved value for the distance.
Row 3 shows current distance between attachment and load.
Row 4 shows the status for the damping.
0 = Off, no damping.
1 = On, damping active.
3. Set value for the distance in row 1, Attachment lower auto damp.

2. Row 1 shows the setting value for the distance to the load when
the speed of the lower function should be damped at bottom lift on
machines with container damping.
Row 2 shows the saved value for the distance.
Row 3 shows current distance between attachment and load.
Row 4 shows the status for the damping.
0 = Off, no damping.
1 = On, damping active.
3. Set value for the distance in row 1, Attachment lower auto damp.

2. Row 1 shows the setting value for blocking of spreading on the
attachment at contact with the load.
Row 2 shows the stored value for spreading on the attachment
at contact with the load.
3. Set the end current in row 1, Interlock spreader when alignment.
Change the value with / and store the value with .
zero position.

8.5.7.10 Initiation menus, Other functions
8.5.8 Control system


2. Row 1 shows the setting value for brightness of background
lighting for the panels in the cab in the dark.
Row 2 shows the stored value for brightness of background lighting
for the panels in the cab in the dark.
3. Set the value for the panel's searchlight in darkness on row 1,
Panel searchlight brightness at darkness.Change the value
with / and store the value with .

lighting for the panels in the cab in daylight.
for the panels in the cab in daylight.
3. Set the value for the panel's searchlight in daylight on row 1, Panel
searchlight brightness at daylight. Change the value with /
and store the value with .

2. Row 1 shows the setting value for brightness of function lighting in
the panels in the cab in the dark.
Row 2 shows the stored value for brightness of function lighting in
the panels in the cab in the dark.
3. Set the value for the panel's function light in darkness on row 1,
Panel function light brightness at darkness. Change the value

2. Row 1 shows the setting value for brightness of function lighting in
the panels in the cab in daylight.
Row 2 shows the stored value for brightness of function lighting in
the panels in the cab in daylight.
3. Set the value for the panel's function light in daylight on row 1,
Panel function light brightness at daylight. Change the value


lighting in the switches in the cab in the dark.
in the switches in the cab in the dark.
3. Set the value for the button searchlight in darkness on row 1,
Button searchlight brightness at darkness. Change the value

lighting in the switches in the cab in daylight.
in the switches in the cab in daylight.
3. Set the value for the button searchlight in daylight on row 1, Button
searchlight brightness at daylight. Change the value with /

2. Row 1 shows the setting value for brightness of indicator lights
on the attachment in the dark.
Row 2 shows the stored value for brightness of indicator lights
on the attachment in the dark.
3. Set the value for brightness of indicator lights for attachment
in darkness in row 1, Attach. indication light brightness at
darkness. Change the value with / and store the value
with .

2. Row 1 shows the setting value for brightness of indicator lights
on the attachment in daylight.
Row 2 shows the stored value for brightness of indicator lights
on the attachment in daylight.
3. Set the value for brightness of indicator lights for attachment in
daylight in row 1, Attach. indication light brightness at daylight.


2. Row 1 shows the setting value for display of load capacity in the
main menu on the display in the cab.
Row 2 shows the stored value for display of load capacity in the
main menu on the display in the cab.
3. Set the value for brightness of indicator lights for attachment in
daylight in row 1, Attach. indication light brightness at daylight.
8.5.8.2 Initiation menus, Monitoring
8.2 Monitoring 1/XX INITIATE

2. Row 1 shows max. speed forwards in km/h.
Row 2 shows the stored value for max. speed forwards.
3. Set max. speed forward in km/h. on row 1, Speed limit forward.

2. Row 1 shows max. speed reverse in km/h.
Row 2 shows the stored value for max. speed reverse.
3. Set max. speed backward in km/h. on row 1, Speed limit reverse.

2. Row 1 shows the service interval.
Row 2 shows the saved value for the service interval.
3. Set service interval on row 1, Service time interval. Change the
value with / and store the value with .
The service interval can be changed between 0 and maximum
service interval for the machine. If the interval is set to 0 then the
service indication is switched off completely.


2. Row 1 shows resetting of the service interval.
Row 2 shows the saved value for resetting.
3. Activate reset on row 1, Service time interval reset. Change the

2. Row 1 shows the number of hours left to service when Event
menu, service, shall be shown.
Row 2 shows the saved value for resetting.
3. Set the number of hours remaining to service when Event menu,
service, should be shown on row 1, Service time pop up hours.

2. Row 1 shows the correction value for weight when picking up.
Row 2 shows the saved correction value.
Row 3 shows the picking weight plus the correction value.
Row 4 shows the picking weight plus the correction value in kg.
3. Set correction value for weight during picking on row 1, Pick
weight limit offset. Change the value with / and store the
value with .

2. Row 1 shows the correction value for weight when depositing.
Row 2 shows the saved correction value.
Row 3 shows the deposit weight plus the correction value.
Row 4 shows the deposit weight plus the correction value in kg.
3. Set correction value for weight during setting down on row 1, Drop
weight limit offset. Change the value with / and store the
value with .


2. Row 1 shows the setup value for the speed limit lift height or load
position.
Row 2 shows the saved speed limit.
Row 3 shows the highest permitted speed limit.
Row 4 shows the status lift height digital sensor (S7211)
3. Set speed limit lift height on row 1, Speed limit lift height or load
position. Change the value with / and store the value with .

2. Row 1 shows setting value for ECO Drive Mode in the machine,
this determines which operating mode the machine is in. For other
setup of Eco Drive mode, see 1.11 Start & Stop 1/XX INITIATE,
page 8:99.
Row 2 shows the saved value for ECO-mode.
0 = Not available.
1 = Power mode
2 = Normal mode.
3 = ECO mode.
4 = Adjustable via customer settings, see Operator's manual.
3. Set the position for Eco Drive Mode on row 1, ECO Drive Mode
selection. Change the value with / and store the value with
.

2. Row 1 shows the speed limitation weight.
Row 2 shows the setting value for load limit 1.
Row 3 shows the saved value for load limit 1.
3. Set load limit 1 on row 2, Load limit 1. Change the value with /


2. Row 1 shows the speed limitation weight.
Row 2 shows the setting value for load limit 2.
Row 3 shows the saved value for load limit 2.
3. Set load limit 2 on row 2, Load limit 2. Change the value with /

2. Row 1 shows the setting value for the speed limit weight, speed
limit 1.
Row 2 shows the saved speed limit 1.
Row 4 shows the lowest permitted speed limit.
3. Set speed limit 1 on row 1, Speed limit 1. Change the value with
/ and store the value with .

2. Row 1 shows the setting value for the speed limit weight, speed
limit 2.
Row 2 shows the saved speed limit 2.
Row 4 shows the lowest permitted speed limit.
3. Set speed limit 2 on row 1, Speed limit 2. Change the value with

2. Row 1 shows the setting value for deactivation of engine speed
limitation at cold start.
Row 2 shows saved value for deactivation of engine speed
limitation at cold start.
0 = No limitation.
1 = Engine speed limited for cold engine.
3. Set engine speed limitation on row 1, Disable cold start engine
speed limit. Change the value with / and store the value
with .


2. Row 1 shows the setting value for limitation if there is no driver tag.
Row 2 shows saved value for limitation if there is no driver tag.
0 = No limitation.
1 = Not possible to start engine.
2 = Speed is limited to 5 km/h.
3. Set the limitation if there is no driver tag on row 1, Limitation no
driver tag. Change the value with / and store the value
with .

2. Row 1 shows the setting value for blocking the diagnostic code.
Row 2 shows the saved value for blocking the diagnostic code.
0 = Diagnostic code not blocked.
1 = Service code needed to access diagnostics.
3. Set blocking of code for diagnostics in row 1, Block diagnostic
code. Change the value with / and store the value with .

2. Row 1 shows the setting value for height limitation.
Row 2 shows the saved value for height limitation.
Row 3 shows the current height.
3. Set height limitation in row 1, Mast height limit/warning. Change
the value with / and store the value with .

2. Row 1 shows the setting value for height for speed limitation at
contact.
Row 2 shows the saved value for height for speed limitation at
contact.
Row 3 shows the current height.
3. Set height limitation in row 1, Mast height limit/warning. Change
the value with / and store the value with .

8.5.9 Frame, body, cab and accessories


2. Row 1 shows the setting value for whether function group 1 can be
bypassed with code lock.
Row 2 shows the stored value for whether function group 1 can be
3. Set the setting in row 1, Enable override with code. Change the
0 = The function group cannot be bypassed with code lock.
1 = The function group can be bypassed with code lock.





8.5.9.4 Initiation menus, Climate system

9.4 Climate System 3/XX INITIATE
2. Row 1 shows the sleep mode functionality. Sleep mode means
that cab cooling/heating is switched off when the cab door is open.
Row 2 shows the saved value for the status of sleep mode
functionality.
3. Activate sleep mode functionality on row 1, Sleep mode
functionality enable, with a 1. Charge the value with / and
store the value with .
8.5.9.5 Initiation menus, Windscreen wipers

9.5 Wiper & Washer Sys 1/XX INITIATE
2. Row 1 shows the time interval for fast wiper interval.
Row 2 shows the saved value for the time interval.
3. Set the time interval for fast intermittent wiping on row 1,
Intermittent wiper fast. Change the value with / and store
the value with .


2. Row 1 shows the time interval for slow wiper interval.
Row 2 shows the saved value for the time interval.
3. Set the time interval for slow intermittent wiping on row 1,
Intermittent wiper slow. Change the value with / and store
the value with .

2. Row 1 shows pre-wash.
Row 2 shows the stored value for pre-wash.
3. Set the value for pre-wash in row 1, Prewash wiper. Change the
8.5.9.6 Initiation menus, Lighting

9.6 Lighting Sys 1/XX INITIATE
2. Row 1 shows the setting for working lights when starting the
engine.
Row 2 shows the stored value for working lights when starting
the engine.
3. Set use of working lights when starting the engine on row 1,
Working lights on during start engine. Change the value with
0 = switched off when the starter motor is running.
1 = switched on.

2. Row 1 shows the setting for error code display for open circuit for
lighting and revolving beacon.
Row 2 shows the stored value for error code display for open
circuit for lighting and revolving beacon.
3. Set error code display for open circuit on row 1, Disable O.C error
code light/rotating beacon. Change the value with / and
On machines with LED lighting, an error code will be generated
because the power consumption of LED lights is low. By setting
this value, incorrect error codes for lighting can be avoided.
0 = error code display for open circuit active.
1 = error code display for open circuit deactivated.


2. Row 1 shows the setting for activating functions while driving
backwards. Using this function, you can choose which functions
should be started first when machine speed has fallen below 3
km/h.
Row 2 shows the stored value for activating the functions.
3. Set the value for back-up light/reverse alarm in row 1, Disable rev
light/alarm until moving in reverse direction. Change the value
8.5.9.7 Initiation menus, Signal system
9.7 Signalling Sys 1/XX INITIATE

2. Row 2 shows the saved value for use.
3. Set use of rotating beacon on row 1, Rotating beacon cab and
boom. Change the value with / and store the value with .
0 = off.
1 = activated only with the switch.
2 = activated with the switch or during reversing.
3 = activated with the switch or when the engine is running.
4 = activated with the switch or during ignition on.
9.7 Signalling Sys 2/XX INITIATE

2. Row 1 shows the use of the revolving beacon, frame.
Row 2 shows the saved value for use.
3. Set use of rotating beacon on row 1, Rotating beacon frame.
0 = off
1 = activated only with the switch.
2 = activated with the switch or during reversing.
3 = activated with the switch or during driving forward.
4 = activated with the switch or when the engine is running.
5 = activated with the switch or during automatic functions.

8.5.9.14 Initiation menus, Central lubrication
9.14 Central Lubr 1/XX INITIATE

2. Row 1 shows the setting value for the capacity of central
lubrication, frame.
Row 2 shows the saved value for the capacity.
3. Set the capacity for central lubrication, frame in row 1, Grease
capacity frame adjust 0-150% Change the value with / and
0% means lubrication is turned off and at 150% the central
lubrication system lubricates about 50% more than in normal mode.
9.14 Central Lubr 2/XX INITIATE

2. Row 1 shows the setting value for the capacity of central
lubrication, attachment.
Row 2 shows the saved value for the capacity.
3. Set the capacity for central lubrication, attachment in row 1,
Grease capacity attach. adjust 0-150% Change the value with
0% means lubrication is turned off and at 150% the central
lubrication system lubricates about 50% more than in normal mode.
8.5.11 Common electrics

11.1 Distr Of Electr 1/XX INITIATE

2. Row 1 shows the setting for activating functions while driving
backwards. Using this function, you can choose which functions
should be started first when machine speed has fallen below 3
km/h.
Row 2 shows the stored value for activating the functions.
3. Set the value for back-up light/reverse alarm in row 1, Disable rev
light/alarm until moving in reverse direction. Change the value

8.5.11.5 Initiation menus, Voltage feed
11.5 Distr Of Electr 1/XX INITIATE

2. Row 1 shows the time for automatic system and engine shut down.
Row 2 shows the saved value for time.
3. Set the time for automatic system and engine shut down on row 1,
Automatic system shut down time. Change the value with /

9:1
9 Frame, body, cab and accessories
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ................................................................. 9:3
9.1.1 Multi-function lever ....................................................................................9:13
9.2 Safety and emergency equipment .................................................................9:15
9.2.1 Control breaker .........................................................................................9:15
9.2.2 Seat belt ....................................................................................................9:15
9.2.3 Fire extinguisher........................................................................................9:15
9.2.5 Alcolock .....................................................................................................9:15
9.3 Seat................................................................................................................9:16
9.3.4 Bumper......................................................................................................9:17
9.3.8 Passenger seat .........................................................................................9:17
9.3.11 Arm rest.....................................................................................................9:17
9.3.17 Head rest...................................................................................................9:17
9.3.19 Sensor, operator-in-seat............................................................................9:17
9.4 Heating, ventilation and air conditioning ........................................................9:18
9.4.1 Fresh air filter ............................................................................................9:25
9.4.2 Fresh air and recirculation damper............................................................9:25
9.4.3 Cab fan......................................................................................................9:27
9.4.4 Heat exchanger heat .................................................................................9:28
9.4.5 Water valve ...............................................................................................9:29
9.4.6 Sensor coolant temperature ......................................................................9:30
9.4.7 Compressor air conditioning......................................................................9:30
9.4.8 Condenser unit ..........................................................................................9:32
9.4.9 Receiver drier ............................................................................................9:33
9.4.10 Pressure switch .........................................................................................9:35
9.4.11 Expansion valve ........................................................................................9:36
9.4.12 Temperature deicing sensor ......................................................................9:37
9.4.13 Heat exchanger, cooling............................................................................9:38
9.4.14 Air distributor .............................................................................................9:40
9.4.15 Defroster nozzles ......................................................................................9:41
9.4.16 Fan temperature sensor ...........................................................................9:42
9.4.17 Interior temperature sensor .......................................................................9:43
9.4.18 Ambient temperature sensor .....................................................................9:44
9.4.20 Timer diesel heater....................................................................................9:44
9.4.21 Diesel heater .............................................................................................9:45
9.4.25 Preparation, cab fan ..................................................................................9:45
9.5 Wiper/washer system.....................................................................................9:46
9.5.4 Washer motor and reservoir......................................................................9:49
9.5.5 Wiper motor front ......................................................................................9:50
9.5.6 Wiper motor roof .......................................................................................9:51
9.5.7 Wiper motor rear .......................................................................................9:52
9.6 Lighting system ..............................................................................................9:54
9.6.1 Headlights .................................................................................................9:57
9.6.2 Running lights ...........................................................................................9:57
9.6.3 Tail lights ...................................................................................................9:58
9.6.4 Brake light .................................................................................................9:58
9.6.5 Back-up lights............................................................................................9:58
9.6.6 Direction indicators....................................................................................9:59
9.6.7 Warning lamp, Hazard...............................................................................9:59
9.6.8 Revolving beacon......................................................................................9:59
9.6.9 Working lights, cab ....................................................................................9:60
9.6.10 Work lights, mast.......................................................................................9:60
9.6.11 Work lights, attachment.............................................................................9:61
9.6.12 Interior lighting...........................................................................................9:61
9.6.13 Extra working lights frame .........................................................................9:61

9.7 Signalling system ...........................................................................................9:62

9.7.1 Horn ..........................................................................................................9:64
9.7.2 Warning lamp, Hazard...............................................................................9:64
9.7.3 Revolving beacon......................................................................................9:64
9.7.4 Warning parking brake ..............................................................................9:64
9.7.5 Reverse alarm ...........................................................................................9:64
9.7.7 Buzzer .......................................................................................................9:65
9.8 Entertainment and communication ................................................................9:66
9.8.1 Audio system.............................................................................................9:66
9.8.7 Voltage converter ......................................................................................9:67
9.9 Glass/windows/mirrors...................................................................................9:68
9.9.1 Windscreen ...............................................................................................9:69
9.9.2 Side window ..............................................................................................9:71
9.9.3 Roof window..............................................................................................9:73
9.9.4 Rear window .............................................................................................9:73
9.9.5 Rear view mirror ........................................................................................9:74
9.9.8 Rear view camera and load camera..........................................................9:74
9.10 Cab structure and suspension .......................................................................9:77
9.10.1 Cab frame .................................................................................................9:77
9.10.2 Doors.........................................................................................................9:77
9.10.3 Cab undercarriage ....................................................................................9:78
9.11 Cab interior ....................................................................................................9:79
9.11.2 Interior fittings, plastic ...............................................................................9:79
9.11.3 Interior fittings, textile ................................................................................9:83
9.11.4 Floor covering ...........................................................................................9:84
9.11.5 Insulation ...................................................................................................9:84
9.11.6 Sun visors .................................................................................................9:85
9.11.8 Writing panel and deed pigeon-hole..........................................................9:85
9.12 Frame.............................................................................................................9:86
9.13 Body structure................................................................................................9:87
9.13.1 Wings ........................................................................................................9:87
9.13.2 Hood engine compartment ........................................................................9:87
9.13.3 Footsteps and hand rail.............................................................................9:87
9.13.4 Counterweight ...........................................................................................9:88
9.13.5 Battery compartment .................................................................................9:88
9.13.8 Tool kit .......................................................................................................9:88
9.13.9 Lifting lugs .................................................................................................9:89
9.14 Central lubrication ..........................................................................................9:90
9.14.1 Pump unit ..................................................................................................9:90
9.14.2 Distribution block .......................................................................................9:91
9.14.3 Lines..........................................................................................................9:91
9.14.4 Lubricant nipples .......................................................................................9:92
9.14.5 Sensor, central lubrication .........................................................................9:92
9.15 Paint/coatings ................................................................................................9:93

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:3
9 Frame, body, cab and

accessories
Frame, body, cab and accessories, general
and instructions for components and systems belonging to the
frame, body, cab and accessories, refer to the relevant supplier
documentation.


9:4 9 Frame, body, cab and accessories – Frame, body, cab and accessories
Frame, body, cab and accessories,

description
The machine consists of frame, body and cab.
The frame is the machine's structural part and is made of high-strength

steel.
The body consists of wings, engine hood and other parts mounted on
the frame.
The cab is built separately and insulated from the frame using
heavy-duty rubber dampers. Driver's seat, steering wheel and control
lever for hydraulics can be adjusted for optimal individual operating
position. Effective insulation results in a minimum of vibration and a low
sound level. The machine is equipped with a heating and ventilation
unit with air conditioning.
WARNING
Each case of mechanical impact on the cab may involve
risks since the strength is changed. Consequently,
making holes in load bearing parts is forbidden.
Contact Cargotec for recommendations.
WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!
CAUTION
All work on the roof pane is forbidden (e.g. making
holes or cutting).
Risk of material damage.
Small cracks in the material around outer edges for
example indicate that the strength of the roof window
is affected and it must be replaced immediately.

9 Frame, body, cab and accessories – Controls and instruments 9:5

Cab overview
1. Travel direction selector and parking brake 8. Right-hand dashboard panel, rear section
2. Multi-function lever 9. Arm rest and storage box
3. Steering wheel 10. Driver's seat
4. Steering wheel panel 11. Accelerator
5. Display with function keys 12. Brake pedals
6. Right-hand dashboard panel, front section 13. Control, driver's seat
7. Right-hand dashboard panel with linear levers or
control lever, centre section
Rear cab section, see Rear cab section, page 9:8.

9:6 9 Frame, body, cab and accessories – Controls and instruments
Steering wheel panel
Steering wheel panel

14. Ignition key lock
14
21 22 23 30 16 17 15. Engine start and stop button
16. Indicator light, parking brake
17. Indicator light, high beams
18
18. Indicator light for active error codes
24 19
19. Indicator light for direction indicators
25 20 20. Warning lamp, by-pass of safety system
21. Switch for windscreen wiper, windscreen, continuous
26
22. Switch for windscreen wiper, windscreen, intermittent wiping
012692
23. Switch for windscreen flusher
27 28 29 32 31 33 15 24. Switch for windscreen wiper, roof, intermittent wiping
Steering wheel panel 25. Switch, windscreen wiper roof, continuous
26. Switch, windscreen wiper rear, continuous
27. Switch for windscreen wiper, rear, intermittent wiping
28. Light sensor
29. No function
30. Switch for manual shifting up
31. Switch for manual shifting down
32. Switch for automatic shifting
33. Travel direction indicator, Forward Neutral Reverse
Right-hand dashboard panel, front section
34 35 36 37 38 39 40 34. Control breaker

43
35. Spare
36. Recirculation switch
37. Switch for defroster
38. Switch for reduced fan speed
41 42 44 45 46 39. Switch for automatic regulation of air conditioning

40. Switch for increased fan speed
41. Switch for increased temperature
42. Switch for reduced temperature
012693
43. Switch for cooling

47 48 49 50 51 52 44. Switch for air distribution, to the floor
45. Switch for air distribution, to the operator
46. Switch for air distribution, to the roof
47. Switch for by-pass of safety system
48. Spare
49. Spare
50. Spare
51. Spare
52. Switch for audio off (radio)

Right-hand control panel, centre section
Right-hand control panel, centre section

53. Control for load handling
a Travel direction selector, Forward - Neutral - Reverse
b Control for lifting/ lowering
c Control for tilt
d Control for side shift
Control for spreading 20'–40' (Shift)
e Spare
f Spare
g Shift button
h Spare
i Switch to open the twistlocks
j Control for spreading 20'–40' (control lever Cobra)
54. Spare
55. Spare
56. Spare
57. Switch for automatic spreading 20'-40'
58. Switch for 30'-stop
59. Spare
60. Spare
61. Spare
62. Switch for twistlocks, automatic/manual twistlocks
63. Spare
64. Switch for horn
Right-hand dashboard panel, centre section

• Linear levers
• Control lever EGO
• Control lever Cobra

Right-hand control panel, rear section
Right-hand control panel, rear section

65. Switch for work lights on cab
66. Switch for work lights on mast
67. Switch for work lights attachment
68. Switch for extra work lights on front wings
69. Switch for back-up light
70. Switch for length adjustment of the right-hand control panel
71. No function
72. Switch for height adjustment of the right-hand control panel
Navigation for control system when menus are active or manual
control of values in menus with this option.
73. Function keys and navigation wheel for control system
74. Switch for headlights
75. Switch, interior lighting
76. Switch, revolving beacon
77. Switch for flashing hazard lights
Right-hand dashboard panel, rear section and display
Rear cab section
Rear cab section

78. Cover lid
79. Electronic box with fuses and relays
Connector VDI
80. Key lock, by pass
81. Tag reader for operator identification
82. Timer diesel heater
Rear cab section

Roof panel
Roof panel
83. Light sensor
84. Not used
85. Indicator light for locked load
86. Indicator light, contact
Roof panel 87. Indicator light for unlocked load
Control for load handling

For more controls for load handling and associated functions, see
section Operator's manual section 4.6 Load handling.

Operating menus, overview
Example of operating menus 4. Engine operating menu

1. Operating menu 5. Transmission and hydraulics operating menu
2. Operating menu, trip computer work shift 6. Operating menu electrical system
3. Operating menu extra functions, e.g. scales 7. Operating menu customer settings

Silicone panel right-hand dashboard panel front

section, replacement
4 Turnover the panel and remove the nuts and washers that secure
the silicone panel.
5 Replace the silicone panel.
CAUTION
Product damage.
screws too hard.
Switch right-hand dashboard panel front section,

replacement
4 Detach the connector from the switch.
5 Replace the switch.
CAUTION
Product damage.
screws too hard.

Silicone panel right-hand dashboard panel rear

section, replacement
2 Open the cover on the storage box.
015771
1 2
1. Navigation wheel
2. Lid, storage box

015762
4 Loosen the spring and carefully turnover the storage box.

Avoid stretching the cables.

1 2 5 Carefully separate the navigation wheel and silicon panel's

connectors.
CAUTION
The navigation wheel's contact is only soldered onto
the circuit board.
Product damage.
Exercise caution when the connector is separated in
order to avoid damage to the circuit board.
6 Remove the nuts and washers that secure the silicone panel.
015761
4 3
1. Contact, navigation wheel
2. Nut, silicone panel
3. Nut, silicone panel
4. Contact, silicone panel
7 Carefully remove the navigation wheel's circuit board with sensor

from the silicone panel.
Pull the navigation wheel straight up and undo the plastic nut
under the wheel.
CAUTION
Product damage.
screws too hard.
Navigation wheel parts

1. Navigation wheel
2. Plastic nut
3. Washer
4. Circuit board
Navigation wheel, replacement

See Silicone panel right-hand dashboard panel rear section,
replacement, page 9:11.

9 Frame, body, cab and accessories – Multi-function lever 9:13
Silicone panel steering panel, replacement

2 Remove the five screws.
015769
1 2 3 3 Turnover the panel and disconnect the contact.

4 Remove the nuts and washers that secure the silicone panel.
015770
1. Silicone panel
2. Contact
3. Nut
9.1.1 Multi-function lever

General
Light control, horn and direction indicators are handled by a
2 multi-function lever (position 2).
015221

9:14 9 Frame, body, cab and accessories – Multi-function lever
Multi-function lever, replacement

2 Remove the gaiter from the multi-function lever.
015778
3 Remove the screws and the cover.

015776
4 Remove the screws and fold out the multi-function lever.

Mark the pins and then remove them.
5 Replace the multi-function lever.
6 Fit in the reverse order. Replace pins as marked.
015777

9 Frame, body, cab and accessories – Safety and emergency equipment 9:15
9.2 Safety and emergency equipment

9.2.1 Control breaker
Control breaker, description
See Control breaker voltage, description, page 11:18.
9.2.2 Seat belt

Seat belt, description
Two-point seatbelt fitted in the seat. See Driver's seat, page 9:16.
There are also 3-point seatbelt .
For diagnostic menu, see 9.3 Seat 1/XX DIAGNOSE, page 8:58.
An event menu appears on the display and indicates that the speed of
the machine is above 3 km/h and the seat belt sensor's output signal is
0 V (seat belt not buckled).
9.2.3 Fire extinguisher

Fire extinguisher, description
Usage instructions are on the fire extinguisher.
If the machine is equipped with fire extinguisher then it must be

approved in accordance with European standard EN3. The fire
extinguisher must be selected so that it is designed for use against fires
in: fibrous fuels (Class A), liquid fuels (Class B), gaseous fuels (Class
C) and electrical appliances. Adapted fire extinguishing equipment can
be ordered from Cargotec.
Fire extinguishers must only be service and repaired by personnel

with special training.
9.2.5 Alcolock
Alcolock, description
The machine may be equipped with an alcolock. Starting the engine

requires an approved breath test from the operator. The alcolock is an
independent system which communicates with the machine's control
system. The alcolock unit is fitted in the cab.
For more information, see Supplier documentation.

016631

9:16 9 Frame, body, cab and accessories – Seat
9.3 Seat
Seat, general
The seat's function is to provide the operator with a good sitting position
and contribute to a good work environment. The cab's seat has several
adjustment options and fulfils high comfort standards.
Driver's seat
Standard seat
Standard seat
The driver's seat is equipped with several controls for adjustment as
follows (adjustment is easier when nobody is sitting in the seat):
1. Seat belt, 2-point.
Seat belt, 3-point .
2. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.
3. Back rest angle.
Release the lock with the lever, set the desired tilt angle and
release the lever to lock in the desired position.
4. Longitudinal adjustment.
Release the seat with the lever, set the desired distance and
release the lever to lock in the desired position.
5. Height of seat.
Turn the knob until desired height position is obtained.
6. Angle setting
Turn the knob until the damping suits the body weight.
7. Seat tilt.
Release the tilt with the control, set the desired tilt and release the
control to lock in the desired position.
Driver's seat with adjustment possibilities
8. Seat length.
Release the seating length using the control, set the desired length
and release the control to lock in the desired position.
The standard seat can be equipped with the following options:

• Head rest.
• Arm rest on the left-hand side.
Optional seat
As an option, the machine can be equipped with seats of a different

make and with other functions.
Passenger seat
Passenger seat
As an option, the machine can be equipped with a folding passenger

seat with two-point belt on the left of the driver's seat.
To fold up the seat:

1. Raise the seat past folded-up position.
2. Pull the seat towards the driver's seat.
3. Lower the seat and check that the recess on the seat cushion's
frame is secured against the bracket (see figure).

9 Frame, body, cab and accessories – Bumper 9:17
Driver's seat, replacement

2 Remove the nuts from the seat's mountings.
3 Disconnect the cable harness from the seat.
4 Secure the right-hand console so it does not fall down when the
seat is lifted out.
Secure it with a cord from the roof, or get the help of a colleague.
5 Remove the seat.
9.3.4 Bumper
Bumper, description
The shock absorbers are integrated in the suspension unit and are
self-adjusting, that is, adjust automatically to the operator\qs weight.
9.3.8 Passenger seat

Passenger seat, description
The seat folds (vertically) in order not to obstruct the entrance when not
in use. Located to the left of the driver's seat.
9.3.11 Arm rest

Armrests, description
Right side armrest is integrated into the right console and is attached to
the seat's seat frame. The height can be adjusted separately.
Arm rest for left side is an option .
9.3.17 Head rest

Head restraint, description
Some models of seat can be adjusted with a head restraint for

increased comfort.
9.3.19 Sensor, operator-in-seat

Sensor operator in seat, description
Sensor, operator-in-seat (B2300) detects whether the seat cushion on
the driver's seat is depressed, which indicates to the control system
that the driver's seat is occupied. This is used to warn with a buzzer,
located in Control unit KPU (D7902) (right console), if the operator
leaves the driver's seat without applying the parking brake. When
operator-in-seat sensor (B2300) indicates that the operator has left the
driver’s seat, the operation and hydraulic functions are blocked.
For diagnostic menu, see 9.3 Seat 1/XX DIAGNOSE, page 8:58.

9:18 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
description
The machine’s system for heating, ventilation and air conditioning is
available in two versions:
EHC
The machine is equipped with EHC (Electronic Heat Control) as
standard, this means electronic control of the fan, air distribution and
heating. The heating is connected to the engine's cooling system and
provides heat when the engine is hot.
The heater unit consists of climate unit and silicone panel.
The unit is controlled using switches on the silicone panel, the settings
are shown on the display.
Climate unit The climate unit contains air filter, fresh air and recirculation damper,
heat exchanger heat, cab fan, air distributor, heating valve and
1. Cab fan and Fan motor (M6570)
temperature sensor.
2. Fine filter
1. The climate unit draws in air from outside (through the air intake at
3. Heat exchanger heat the front of the cab) or from inside the cab, the option is controlled
4. Heat exchanger, cooling using the fresh air damper.
5. Actuator motor recirculation (Y6120) 2. The fans, which are controlled variably 0–100 %, draw in air
through the fresh air filter and heat exchanger heat.
6. Fresh air and recirculation damper
3. For heating, the heating valve is opened, which is controlled
7. Air distributor, Damper motor (Y6720) and variably 0–100 %, and controls how much of the engine's coolant
Sensor fan temperature (B7752) should pass via heat exchanger heat.
8. Air connection, Sensor temperature interior 4. When the air passes via the heat exchanger, the air temperature
(B7751) can be maintained or increased.
9. Temperature deicing sensor (B7753) 5. The fans blow the cleaned and temperature-controlled air into the
air distributor.
6. The air distributor directs the air towards channels in the cab's
interior for floor, defroster and air vents.
7. The temperature sensor measures the temperature of the air in the
cab and of the air in the air distributor.

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:19
ECC
As an option, the machine can be equipped with air conditioning,

ECC (Electronic Climate Control). This means electronic control of
fan, air distribution, cooling and heating. The heating is connected
to the engine's cooling system and provides heat when the engine is
hot. The cooling is generated by the A/C compressor, which is driven
by the engine.
The function of the air conditioning is to:

• heat the air when it is cold,
• dehumidify the air when it is damp,
• clean the air of impurities,
• cool the air when it is hot,
• defrost (defroster function).
The air conditioning consists of climate unit, A/C compressor, receiver

drier, condenser and silicone panel.
The climate unit contains air filter, fresh air and recirculation damper,
heat exchanger heat, heat exchanger cooling, expansion valve,
receiver drier, cab fan, air distributor, heating valve and temperature
sensor.
1. The climate unit draws in air from outside (through the air intake at
the front of the cab) or from inside the cab, the option is controlled
using the fresh air damper.
2. The fans, which are controlled variably 0–100 %, draw in air
through the fresh air filter and the heat exchangers.
3. For heating, the heating valve is opened, which is controlled
variably 0–100 %, and controls how much of the engine's coolant
should pass via heat exchanger heat.
4. For cooling, the compressor is activated, which compresses the
refrigerant and routes it onward into the condenser. There the
warm refrigerant is cooled using the engine's cooling fan and the
ambient air, on which the refrigerant is condensed into fluid.
The cooling function is automatically deactivated when a door is
open. When the door is closed the cooling is reactivated. The air
conditioning unit has a delay of 45 seconds between deactivation
and activation.
5. The refrigerant is routed onward from the condenser to the receiver
drier and the expansion valve. The expansion valve controls the
evaporation of the refrigerant which takes place in heat exchanger
cooling (evaporator). When the refrigerant is evaporated, cooling
is created in heat exchanger cooling.
6. When the air passes via the heat exchangers, the air temperature
can be maintained, reduced or increased.
7. The fans blow the cleaned and temperature-controlled air into the
air distributor.
8. The air distributor directs the air towards channels in the cab's
interior for floor, defroster and air vents.
9. The temperature sensor measures the temperature of the air in the
cab and of the air in the air distributor.

Heating, ventilation and air conditioning, function

description

1 The Increase temperature switch U=5V Cab overview, page 9:5
(S1051-1) or Decrease temperature D1: 9.4 Climate System 2/XX DIAGNOSE,
switch (S1051-2) sends a voltage signal page 8:59
to the KPU control unit (D7902).
2 The Increase fan speed switch (S1180-1) U=5V Cab overview, page 9:5
or Decrease fan speed switch (S1180-2) D1: 9.4 Climate System 2/XX DIAGNOSE,
sends a voltage signal to the KPU page 8:59
control unit (D7902).
3 Air distribution to roof (S1053-1), to U=5V Cab overview, page 9:5
operator (S1053-2) or to floor (S1053-3) D1: 9.4 Climate System 3/XX DIAGNOSE,
switches send a voltage signal to KPU page 8:60
4 Automatic regulation of the climate U=5V Cab overview, page 9:5
system switch (S1054) sends a voltage D1: 9.4 Climate System 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). page 8:59
5 Cooling switch (S1120) sends a voltage U=5V Cab overview, page 9:5
signal to the KPU control unit (D7902). D1: 9.4 Climate System 1/XX DIAGNOSE,
page 8:59
6 Interior temperature sensor (B7751) R = 10 kΩ at 25 °C Interior temperature sensor, description,
sends a voltage signal proportional to page 9:43
the temperature to KCU control unit D6: 9.4 Climate System 4/XX DIAGNOSE,
(D7901). page 8:60 and 9.4 Climate System 5/XX
DIAGNOSE, page 8:60


7 Fan temperature sensor (B7752) R = 10 kΩ at 25 °C Fan temperature sensor, description, page
sends a voltage signal proportional to 9:42
DIAGNOSE, page 8:60
8 Ambient temperature sensor (B7740) R = 10 kΩ at 25 °C Ambient temperature sensor, description,
DIAGNOSE, page 8:60
9 KCU control unit (D7901) regulates Checked by control 11.5.3.1 Control unit KCU (D7901), page
temperature and air distribution with system, error shown with 11:25
signals from sensors and controls. error code.
10 The engine produces heat while running. -
It is cooled with the cooling system. The
heat from the cooling system is used to
heat the cab air.
11 KCU control unit (D7901) controls Water U = ±10 V 11.5.3.1 Control unit KCU (D7901), page
valve (Y6730), which routes hot water 11:25
for heating heat exchanger. D11: 9.4 Climate System 14/XX DIAGNOSE,
page 8:63 and 9.4 Climate System 15/XX
DIAGNOSE, page 8:63
12 The water valve's opening (%) is fed U = 0.5-4.5 V Water valve, description, page 9:29
back to the KCU control unit (D7901). D12: 9.4 Climate System 7/XX DIAGNOSE,
This gives information for controlling the page 8:61
water valve's position.
13 Sensor, engine temperature, sends a Checked by control
voltage signal proportional to the engine system, error shown with
temperature to Control unit, engine error code.
(D7940).
14 Heat exchanger heat supplies heat to - Heat exchanger heat, description, page 9:28
the cab air. The heat is transferred from
the engine's cooling system to the cab
air.
15 Control unit, engine (D7940) transmits Checked by control 11.5.3.6 Control unit, engine (D7940), page
engine temperature in the cooling system, error shown with 11:33
system on the CAN bus. error code.
16 KCU control unit (D7901) controls Checked by control Fresh air and recirculation damper,
Actuator motor, recirculation (Y6120) system, error shown with description, page 9:25
which sets the fresh air or recirculation error code. D16: 9.4 Climate System 11/XX DIAGNOSE,
damper in the required position. page 8:62 and 9.4 Climate System 12/XX
DIAGNOSE, page 8:62
17 KCU control unit (D7901) controls Fan Checked by control Cab fan, description, page 9:27
motor (M6570), which increases the system, error shown with D17: 9.4 Climate System 16/XX
airflow in the cab. error code. DIAGNOSE, page 8:63
18 KCU control unit (D7901) controls U = ±12 V Air distributor, description, page 9:40
Damper motor (Y6720), which sets the D18: 9.4 Climate System 16/XX
air distributor to the required position. DIAGNOSE, page 8:63 and 9.4 Climate
The air distributor directs the air to System 17/XX DIAGNOSE, page 8:63
window or floor. Some of the air is
always directed to the defroster nozzles
in the panel. These must be opened and
closed manually.
19 The air distributor's position is fed back U = 0.5-4.5 V Air distributor, description, page 9:40
to KCU control unit (D7901). This D19: 9.4 Climate System 8/XX DIAGNOSE,
gives information for controlling the air page 8:61
distributor's position.


20 Control unit KFU (D7971) supplies U = 24 V 11.5.3.4 Control unit KFU (D7971), page
voltage to Magnetic clutch (M6450) on 11:31
the compressor. D20: 9.4 Climate System 13/XX
DIAGNOSE, page 8:62
21 The compressor draws gaseous - Compressor air conditioning, description,
refrigerant from the evaporator, page 9:30
compresses it, and forces it on to the
condenser.
22 -
23 The condenser cools the refrigerant. - Condenser unit, description, page 9:32
The gaseous refrigerant condenses to
liquid form and is pumped on in the
circuit.
24 The receiver drier absorbs any moisture - Receiver drier, description, page 9:33
from the cooling circuit. The fluid
reservoir stores the refrigerant.
25 The pressure switch (B2460) sends a U = 24 V Pressure switch, description, page 9:35
signal to the KCU control unit (D7901) D25: 9.4 Climate System 6/XX DIAGNOSE,
if the pressure in the system becomes page 8:61.
abnormally high or low.
26 The expansion valve adjusts the - Expansion valve, description, page 9:36
amount of refrigerant that is let in to the
evaporator. If the temperature in the
evaporator's outlet pipe increases, the
expansion valve increases the flow of
refrigerant so that heat dissipation in the
evaporator increases.
27 Temperature deicing sensor (B7753) R = 10 kΩ at 25 °C Temperature deicing sensor, description,
DIAGNOSE, page 8:60
28 Heat exchanger, cooling, dissipates heat - Heat exchanger, cooling, description, page
from the cab air. The heat is transferred 9:38
from the air to the refrigerant and
transforms the refrigerant to a gaseous
state.
29 Defroster switch (S1390) sends a Checked by control Cab overview, page 9:5
voltage signal to the KPU control unit system, error shown with D1: 9.4 Climate System 1/XX DIAGNOSE,
(D7902) that activates the defroster error code. page 8:59
program for the climate system for nine
minutes.
30 Recirculation switch (S1910) sends a Checked by control Cab overview, page 9:5
voltage signal to the KPU control unit system, error shown with D1: 9.4 Climate System 1/XX DIAGNOSE,
(D7902) that activates recirculation. error code. page 8:59
31 KCU control unit (D7901) controls Checked by control Fresh air and recirculation damper,
Actuator motor, recirculation (Y6120) system, error shown with description, page 9:25.
which sets the fresh air or recirculation error code. D16: 9.4 Climate System 11/XX DIAGNOSE,
damper in the recirculation mode. page 8:62 and 9.4 Climate System 12/XX
DIAGNOSE, page 8:62
32 Pause heater switch (S1019) sends a Checked by control Cab overview, page 9:5
voltage signal to the KPU control unit system, error shown with D1:
(D7902). error code.


33 KCU control unit (D7901) controls U = 24 V .
the Circulation pump heating system D33:
(M6670) which pumps the coolant
through the heating system when the
engine is turned off.
The pause heater is automatically
switched off by means of a thermostat
in the coolant circuit when the coolant
temperature is below a set value
34 Air filter contact (B2190) sends a signal U = 24 V D34: 9.4 Climate System 6/XX DIAGNOSE,
to the KCU control unit (D7901) if the page 8:61
pressure in the fresh air filter becomes
abnormally high.
35 Control unit KID (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
heating and ventilation settings in the system, error shown with 11:29
display. error code.
General recommendations for work on the air

conditioning unit
CAUTION
Authorisation is required to perform repairs on the
climate control unit.
WARNING
If there is a rupture of a cooling hose or leakage on the
plant – turn off the unit immediately.
It is dangerous to get refrigerant on the skin or in the
eyes.
Never release refrigerant in an enclosed space, the gas
may cause suffocation e.g. in assembly pits.
Never weld on or near a closed cooling system.
Drain the refrigerant during repairs on the air
conditioning.
Work on the refrigerant circuit must only be performed
by an accredited company.

Air conditioning unit, troubleshooting the cooling

circuit
NOTE
The air conditioning unit does not work at temperatures below
approx. 0 °C since the pressure in the refrigerant circuit is too
low. If the pressure in the refrigerant circuit becomes too low
then the low pressure switch disconnects the power supply to
the compressor's magnetic coupling, which means that the air
conditioning unit stops working.
NOTE
During normal operation the air conditioning is stopped when a
door is opened. This function may need to be switched off during
troubleshooting. For instructions on how this is performed, see
9.4 Climate System 3/XX INITIATE, page 8:124.
1 Read the safety instructions for coolant before starting work, see
Refrigerant, page B:16.
2 Read the General instructions before working on the climate
system, see General recommendations for work on the air
conditioning unit, page 9:23.
4 Carry out performance tests on the air conditioning unit in
accordance with the maintenance manual, section 9 Frame,
body, cab and accessories, group 9.4 Heating, ventilation and
air conditioning.
5 Check that the hoses and components on the pressure side
maintain a roughly even temperature by feeling them with your
hand.
NOTE
In the event of a stop in one of cooling circuit's components, and
during long-term operation, certain parts (possibly hoses before
the condenser) may be very hot. Risk of burn injuries.
6 All hoses and components on the pressure side (from the

compressor to the expansion valve) should be hot.
7 All hoses and components on the suction side (from the evaporator
to the compressor) should be cold.
8 Check that the expansion valve is not frosty or cold.
Frost or cold temperatures on the inlet side of the expansion valve
indicate that it is defective or clogged and that circulation is limited
or stopped on the pressure side.
9 Check that the compressor engages and disengages normally.
Run the cab fan at low speed and allow the compressor to work
at high rotation speed. When the temperature of the air vents
approaches 0 °C, the compressor is disengaged via ECC and is
re-engaged when the temperature has risen approx. 3-7 °C. (If the
compressor is not disengaged then there is a risk of the evaporator
icing up and cooling performance diminishing.)
Expansion valve

9 Frame, body, cab and accessories – Fresh air filter 9:25
9.4.1 Fresh air filter

Fresh air filter, description
The fresh air filter is fitted behind the fresh air grille for the fresh air
intake to the cab, on the front of the cab. The filter insert is re-usable
and can be washed in warm water and hand dishwashing detergent.
As an option, the machine can be equipped with a fine filter in

addition to the fresh air filter. The fine filter is a disposable paper filter
and is fitted behind a cover plate on the front of the cab. There is
always a fine filter on machines with ECC.
1. Screw, cover plate fine filter

2. Screw, fresh air grille
9.4.2 Fresh air and recirculation damper

Fresh air and recirculation damper, description
The fresh air and recirculation damper is only available on machines

with ECC. The damper is fitted by the fresh air intake on the climate unit
at the front of the cab. The damper controls fresh air or recirculation air
to the air vents in the cab. The fresh air and recirculation damper is
controlled electrically by Actuator motor recirculation (Y6120).
Actuator motor recirculation (Y6120) is supplied with voltage by Control

unit KCU (D7901). The signal can be checked with the diagnostic
menu, see 9.4 Climate System 11/XX DIAGNOSE, page 8:62 and 9.4
Climate System 12/XX DIAGNOSE, page 8:62.
Climate unit
2. Fine filter
3. Heat exchanger heat
4. Heat exchanger, cooling
5. Actuator motor recirculation (Y6120)
7. Air distributor, Damper motor (Y6720) and
Sensor fan temperature (B7752)
8. Air connection, Sensor temperature interior
(B7751)
9. Temperature deicing sensor (B7753)

9:26 9 Frame, body, cab and accessories – Fresh air and recirculation damper
Actuator motor recirculation, replacement

2 Remove the fresh air grille.
3 Remove the cover plate holding the wiper motor, see Wiper motor
front, replacement, page 9:50.
4 Remove the right-hand console under heat exchanger cooling.

a) Remove the screws.
b) Pull the console straight out.
5 Remove the panel by the accelerator pedal in order to access the
actuator motor's attaching bolts, see Front floor panel, accelerator
pedal, replacement, page 9:80.
6 Remove the actuator motor's attaching bolts and spacers.

7 Carefully pull the actuator motor forwards so that the fresh air and
recirculation damper releases from the left-hand console.
8 Release the fresh air and recirculation damper from the motor by
pulling the damper to the left.
9 Disconnect the cable harness from the actuator motor.
1. Bolt 10 Before reassembly:
2. Washer Plug in the connector to the motor and change it to the position
for fresh air.
3. Spacer
5. Nut

9 Frame, body, cab and accessories – Cab fan 9:27
9.4.3 Cab fan

Cab fan, description
The cab fan blows air into the cab. The fan is driven by fan motor
(M6570) and is fitted in the climate unit at the front of the cab.
Fan motor (M6570) is supplied with voltage by Control unit KCU

(D7901). The signal can be checked with the diagnostic menu, see 9.4
Climate unit
2. Fine filter
7. Air distributor and Damper motor (Y6720)
(B7751)
Cab fan, replacement

3 Remove the bolts securing the cab fan to be replaced.
4 Unplug the connector from the cab fan.
5 Replace the cab fan.

9:28 9 Frame, body, cab and accessories – Heat exchanger heat
9.4.4 Heat exchanger heat

Heat exchanger heat, description
Pipes and fins in heat exchanger heat transfer heat from the hot coolant
in the engine to the ventilation air in the cab. Heat exchanger heat is
fitted in the climate unit at the front of the cab.
NOTE
Clamps should be installed on the hoses to prevent unnecessary
loss of coolant when any work is done on the coolant circuit.
Wear protective gloves and use a collection vessel to collect the
coolant that runs out.
NOTE
After work is performed, check the coolant circuit for leaks and
Climate unit check the coolant level. Top up coolant if necessary.
2. Fine filter
(B7751)
Heat exchanger, heating, replacement

4 Drain the cooling system of coolant, see Maintenance manual.
5 Clamp the hoses to and from the heat exchanger with pinch-off
pliers to prevent coolant escaping.
6 Disconnect the coolant hoses from the heat exchanger under the
cab.

9 Frame, body, cab and accessories – Water valve 9:29
7 Withdraw the heat exchanger from its rest position.

8 Replace the heat exchanger.
9.4.5 Water valve

Water valve, description
Actuator motor water valve (Y6730) opens and closes the water valve
in order to control the heater unit's capacity for heating from 0 (closed
valve) to 100% (open valve). The water valve is fitted at the rear, under
the cab floor on a bracket on the climate unit.
Actuator motor water valve (Y6730) is supplied with voltage by Control

unit KCU (D7901). The signal can be checked with diagnostic menu
9.4 Climate System 7/XX DIAGNOSE, page 8:61.
1. Water valve
2. Actuator motor water valve (Y6730)
Water valve, replacement

2 Install clamps on the hoses to prevent coolant from running out.
3 Undo the hose clamps and remove the hoses. Use a receptacle to
collect any coolant that runs out.
4 Disconnect the cable harness from the actuator motor.
5 Remove the actuator motor from the bracket.
6 Remove the water valve from the bracket.
7 Fit in the reverse order
1. Water valve NOTE

2. Actuator motor water valve (Y6730) After fitting the water valve, check the valve for leaks and check
the coolant level. Top up coolant if necessary.
NOTE
The water valve centre shaft has a groove that can be used for
fault tracing the heating system.

9:30 9 Frame, body, cab and accessories – Sensor coolant temperature
9.4.6 Sensor coolant temperature

Coolant temperature sensor, description
Sensor, coolant temperature, is fitted on the engine and detects the
engine's coolant temperature, see Supplier documentation.
system 8/XX DIAGNOSE, page 8:24.
9.4.7 Compressor air conditioning

Compressor air conditioning, description
The compressor drives the air conditioning by working as a pump. It

draws in cold, low-pressure gas from the evaporator, compresses 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
electromagnetic clutch, which is controlled by a thermostat.
The signal can be checked with the diagnostic menu, see 9.4 Climate
System 13/XX DIAGNOSE, page 8:62.
Compressor air conditioning

9 Frame, body, cab and accessories – Compressor air conditioning 9:31
Compressor air conditioning, replacement
IMPORTANT
Working on the air conditioning requires special
authorisation.
NOTE
It is extremely important to prevent contamination and foreign
particles from getting into the refrigerant circuit. Carefully clean
the area where the cooling circuit is to be worked on, before
starting to dismantle.
Always replace the receiver driers when work is performed in the
refrigerant circuit.
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
4 Drain the A/C system of refrigerant R134a using the intended
draining equipment.
5 Loosen the belt tension (position 1) and remove the belt.
6 Loosen the hose connections and disconnect the inlet and outlet
hoses from the compressor. Plug the couplings in order to prevent
contaminants.
7 Remove the compressor from the engine.
8 Empty the oil from the old compressor (through inlet/outlet) and
measure the quantity.
9 Empty the oil from the new compressor. The compressor is filled
with cooling oil on delivery.
10 Refill the new compressor with the new oil in the same amount
drained from the old one.
In the event of refrigerant loss, there may also be a certain oil
loss because approx. 25% of the oil volume is taken up by the
refrigerant.
For oil volume and type in the system, see section F Technical
data.
1. Belt tensioner recess for pull handles 11 Fit in the reverse order.
12 Turn the compressor over several turns by hand.
13 Using vacuum equipment, refill the system with R134a refrigerant
and test for leaks.
14 Check the function of the system.

9:32 9 Frame, body, cab and accessories – Condenser unit
9.4.8 Condenser unit

Condenser unit, description
Volvo TAD851VE and TAD871VE

Volvo TAD572VE and TAD850VE
1. Intercooler
1. Intercooler
3. Condenser
3. Condenser
4. Water cooler
4. Water cooler
The condenser unit is fitted on the cooling unit behind the engine.
The condenser is a heat exchanger and its function is to convert the
hot high-pressure gas from the compressor into liquid form. Pipes
and flanges in the condenser battery absorb the heat, which is then
dissipated with a fan.
Refrigerant temperature in the condenser varies depending on the

ambient temperature and the air flow through the condenser. When
the refrigerant has condensed to fluid, the fluid is forced onward to
the receiver drier.
IMPORTANT
authorisation.
Cummings QSB6.7 NOTE

1. Intercooler It is extremely important to prevent contamination and foreign
2. Water cooler particles from getting into the refrigerant circuit. Carefully clean the
area where the cooling circuit is to be worked on, before starting to
3. Transmission oil cooler dismantle.
4. Condenser Always replace the receiver driers when work is performed in the
5. Hydraulic oil cooler refrigerant circuit.

9 Frame, body, cab and accessories – Receiver drier 9:33
9.4.9 Receiver drier

Receiver drier, description
The receiver drier collects liquid refrigerant, binds moisture and filters
out impurities. The filter contains a particle trap and a hygroscopic
medium. The housing functions as an expansion tank in the cooling
circuit. The receiver drier is fitted under a hatch on the left-hand side at
the front of the cab
For inspection of drying filter, see Maintenance manual.
1. Receiver drier
Receiver drier, replacement
IMPORTANT
authorisation.
NOTE
NOTE
Normally the receiver drier is not a consumable component in the
The receiver drier should only be replaced when the refrigerant
circuit has been opened, depressurised for a long time or when
one of the refrigerant circuit's other components has been
replaced, when it is also recommended to replace filters.
NOTE

9:34 9 Frame, body, cab and accessories – Receiver drier
4 Remove the front left-hand cover on the cab.
5 Drain the air conditioning of refrigerant R134a, with the intended

draining equipment.
6 Release the pipe fittings from the receiver drier.
7 Plug the hoses to avoid contamination of the refrigerant circuits.
8 Undo the hose clamps and remove the receiver drier.
9 Replace the receiver drier.
NOTE
An unused receiver drier is pressurised with nitrogen gas
and its connections are equipped with plugs in order to avoid
contamination during storage and handling.
During fitting it is therefore useful to see how the overpressure
flows out when the plugs are loosened.
Once the plugs have been loosened, fitting should take place
as soon as possible in order to avoid contamination of the air's
moisture content. A receiver drier that has no overpressure for an
unknown reason may be contaminated and should not be used.
10 Connect the pipe fittings to the receiver drier.

11 Check for leaks and refill the machine with refrigerant R134a, with
the intended equipment.
For volume, see section F Technical data.
12 Fit the front left-hand cover on the cab.

9 Frame, body, cab and accessories – Pressure switch 9:35
9.4.10 Pressure switch

Pressure switch, description
The pressure switch (B2460) is fitted on the receiver drier behind the
cover at the front left-hand side of the cab.
In the event of a pressure drop, the pressure switch warns via the KCU
control unit (D7901) and cooling circuit ceases to function. The signal
can be checked with the diagnostic menu, see 9.4 Climate System
1. Pressure switch
Pressure switch, replacement
IMPORTANT
authorisation.
NOTE
NOTE

9:36 9 Frame, body, cab and accessories – Expansion valve
4 Remove the front left-hand cover on the cab.

5 If the system contains the correct amount of refrigerant then it
does not need to be drained. The connection of the receiver drier
to the pressure switch is equipped with a non-return valve that
prevents the refrigerant from flowing out.
If the system does not contain the correct amount of refrigerant,
the air conditioning must be drained of refrigerant R134a, with the
equipment intended for the purpose.
6 Disconnect the cable harness from the pressure switch.

7 Unscrew the pressure switch.
8 Screw in a new pressure switch.
9 Connect the cable harness to the pressure switch.
10 Check for leaks and refill the machine with refrigerant R134a if
necessary, using the intended equipment.
11 Fit the front left-hand cover on the cab.
9.4.11 Expansion valve

Expansion valve, description
The expansion valve is the part of the refrigerant circuit that separates
the high-pressure side from the low-pressure side. The expansion
valve is fitted under the rear of the climate unit under the cab floor.
The refrigerant arrives in liquid form at the expansion valve under

high pressure and leaves it under low pressure. After the expansion
valve, the refrigerant converts to a gaseous state and is transported
to the compressor once again. The amount of refrigerant that passes
through the expansion valve varies depending on the heat load. The
valve works from fully open to fully closed and searches between these
for an optimal evaporation point.

9 Frame, body, cab and accessories – Temperature deicing sensor 9:37
Expansion valve, replacement
When replacing the expansion valve, see the appropriate information

under section Heat exchanger, cooling, replacement, page 9:38 and
Temperature deicing sensor, description, page 9:37.
9.4.12 Temperature deicing sensor

Temperature deicing sensor, description
Sensor, temperature deicing (B7753), is fitted on the rear connection

pipe for heat exchanger cooling in the climate unit at the front of the cab.
Sensor, temperature deicing (B7753), sends a voltage signal to Control

Climate unit
2. Fine filter
(B7751)
Sensor, temperature deicing, replacement
NOTE
1 When the de-icing sensor is replaced on a horizontal pipe, it is
important that the de-icing sensor should be positioned between
03.00 and 05.00 o'clock (see figure 1).
03.00 It is also very important for climate unit function that the de-icing
sensor has full contact with the pipe, it is fixed to the pipe with a
cable tie and that insulation material is applied over the de-icing
2 sensor and pipe.
See appropriate parts of Heat exchanger, cooling, replacement, page

05
006316
9:38.
.0
0
1. Pipe

9:38 9 Frame, body, cab and accessories – Heat exchanger, cooling
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
Heat exchanger cooling cools on the way into the cab. The heat
exchanger is fitted together with heat exchanger heat in the climate
unit at the front of the cab.
The heat exchanger for cooling consists of pipes carrying refrigerant
through the cooling fins. The heat from the cab's air is channelled via
the flanges to the refrigerant in the pipes.
The refrigerant changes from liquid form before the expansion valve to
gaseous form in the heat exchanger and becomes cold.
Climate unit
2. Fine filter
(B7751)
Heat exchanger, cooling, replacement
IMPORTANT
authorisation.
NOTE
NOTE

9 Frame, body, cab and accessories – Heat exchanger, cooling 9:39
4 Drain the air conditioning of refrigerant R134a, with the intended

draining equipment.
7 Remove the heat exchanger for heat, see Heat exchanger,
heating, replacement, page 9:28.
8 Disconnect the A/C hoses from the expansion valve.

9 Detach the screw, that secure the expansion valve to the hosing.
10 Disconnect the cable harness from the sensor.
11 Remove the evaporator together with the expansion valve.
12 Remove the two fitting nuts of the evaporator from the expansion
valve.
13 Remove the sensor from the heat exchanger, the sensor is fitted
on the pipe under the insulation.
1 a) Remove the insulation.
b) Note how the sensor is attached.
c) Cut off the cable tie that secures the sensor to the pipe.
03.00
d) Remove the sensor from the pipe.
14 Fit the sensor and the expansion valve on the new heat exchanger.
2
NOTE
05
006316
When the de-icing sensor is replaced on a horizontal pipe, it is

.0
important that the de-icing sensor should be positioned between

0
03.00 and 05.00 o'clock (see figure 1).

1. Pipe It is also very important for climate unit function that the de-icing
2. Temperature deicing sensor (B7753) sensor has full contact with the pipe, it is fixed to the pipe with a
cable tie and that insulation material is applied over the de-icing
sensor and pipe.

16 Use new O-rings when installing and replace the old receiver drier
before refilling the cooling system.
17 Check for leaks and refill the machine with refrigerant R134a, with
the intended equipment.

9:40 9 Frame, body, cab and accessories – Air distributor
9.4.14 Air distributor

Air distributor, description
The air distributor distributes the air between the defroster and the floor
nozzles, some of the air always flows to the panel nozzles. The air
distributor is fitted at the top of the climate unit, under the dashboard
panel. The air distributor contains a damper that is controlled by
Damper motor (Y6720).
Damper motor (Y6720) is supplied with voltage by Control unit KCU

(D7901). The signal can be checked by the diagnostic menu, see 9.4
Climate System 16/XX DIAGNOSE, page 8:63 and 9.4 Climate System
Climate unit
2. Fine filter
(B7751)
Air distributor, replacement

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. Dashboard panel
2. Steering column adjustment
3. Lower protective cover

9 Frame, body, cab and accessories – Defroster nozzles 9:41
7 Remove the air distributor from its mounting.

8 Replace the air distributor, fitting it in the reverse order.
Air distributor
9.4.15 Defroster nozzles

Defroster nozzles, description
There are a number of adjustable defroster nozzles in the cab interior,
for example, five at the windscreen for defrosting and six adjustable
defroster nozzles in the dashboard panel. Adjustable flow and direction
(flow is proportional to fan speed).
A large air vent is located low in the cab (floor). This allows the
adjustment of the air flow from the lower part of the cab to defroster.
Defroster nozzles to cab.
Defroster nozzles, replacement

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster nozzle
in the dashboard.

9:42 9 Frame, body, cab and accessories – Fan temperature sensor
4 Detach the air hose from the defroster nozzle.

9.4.16 Fan temperature sensor

Fan temperature sensor, description
Sensor fan temperature (B7752) is fitted on the air distributor and
measures the temperature of the air blown into the cab.
The sensor sends a voltage signal to Control unit KCU (D7901). The
signal can be checked with the diagnostic menu, see 9.4 Climate
System 4/XX DIAGNOSE, page 8:60 and 9.4 Climate System 5/XX
1 DIAGNOSE, page 8:60.
006304
1. Fan temperature sensor (B7752)
Sensor, fan temperature, replacement

2 Remove the air distributor, see Air distributor, replacement, page
9:40.
3 Detach the temperature sensor from the air distributor.
1
006304
1. Fan temperature sensor (B7752)

9 Frame, body, cab and accessories – Interior temperature sensor 9:43
9.4.17 Interior temperature sensor

Interior temperature sensor, description
Sensor, temperature interior (B7751) detects the temperature of the air
in the cab. The sensor is fitted in the panel in front of the operator
on the left.
Sensor, temperature interior (B7751), sends a voltage signal to Control

Sensor temperature interior (B7751)
Sensor, temperature interior, replacement

2 Remove the dashboard panel.
3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
6 Replace the temperature sensor.
007985

9:44 9 Frame, body, cab and accessories – Ambient temperature sensor
9.4.18 Ambient temperature sensor

Ambient temperature sensor, description
Ambient temperature sensor (B7740) is located on the rear edge of the
roof. The sensor detects the current outside temperature without being
affected by the heat from the vehicle.
Sensor, ambient temperature (B7740), sends a voltage signal to

Control unit KCU (D7901). The signal can be checked with the
diagnostic menu, see 9.4 Climate System 4/XX DIAGNOSE, page 8:60
and 9.4 Climate System 5/XX DIAGNOSE, page 8:60.
Sensor, ambient temperature
9.4.20 Timer diesel heater

Timer diesel heater, description
The diesel heater is controlled by a separate timer that is fitted in the

cab. The timer can be used to set running time and three separate
activation times.
For setting the diesel heater timer, see Operator’s manual.
A. Menu bar
B. Status field (Main menu)
Input field (Submenu)
C. Selection front / rear
D. Button 1
E. Button 2

9 Frame, body, cab and accessories – Diesel heater 9:45
9.4.21 Diesel heater

Diesel heater, description
The diesel heater is used to heat the cab and engine without needing
to start the engine.
The diesel heater heats and circulates the engine's coolant. An extra
electrically-driven circulation pump pumps the coolant though the
diesel heater and heater unit. The diesel heater is supplied with fuel
via a separate fuel pump which is connected to the fuel tank via a
separate fuel line.
9.4.25 Preparation, cab fan

Preparation, cab fan, description
The machine can be prepared for connection of an electrically-driven

cab fan in different units together with heater for engine and hydraulic
oil tank.
The cab socket is supplied with high voltage from an external mains
cable is connected to the mains power connector.
CAUTION
The electrical socket is connected to high voltage (110
- 400 V).
High voltage.
Installation and reconnection of the socket must only
1. Holder cab fan
be performed by personnel authorised for work with
high voltage.
2. Electrical socket cab fan

9:46 9 Frame, body, cab and accessories – Wiper/washer system
9.5 Wiper/washer system

Wiper/washer system, description
The wiper arm is attached to the wiper motor's shaft over a grooved
3 taper. The shaft is made of hardened steel and the wiper arm's bracket
is made of a mild die cast material.
When installing it is important to make sure that the grooves are free
from burrs and similar. Also, the nuts must be tightened so tight that
the grooves are pressed into the bracket and work as drive flanges.
Counterhold the wiper arm when installing so that the force is not
transmitted to the wiper motor, which may then be damaged.
1
001878
1. Wiper, front
2. Wiper, roof
3. Wiper, rear
Wiper and washer system, description

1 Switch, windscreen wiper continuous U = 24 V Cab overview, page 9:5
(S1190-FR) sends a voltage signal to D1: 9.5 Wiper & Washer Sys 7/XX
Control unit KPU (D7902). DIAGNOSE, page 8:65
2 Switch, windscreen wiper intermittent U = 24 V Cab overview, page 9:5
(S1520-FR) sends a voltage signal to D2: 9.5 Wiper & Washer Sys 7/XX
Control unit KPU (D7902). DIAGNOSE, page 8:65
a request for continuous wiping or system, error shown with 11:27
intermittent wiping of the windscreen on error code.
the CAN bus.

9 Frame, body, cab and accessories – Wiper/washer system 9:47

voltage to Relay, wiper motor left 11:25
(K6501-LE). D4: 9.5 Wiper & Washer Sys 8/XX
DIAGNOSE, page 8:65
5 Relay, wiper motor left (K6501-LE) U = 24 V -
supplies power to Wiper motor front left D4: 9.5 Wiper & Washer Sys 8/XX
(M6501-LE). DIAGNOSE, page 8:65
6 Wiper motor front left (M6501-LE) drives -
the wiper blades on the windscreen.
7 Wiper motor front left (M6501-LE) sends U = 0.5-4.5 V D5: 9.5 Wiper & Washer Sys 8/XX
a voltage signal proportional to the DIAGNOSE, page 8:65
motor’s position to Control unit KCU
(D7901). This gives information for
controlling the wiper blade's position.
8 Switch, roof window wiper continuous U = 24 V Cab overview, page 9:5
(S1190-UP) sends a voltage signal to 11.5.3.2 Control unit KPU (D7902), page
Control unit KPU (D7902). 11:27
D7: 9.5 Wiper & Washer Sys 11/XX
DIAGNOSE, page 8:66
9 Switch, roof window wiper intermittent U = 24 V Cab overview, page 9:5.
(S1520-UP) sends a voltage signal to 11.5.3.2 Control unit KPU (D7902), page
DIAGNOSE, page 8:66
intermittent wiping of the roof window on error code.
the CAN bus.
power to Wiper motor, roof window I = 1–6 A 11:25
(M6503). D11: 9.5 Wiper & Washer Sys 12/XX
DIAGNOSE, page 8:67
12 Wiper motor roof window (M6503) drives - D11: 9.5 Wiper & Washer Sys 12/XX
the wiper blades on the roof window. DIAGNOSE, page 8:67
13 Wiper motor, roof window (M6503) U = 0.5-4.5 V D13: 9.5 Wiper & Washer Sys 12/XX
sends a voltage signal proportional to DIAGNOSE, page 8:67
the motor’s position to Control unit KCU
14 Switch, rear window wiper continuous U = 24 V Cab overview, page 9:5
(S1190-RE) sends a voltage signal to 11.5.3.2 Control unit KPU (D7902), page
D14: D15: 9.5 Wiper & Washer Sys 4/XX
DIAGNOSE, page 8:64
15 Switch, rear window wiper intermittent U = 24 V Cab overview, page 9:5
(S1520-RE) sends a voltage signal to 11.5.3.2 Control unit KPU (D7902), page
DIAGNOSE, page 8:64
intermittent wiping of the rear window on error code.
the CAN bus.

9:48 9 Frame, body, cab and accessories – Wiper/washer system

power to Wiper motor, rear window I = 1–6 A 11:25.
(M6502). D17: 9.5 Wiper & Washer Sys 5/XX
DIAGNOSE, page 8:64
18 Wiper motor rear window (M6502) - Wiper motor rear, description, page 9:52
powers the wiper blade on the rear D17: 9.5 Wiper & Washer Sys 5/XX
window. DIAGNOSE, page 8:64
19 Wiper motor, rear window (M6502) U = 0.5-4.5 V Wiper motor rear, description, page 9:52
sends a voltage signal proportional to D19: 9.5 Wiper & Washer Sys 5/XX
the motor’s position to Control unit KCU DIAGNOSE, page 8:64
20 Washer switch (S1200) sends a voltage U = 24 V Cab overview, page 9:5
signal to the KPU control unit (D7902). D20: 9.5 Wiper & Washer Sys 6/XX
DIAGNOSE, page 8:65, 9.5 Wiper & Washer
Sys 10/XX DIAGNOSE, page 8:66 and 9.5
Wiper & Washer Sys 13/XX DIAGNOSE,
page 8:67
request for washing of windscreen or system, error shown with 11:27
rear and roof window on the CAN bus. error code.
Washing occurs in the screens where
the wiper is activated.
If none of the wipers are activated,
the wipers on the windscreen and
windscreen washing are activated.
voltage to Relay washer motor 11:25
windscreen (K6511). D22: 9.5 Wiper & Washer Sys 10/XX
DIAGNOSE, page 8:66
23 Washer motor, windscreen (M6511) Washer motor and reservoir, description,
pumps washer fluid to the nozzles on page 9:49
the wiper arms.
24 Control unit KCU (D7901) supplies U = 24 V D24: 9.5 Wiper & Washer Sys 6/XX
power to Washer motor rear window/roof I = 0.5–6 A DIAGNOSE, page 8:65 and 9.5 Wiper &
window (M6512/M6513). Washer Sys 13/XX DIAGNOSE, page 8:67
25 Washer motor rear window/roof window - Washer motor and reservoir, description,
(M6512/M6513) pumps washer fluid to page 9:49
the nozzles on the wiper arms. D24: 9.5 Wiper & Washer Sys 6/XX
DIAGNOSE, page 8:65 and 9.5 Wiper &
Washer Sys 13/XX DIAGNOSE, page 8:67
26 Contact level washer fluid (B2991) U = 24 V Washer motor and reservoir, description,
sends a voltage signal to the KCU page 9:49
control unit (D7901) with a low washer D26: 9.5 Wiper & Washer Sys 6/XX
fluid level. DIAGNOSE, page 8:65, 9.5 Wiper & Washer
Sys 10/XX DIAGNOSE, page 8:66 or 9.5
Wiper & Washer Sys 13/XX DIAGNOSE,
page 8:67
27 Control unit KCU (D7901) sends low Checked by control 11.5.3.1 Control unit KCU (D7901), page
washer fluid level on the CAN bus. system, error shown with 11:25
error code.
28 KID control unit (D7950) shows the Checked by control 11.5.3.3 Control unit, KID (D7950), page
event menu for low washer fluid level. system, error shown with 11:29
error code.

9 Frame, body, cab and accessories – Washer motor and reservoir 9:49
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
The washer motors are fitted in the reservoir for washer fluid. The
reservoir is fitted at the rear on the left-hand side of the cab. There are
non-return valves on the lines from the reservoir to the wiper arms. The
nozzles are mounted on the wiper arms.
Washer motor, windscreen (M6511) is supplied with voltage on

activation of Relay, washer motor front (K6511). Relay, washer motor
front (K6511) is controlled by Control unit KCU (D7901), the signal
can be checked using a diagnostic menu, see 9.5 Wiper & Washer
Sys 10/XX DIAGNOSE, page 8:66.
Washer motor, roof window (M6513) is supplied with voltage on

activation of Control unit KCU (D7901), the signal can be checked using
diagnostic menu, see 9.5 Wiper & Washer Sys 13/XX DIAGNOSE,
page 8:67.
Washer motor, rear window (M6512) is supplied with voltage on

activation of Control unit KCU (D7901), the signal can be checked
using diagnostic menu, see 9.5 Wiper & Washer Sys 6/XX DIAGNOSE,
A. Filling, washer fluid page 8:65.
Washer motor and reservoir, replacement

2 Grip the washer fluid reservoir and remove the nuts holding it in
the cab and the cover plate in the cab.
3 Remove the cover plate over the washer fluid reservoir.
4 Fit the washer fluid reservoir only without cover plate on the cab
temporarily using the nuts.
5 Drain the washer fluid from the reservoir by disconnecting one of
the hoses from the motor.
6 Disconnect the cable harness from the motors.
003619
7 If the reservoir shall be replaced:

A B Remove the reservoir from the cab.
Washer fluid reservoir without cover plate
8 If a motor shall be replaced:
A. Washer fluid reservoir
Remove the motor from the reservoir. A rubber bushing seals
B. Washer motor between the pumps and the reservoir.
9 If the reservoir shall be replaced:
Transfer the motors to the new reservoir.
11 Fill the reservoir up with screenwasher fluid.

9:50 9 Frame, body, cab and accessories – Wiper motor front
9.5.5 Wiper motor front

Wiper motor front, description
Wiper motor, Windscreen (M6501) drives the windscreen’s wiper. The
3 wiper arm is mounted directly on the motor. The motor produces the
movement of the wiper.
Wiper motor, windscreen (M6501) is supplied with voltage on activation

of Relay, wiper motor front (K6501). Relay, washer motor front
(K6511) is controlled by Control unit KCU (D7901), the signal can be
checked using a diagnostic menu, see 9.5 Wiper & Washer Sys 8/XX
1
001878
1. Wiper, front
2. Wiper, roof
3. Wiper, rear
Wiper motor front, replacement

2 Disconnect the washer fluid hose.
3 Raise the nut protector and remove the nut securing the wiper
arm (two nuts).
4 Remove the four screws securing the cover plate.
5 Remove the washer fluid hose and unplug the connector from
the wiper motor.
6 Lift away the plate from the machine.

9 Frame, body, cab and accessories – Wiper motor roof 9:51
7 Remove the two nuts securing the motor to the cover plate.
8 Replace the wiper motor.
9 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
NOTE
When installing it is important to make sure that the grooves are
free from burrs and similar. Also, the nuts must be tightened to
16-20 Nm, so that the grooves are pressed into the bracket and
work as drive flanges.
9.5.6 Wiper motor roof

Wiper motor roof, description
3
Wiper motor, roof (M6503) drives the roof wiper. The wiper arm is
mounted directly on the motor. The motor produces the movement
of the wiper.
Wiper motor, roof (M6503) is supplied with voltage on activation of

Control unit KCU (D7901), the signal can be checked using diagnostic
menu, see 9.5 Wiper & Washer Sys 12/XX DIAGNOSE, page 8:67.
1
001878
1. Wiper, front
2. Wiper, roof
3. Wiper, rear
Wiper motor roof, replacement

2 Remove the two screws securing the plastic cover to the wiper
motor.

9:52 9 Frame, body, cab and accessories – Wiper motor rear
3 Disconnect the washer hose and the wiper motor connector.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove the two screws securing the wiper motor.
7 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
NOTE
9.5.7 Wiper motor rear

Wiper motor rear, description
The wiper motor drives the wiper for the rear window. The wiper arm
3 is mounted directly on the motor. The motor produces the movement
of the wiper.
Wiper motor, rear (M6502) is supplied with voltage on activation of
Control unit KCU (D7901), the signal can be checked using diagnostic
menu, see 9.5 Wiper & Washer Sys 5/XX DIAGNOSE, page 8:64.
1
001878
1. Wiper, front
2. Wiper, roof
3. Wiper, rear
Wiper motor rear, replacement

2 Remove the upper panels behind the driver's seat, see Rear panel,
upper left, replacement, page 9:81 and Rear panel, upper right,

9 Frame, body, cab and accessories – Wiper motor rear 9:53
3 Remove the two screws securing the plastic cover over the wiper
motor.
4 Unplug the connector from the motor.
5 Raise the plastic cover and remove the nut securing the wiper arm.
Disconnect the washer hose.
6 Remove the two screws securing the motor and the lock nut on
the motor.
8 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
NOTE

9:54 9 Frame, body, cab and accessories – Lighting system
9.6 Lighting system

Lighting system, description
The lighting system includes interior lighting, service lighting
(headlights, direction indicators, back-up lights, brake lights and rear
lights) working lights (cab, mast and machine) and warning beacon.
The working lights are shut off automatically after 5 minute's idle in
order to prevent discharge of the batteries. Extra working lights are
shut off after 2 minutes. The lights are activated automatically again
when the operator 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
Lighting system, function description

The working lights are shut off automatically after 5 minute's idle in
order to prevent discharge of the batteries. Extra working lights are
shut off after 2 minutes. The lights are activated automatically again
when the operator sits in the seat, a gear is selected or the accelerator
pedal is pressed.
NOTE

9 Frame, body, cab and accessories – Lighting system 9:55

1 Work light on cab switch (S1050-1) sends a Switch in ON position: U D1: 9.6 Lighting Sys 11/XX
voltage signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:70 and 9.6
off position: U = 0 V Lighting Sys 30/XX DIAGNOSE, page
8:72
2 Work light on mast switch (S1050-2) sends a Switch in ON position: U D2: 9.6 Lighting Sys 14/XX
voltage signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:70
off position: U = 0 V
3 Extra work light switch (S1050-4) sends a Switch in ON position: U D4: 9.6 Lighting Sys 17/XX
voltage signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:71
4 Reversing light switch (S1032) sends a voltage Switch in ON position: U D5: 9.6 Lighting Sys 10/XX
signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:70
5 Headlight switch (S1000) sends a voltage Switch in ON position: U D6: 9.6 Lighting Sys 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). = 5 V, page 8:67
6 Revolving beacon switch (S1100) sends a Switch in ON position: U D7: 9.7 Signalling Sys 2/XX
voltage signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:73 and 9.7
off position: U = 0 V Signalling Sys 3/XX DIAGNOSE, page
8:73
7 Warning light switch (S1090) sends a voltage Switch in ON position: U D8: 9.7 Signalling Sys 7/XX
signal to the KPU control unit (D7902). = 5 V, DIAGNOSE, page 8:74
8 Multi-function lever (S1600) sends a voltage High beam mode: D9: 9.6 Lighting Sys 1/XX DIAGNOSE,
signal to the KPU control unit (D7902). US1600/56d = 24 V page 8:67 and 9.6 Lighting Sys 6/XX
Direction indicator left: DIAGNOSE, page 8:69
US1600/L = 24 V
Direction indicator right:
US1600/R = 24 V
9 KPU control unit, (D7902) transmits "switch on Checked by control 11.5.3.2 Control unit KPU (D7902),
lights" messages on the CAN bus. system, error shown with page 11:27
error code.
10 Interior lighting switch (S1160) sends a voltage Switch in ON position: U D11: 9.6 Lighting Sys 18/XX
signal to the KCU control unit (D7901). = 5 V, DIAGNOSE, page 8:71
11 The door NC switch (S2660-LE & S2660-RI) Door open: U = 24 V D12: 9.6 Lighting Sys 18/XX
sends a voltage signal to the KCU control unit DIAGNOSE, page 8:71
(D7901).
12 KCU control unit, (D7901) transmits "switch on Checked by control 11.5.3.1 Control unit KCU (D7901),
lights" messages on the CAN bus. system, error shown with page 11:25.
error code.
13 KCU control unit (D7901) supplies voltage to Checked by control 11.5.3.1 Control unit KCU (D7901),
the lights in and around the cab. system, error shown with page 11:25
error code.
14 Work lighting cab roof (E4042-LE & E4042-RI) Light on: U = 24 V Working lights, cab, description, page
lights when work lighting roof is activated. 9:60
D15: 9.6 Lighting Sys 11/XX
DIAGNOSE, page 8:70
15 Work lighting cab roof (E4042-1LE & Light on: U = 24 V Working lights, cab, description, page
E4042-1RI) lights when work lighting roof is 9:60
activated. D16: 9.6 Lighting Sys 30/XX
DIAGNOSE, page 8:72

9:56 9 Frame, body, cab and accessories – Lighting system
16 Work lighting cab roof relay (K3040) UK3040/30 = 24 V Working lights, cab, description, page
is activated when the roof work lighting is UK3040/85 = 0 V 9:60
activated and voltage feds the work lighting cab
roof (E4042-1LEA, E4042-1LEB, E4042-1RIA Cab roof work lights on:
& E4042-1RIB). UK3040/86 = 24 V
UK3040/87 = 24 V
Cab roof work lights off:
UK3040/86 = 0 V
UK3040/87 = 0 V
17 Interior lighting (E4340-LE & E4340-RI) comes Light on: U = 24 V Interior lighting, description, page 9:61
on when a door is opened or when the interior D18: 9.6 Lighting Sys 19/XX
lighting is activated with the interior lighting DIAGNOSE, page 8:71
switch (S1160).
18 Back-up lights (E4050-LE & E4050-RI) Light on: U = 24 V Back-up lights, description, page 9:58.
white are switched on when travel direction D19: 9.6 Lighting Sys 10/XX
backward is selected and when the back-up DIAGNOSE, page 8:70
lights are activated with the switch.
19 The brake pressure sensor (B7681) sends U = 0.5-4.5 V Brake pressure sensor, description,
a voltage signal corresponding to the brake page 4:27
pressure to the KFU control unit (D7971). D22: 4.3 Power Assisted 3/XX
DIAGNOSE, page 8:34
20 KFU control unit (D7971) supplies voltage to Checked by control 11.5.3.4 Control unit KFU (D7971),
the machine lights. system, error shown with page 11:31
error code.
21 Revolving beacon (H4281 & H4282) is Light on: U = 24 V Revolving beacon, description, page
switched on when the revolving working light 9:59
is activated. D24: 9.7 Signalling Sys 2/XX
DIAGNOSE, page 8:73 and 9.7
Signalling Sys 3/XX DIAGNOSE, page
8:73
22 Direction indicators (H4220-LF, H4220-RF, Light on: U = 24 V Direction indicators, description, page
H4220-RL & H4220-RR) are switched on when 9:59
the direction indicators or warning lights are Warning lamp, Hazard, description,
activated. page 9:59
DIAGNOSE, page 8:69 and 9.6
Lighting Sys 8/XX DIAGNOSE, page
8:69
23 Headlights front (E4000-LF & E4000-RF) are Light on: U = 24 V Headlights, description, page 9:57.
switched on when the headlights are activated. D24: 9.6 Lighting Sys 3/XX
DIAGNOSE, page 8:68
24 If the lighting is switched off, Headlights front Light on: U = 24 V Headlights, description, page 9:57
(E4000-LF & E4000-RF) are activated when D25: .
the headlamp flasher is used.
25 Tail lights (H4120-LE & H4120-RI) red come Light on: U = 24 V Tail lights, description, page 9:58
on when headlights are activated. D26: 9.6 Lighting Sys 4/XX
DIAGNOSE, page 8:68
26 Brake lights (H4110-LE & H4110-RI) come on Light on: U = 24 V Brake lights, description, page 9:58
when the brake is activated. D27: 9.6 Lighting Sys 5/XX
DIAGNOSE, page 8:68
27 Work lighting mast (E4043-LE & E4043-RI) Light on: U = 24 V Mast working lights, description, page
come on when work lighting mast are activated. 9:60
DIAGNOSE, page 8:70

9 Frame, body, cab and accessories – Headlights 9:57
28 Extra work lighting frame (E4041-1) comes on Light on: U = 24 V Extra working lights frame, description,
when extra work lighting is activated. page 9:61
DIAGNOSE, page 8:71
29 Extra working lights (E4041-2) are switched on Light on: U = 24 V Extra working lights frame, description,
when extra working lights are activated. page 9:61
DIAGNOSE, page 8:71
30 KPU control unit (D7902) lights the indicator Checked by control 11.5.3.2 Control unit KPU (D7902),
lights on the dashboard panel. system, error shown with page 11:27
error code.
9.6.1 Headlights
Headlights, description
Headlights are located in the front part of the machine in order to give
the operator enhanced vision when manoeuvring in darkness, and to
provide surrounding traffic and the environment an indication of the
machine's position.
The headlights are turned on with a switch on the dashboard panel.

1. Running lights
Headlight bulbs are not replaced individually but the whole unit is
2. Direction indicator, front replaced.
3. Headlights
As an option, the headlights are available with high beam and low
beam. The headlights switch between high and dipped beam using the
multi-function lever. Bulbs can be replaced individually on machines
with this option.
9.6.2 Running lights

Running lights, description
Position lights are fitted on the sides of each lamp housing on the
machine in order to give other traffic and the environment an indication
of the machine's position in darkness.
1. Running lights
2. Direction indicator, front
3. Headlights

9:58 9 Frame, body, cab and accessories – Tail lights
9.6.3 Tail lights

Tail lights, description
The tail lights are fitted at the rear edge of the upper counterweight
at the rear of the machine. The tail lights provide surrounding road
users and the environment an indication of the machine's position in
darkness.
1. Back-up lights
2. Rear and brake lights
3. Direction indicator, rear
9.6.4 Brake light

Brake lights, description
The brake lights are fitted at the rear edge of the upper counterweight
at the rear of the machine. The brake lights are switched on to show
surrounding road users and the environment that the machine is
braking, i.e. reducing speed.
1. Back-up lights
9.6.5 Back-up lights

Back-up lights, description
The tail lights are fitted at the rear of the cab undercarriage. The
back-up lights show surrounding traffic and the environment that the
machine is driving backwards and give the operator increased visibility
in darkness.
The back-up lights are switched on when reverse gear is selected. The
back-up lights can be deactivated with the switch for back-up lights.
1. Back-up lights

9 Frame, body, cab and accessories – Direction indicators 9:59
9.6.6 Direction indicators

Direction indicators, description
There are direction indicators on both the front and the rear of the
machine to indicate to others in traffic and the surroundings that the
machine is about to change direction of travel, i.e. turn.
The indicators are controlled by using the indicator switch (lever), and
is indicated with a green indicator lamp on the steering panel.
1. Headlights
2. Direction indicator, front
3. Running lights
4. Back-up lights
9.6.7 Warning lamp, Hazard

Warning lamp, Hazard, description
The machine is equipped with hazard warning flashers. By pressing a
switch, all the direction indicators can be made to flash simultaneously,
to show others that there is danger, such as a mechanical failure.
9.6.8 Revolving beacon

Revolving beacon, description
The machine is equipped with a revolving beacon, fitted on the rear
edge of the cab. It is used to give surrounding road users and the
environment an indication that a working vehicle is in motion and at
work. An indication to bystanders to exercise caution.
The revolving beacon is controlled by the revolving beacon switch.
As an option, the machine can be equipped with a revolving beacon

at the top of the mast .

9:60 9 Frame, body, cab and accessories – Working lights, cab
Revolving beacon, pole mounted, replacement

2 Undo the wing nut which fixes the revolving beacon to the pole.
3 Lift the rotating warning beacon off.
4 Install the new revolving beacon.
5 Tighten the wing nut.
9.6.9 Working lights, cab

Working lights, cab, description
Working lights on the cab provide visibility when handling a load in

darkness.
The working lights are turned on with a switch on the dashboard panel.
9.6.10 Work lights, mast

Mast working lights, description
Work lights are fitted on the mast. Used to provide the operator with
better vision for load handling in the dark.
As an option, the machine can be equipped with extra work lights .

9 Frame, body, cab and accessories – Work lights, attachment 9:61
9.6.11 Work lights, attachment

Working lights, attachment, description
Working lights on the attachment provide increased visibility when
handling a load in darkness.
As an option, the attachment can be equipped with extra, number and

location vary depending on type of attachment .
9.6.12 Interior lighting

Interior lighting, description
The interior lighting lights up the inside of the cab, and is turned on
with an interior lighting switch and door switches when the doors are
opened. The interior lighting comes on for a limited time, when a door
is opened and the machine is turned off.
There is background illumination in all switches, function keys and

rotary controls. This is so that the driver will be able to read their
functions and settings in darkness.
A reading lamp is an accessory for the writing panel combined

document compartment. The reading lamp is an LED lamp with a
clamp and comes attached to the writing panel. The reading lamp has
an internal battery that is charged via USB. The lamp is switched on
using the switch on the lamp housing. The combined writing panel with
document compartment has brackets to be hung on a door handle,
supported against the steering wheel or fitted on the inner handle.
9.6.13 Extra working lights frame

Extra working lights frame, description
The machine can be equipped with additional working lights located

on the frame (normally on the lamp hoods) in order to provide better
visibility for work in the dark.

9:62 9 Frame, body, cab and accessories – Signalling system
9.7 Signalling system

Signalling system, description
The signal system includes revolving beacon, back-up lights, direction
indicators, horn, reverse alarm, buzzer for automatic spreading and
buzzer in the cab.
NOTE
Signalling system, function description

NOTE
Pos Description Signal description Reference

1 Revolving beacon switch (S1100) Switch in ON position: U = D1: 9.7 Signalling Sys 2/XX DIAGNOSE, page
sends a voltage signal to the KPU 5 V, 8:73 and 9.7 Signalling Sys 3/XX DIAGNOSE,
control unit (D7902). off position: U = 0 V page 8:73
2 Warning light switch (S1090) sends Switch in ON position: U = D2: 9.7 Signalling Sys 7/XX DIAGNOSE, page
a voltage signal to the KPU control 5 V, 8:74
unit (D7902). off position: U = 0 V
3 The travel direction selector in U = 24 V Travel direction selector and parking brake,
position for activated parking brake description, page 2:9
(S1310) sends a voltage signal to the D3: 4.5 Park Brake Sys 1/XX DIAGNOSE,
KPU control unit (D7902). page 8:35
4 Multi-function lever (S1600) sends a Signal button pressed in: D4: 9.7 Signalling Sys 1/XX DIAGNOSE, page
voltage signal to the KPU control unit US1600/31b = 24 V 8:73 and 9.6 Lighting Sys 6/XX DIAGNOSE,
(D7902). Direction indicator left: page 8:69
US1600/L = 24 V
Direction indicator right:
US1600/R = 24 V
5 Horn switch (S1490) sends a voltage Switch in ON position: U = D5: 9.7 Signalling Sys 1/XX DIAGNOSE, page
signal to the KPU control unit 24 V 8:73
(D7902).
6 KPU control unit, (D7902) transmits Checked by control 11.5.3.2 Control unit KPU (D7902), page 11:27
"activation" messages on the CAN system, error shown

9 Frame, body, cab and accessories – Signalling system 9:63
Pos Description Signal description Reference

7 Make-contact (closing switch) Operator in seat: U = 24 V Sensor operator in seat, description, page 9:17
operator-in-seat (B2300) sends a D7: 9.3 Seat 1/XX DIAGNOSE, page 8:58
voltage signal to KCU control unit
(D7901) when there is a load on the
driver's seat.
8 KCU control unit (D7901) transmits Checked by control 11.5.3.1 Control unit KCU (D7901), page 11:25
"switch on lights" messages on the system, error shown
CAN bus. with error code.
9 KCU control unit (D7901) supplies Checked by control 11.5.3.1 Control unit KCU (D7901), page 11:25
voltage to the lights in and around system, error shown
the cab. with error code.
10 Reversing lights (E4050-LE & Light on: U = 24 V Back-up lights, description, page 9:58
E4050-RI) white come on when D11: 9.6 Lighting Sys 10/XX DIAGNOSE,
reverse gear is engaged and when page 8:70
the reversing lights are activated with
the switch.
11 Horn (H8500) sounds when the horn Horn active: U = 24 V Horn, description, page 9:64
is activated. D12: 9.7 Signalling Sys 1/XX DIAGNOSE,
page 8:73
12 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description, page 9:64
when horn is activated. UK3016/85 = 0 V D13: 9.7 Signalling Sys 1/XX DIAGNOSE,
Horn activated: page 8:73
UK3016/86 = 24 V
UK3016/87 = 24 V
13 Loud horn (H8500-2) sounds when Horn active: U = 24 V Horn, description, page 9:64
the horn is activated.
14 Control unit KFU (D7971) supplies Checked by control 11.5.3.4 Control unit KFU (D7971), page 11:31
voltage to the lamps. system, error shown
with error code.
15 Revolving beacon (H4281 & H4282) Light on: U = 24 V D16: 9.7 Signalling Sys 2/XX DIAGNOSE,
is switched on when the revolving page 8:73 and 9.7 Signalling Sys 3/XX
working light is activated. DIAGNOSE, page 8:73
16 Direction indicators (H4220-FL, Light on: U = 24 V Direction indicators, description, page 9:59
H4220-RL, H4220-FR & H4220-RR) Warning lamp, Hazard, description, page 9:59
come on when the direction indicators
or warning lights are activated. D17: 9.6 Lighting Sys 7/XX DIAGNOSE, page
8:69 and 9.6 Lighting Sys 8/XX DIAGNOSE,
page 8:69
17 Reverse gear selected: U Reverse alarm, description, page 9:64
= 24 V D18: 9.7 Signalling Sys 5/XX DIAGNOSE,
page 8:74
18 The buzzer is voltage fed by the KPU Checked by control Buzzer, description, page 9:65
control unit (D7902). system, error shown 11.5.3.2 Control unit KPU (D7902), page 11:27
with error code.
19 KID control unit (D7950) alerts the - 11.5.3.3 Control unit, KID (D7950), page 11:29
driver to certain event menus.
Indicator lights inform the driver A click is heard when Cab overview, page 9:5
if the functions that are active or the event menu is shown
need action by the driver or service in combination with an
personnel. indicator light.
Only certain pop-ups have
sound.

9:64 9 Frame, body, cab and accessories – Horn
9.7.1 Horn
Horn, description
Electromagnetic horn, operated from the multi-function lever (S1600)
or Horn switch (S1490).
The horn is fitted in the space above the drive axle in the frame.
As an option, the machine can be equipped with loud horn. The

loud horn has an electric compressor and is operated with the same
switch that activates the standard horn.
9.7.2 Warning lamp, Hazard

Warning lamp, Hazard, description
See Warning lamp, Hazard, description, page 9:59.
9.7.3 Revolving beacon

Revolving beacon, description
See Revolving beacon, description, page 9:59
9.7.4 Warning parking brake

Warning parking brake, description
A buzzing sound is activated when the operator leave the seat without
activating the parking brake.
A sensor in the seat indicates whether the seat is occupied.
The buzzer is located in the Control unit KPU (D7902), see 11.5.3.2
Control unit KPU (D7902), page 11:27.
9.7.5 Reverse alarm

Reverse alarm, description
When reverse direction is selected, a warning sound and the reversing

lights are activated. This is to indicate to other road users and the
environment that the machine is reversing. An indication to bystanders
to exercise caution.
The reverse alarm receives an input signal from the travel direction
selector and the output signal goes to the reverse alarm and back-up
lights.
The reverse alarm is fitted at the rear of the cab undercarriage.
Alarm volume is determined by the ambient sound level.

9 Frame, body, cab and accessories – Buzzer 9:65
Reverse alarm, replacement

2 Unplug the connector from the reverse alarm.
3 Remove the screws which secure the reverse alarm.
4 Fit the new reverse alarm in reverse order.
9.7.7 Buzzer
Buzzer, description
The buzzer is located in the Control unit KPU (D7902) which is fitted
in the right-hand dashboard panel's front section, see 11.5.3.2 Control
unit KPU (D7902), page 11:27.
To alert the operator, different sounds are given in certain event menus:
• the parking brake is not applied and the engine is switched off and
the driver is not sitting in the seat (continuous sound)
• the parking brake is not engaged and the ignition key lock is in
operating mode, but the driver is not sitting in the seat (continuous
sound)
• low accumulator pressure (continuous sound)
• overload (pulsing, low frequency sound)
• activated direction indicators (ticking sound, high/low frequency).

9:66 9 Frame, body, cab and accessories – Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, description
This section describes items for supporting the driver or facilitating
communication for the driver.
Entertainment and communication consist of the following:

• Radio with CD
• Voltage converter
• Rear view camera with monitor in the cab, see Rear view
camera system, description, page 9:74.
9.8.1 Audio system

Audio system, description
The cab can be equipped with different variants of audio system. It is

powered by battery voltage. A switch is fitted on the front part of the
right-hand dashboard panel for switching off the sound from the audio
system.
The converter is located beside the electronic box, see Voltage

converter, general, page 9:67.
Radio antenna, description

The cab roof provides provisions for the installation of a radio and/or
communication radio.
The radio antenna is fitted in the rear edge of the cab, above the rear
window on the right-hand side of the cab. The antenna is made of
a flexible material.
Radio antenna, replacement

2 Undo the screws which fix the roof panel and remove the roof
panel.
3 Undo the antenna cable connector.

9 Frame, body, cab and accessories – Voltage converter 9:67
4 Undo the lock nut which fixes the antenna to the roof panel and
remove the antenna.
5 Replace the antenna.
006127
9.8.7 Voltage converter

Voltage converter, general
See Voltage converter, description, page 11:21.

9:68 9 Frame, body, cab and accessories – Glass/windows/mirrors
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
The roof window is a safety detail and is therefore always made of
C polycarbonate plastic.
The mirrors are all convex. Interior rear view mirror with extra large
D
viewing angle available as an option.
As an option the machine can be equipped with a rear view camera
and monitor in the cab to improve visibility.
The cab's windows are made of tinted hardened safety glass
(tempered, reinforced), apart from the roof window, which is made of
scratch-resistant polycarbonate material.
001512
A E B As an option, the cab can be equipped with a windscreen in tinted
laminated glass.
A. Side windows
The rear view mirrors are of the convex mirror type. There is an interior
B. Windscreen (front window) rear view mirror on all machines.
C. Roof window
As an option the machine can be equipped with a rear view camera
D. Rear window and monitor in the cab to improve visibility.
E. Windscreen (front side window)
Silicone adhesive, handling advice

The window panes are secured with decor strips adhesive and silicone
adhesive.
NOTE
The purpose of this instruction is to describe how silicone adhesive
923854.0001 should be handled in connection with replacement of
the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0001 is a quick-hardening,
two-component silicone adhesive that can withstand
temperatures between -50 ºC and +200 ºC. The hardening
properties of the adhesive are extremely dependent on the
ambient temperature. An increase of 10 ºC cuts hardening
time in half.
Silicone adhesive 923854.0001 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 in order to avoid undesired
hardening.
Fixing time:
10-20 minutes at 20 ºC
approx. 5 minutes at 60 ºC
Hardening time:
approx. 24 hours at 20 ºC
approx. 1 hour at 60 ºC
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 ºC
and +20 ºC. Storage in a refrigerator or a colder environment
is recommended.

9 Frame, body, cab and accessories – Windscreen 9:69
9.9.1 Windscreen
Windscreen, description
The windscreen is made of tinted hardened safety glass (tempered,
reinforced), apart from the roof window, which is made of
scratch-resistant polycarbonate material.
As an option, the cab can be equipped with a windscreen in tinted

laminated glass.
For location, see Glass/windows/mirrors, description, page 9:68.
Windscreen, replacement
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice, page 9:68.

2 Remove the decor strip from the strip between the windscreen
and cab frame.
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 apart silicone joints with a sharp tool.
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
Removing the decor strip Strong dissolvents, e.g. acetone, must not come
into contact with a window made of polycarbonate
plastic. Dissolvents have a chemical effect on the
polycarbonate plastic which reduces the strength of
the roof.
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.

9:70 9 Frame, body, cab and accessories – Windscreen
1 2 3 6 When the windscreen or a side window is to be replaced, then the

window panes must be adjusted so that the upper edge on the side
window has the same height as the upper edge of the cab roof and
so that the distance between windscreen and side window.
Use spacers against the roof member to ensure that the distances
are maintained.
1,0
1
006268
Adjusting side window - cab roof
1. Side window
006269
2. Rubber strip 1,0
3. Cab frame/door opening
Adjusting side window - windscreen
1. Masking tape
7 Fit the decor strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window 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.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
9 Remove excess silicone from the outer vertical corners, using a

tool made of cardboard. Smooth out the joints on the inside with a
finger soaked in water or soapy water.
10 Apply silicone adhesive 923854.0100 between the strip and
window 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
the corner bolts for the window pane.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
out the joints with a finger, wet with water or soapy water.
IMPORTANT
006272
Cardboard tool template for silicone joint scale 1:1 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 Frame, body, cab and accessories – Side window 9:71
9.9.2 Side window

Side window, description
The side window consists of tinted laminated safety glass and is glued
to the cab frame.
Side window, replacement
NOTE
The method describes a general procedure.

2 Remove the decor strip from the window's rubber strip.
a) If necessary, use special tools to grip the decor strip in the

window's rubber strip.
3 Carefully remove any remains of glass from the rubber strip.
Check that the rubber strip is intact and undamaged. Replace the
rubber strip if necessary.
4 Position and hold the new pane of glass at the bottom edge of
the rubber strip.

9:72 9 Frame, body, cab and accessories – Side window
5 Spray soap solution on the window and rubber strip to facilitate

fitting.
6 Thread the rubber strip around the whole window; use special
tools.
7 Fit the decor strip in the rubber strip using a special tool. Use soap
solution on the decor strip and rubber strip to facilitate fitting.
a) Pull the decor strip around the whole window. Avoid stretching
the decor strip.

9 Frame, body, cab and accessories – Roof window 9:73
b) Cut off the decor strip approx. 2 cm too long.

c) Fit the other end of the decor strip edge to edge.
d) Adjust the decor strip so that the correct fit is obtained.
Push in the remaining part of the decor strip in the rubber strip.
Press the decor strip toward its opposite end.
9.9.3 Roof window

Roof window, description
The polycarbonate roof window is a safety detail, intended to protect the
operator from falling objects. The polycarbonate window is elastic and
virtually unbreakable. Safety is maintained within a temperature range
from +120 °C to -45 °C (becomes brittle first at -110 °C, glass transition
temperature +145 °C). The roof window has a patented surface layer
that increases its durability and resistance to UV light and chemicals.
The roof window is joined with the windscreen. Joints between the
window panes and between roof window and cab are sealed tightly
with silicone adhesive. Apply a new seal of silicone adhesive when
replacing.
WARNING
The strength of the roof window can be substantially
reduced by exposure to substances that contain
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at regular
intervals. Clean only with windscreen washer fluid or
a mild cleaning agent. Rinse thoroughly with plenty
of lukewarm water. Replace a damaged roof window
immediately if it is cracked or scratched!
Roof window, replacement

See Windscreen, replacement, page 9:69.
The roof window is joined with the windscreen. The joint is sealed with
silicone. Apply a new seal of silicone when replacing.
9.9.4 Rear window

Rear window, description
The rear window is attached to the cab with a decor strip.
Rear window, replacement

See Side window, replacement, page 9:71.

9:74 9 Frame, body, cab and accessories – Rear view mirror
9.9.5 Rear view mirror

Rear view mirror, description
The machine is equipped with rear view mirrors on both sides of the
machine, either on the fenders or on the lamp hoods ( ) and in the
cab.
9.9.8 Rear view camera and load camera

Rear view camera system, description
The machine can be equipped with two different systems with rear
view camera.
• Back-up camera.
• Back-up camera with distance warning.
Rear view camera systems are standalone systems.
The rear view camera system can be extended with more cameras,
e.g. camera on boom for improved vision during loading.
9.9.8.1 Back-up camera
Rear view camera, description
The back-up camera is located on the rear edge of the cab

undercarriage and provides increased visibility when reversing. The
rear view camera sends colour images and audio to the monitor in the
cab; see Monitor, rear view camera, description, page 9:75.

9 Frame, body, cab and accessories – Rear view camera and load camera 9:75
9.9.8.2 Monitor back-up camera
Monitor, rear view camera, description
The monitor conveys images and sound from the rear view camera.
The picture is in colour and the brightness is adjusted automatically
according to the light conditions in the cab. The monitor supports
signals from four different cameras.
The monitor is fitted on a hinged bracket to the right, in front of the

door in the cab. As an option, the monitor can be specified mounted
on the left-hand side.
A. Right / Left (volume)

B. Up / Down
C. Off / On
D. Confirm selection (change camera)
E. Show menu
F. Light sensor
Monitor rear view camera with distance warning,

description
The monitor conveys images and sound from the rear view camera.
The picture is in colour and the brightness is adjusted automatically
according to the light conditions in the cab. The monitor supports
signals from four different cameras.
On machines with rear view camera system with distance warning the
monitor also warns with audio and visually in the image from the rear
view camera if objects come within the surveillance area behind the
machine during reversing. Distance warning uses separate sensors,
see Sensor distance warning, description, page 9:76.
The monitor is fitted on a hinged bracket to the right, in front of the

door in the cab. As an option, the monitor can be specified mounted
on the left-hand side.
A. Screen display off / on
B. Indicator light, power
C. Light sensor
D. Shortcuts 1 - 4
E. Cancel
F. Menu navigation
G. Confirm selection

9:76 9 Frame, body, cab and accessories – Rear view camera and load camera
9.9.8.3 Sensor distance warning
Sensor distance warning, description
On machines with rear view camera with distance warning the sensor
for back-up warning is connected to the rear view camera system and
this way gives a visual warning of objects behind the machine in the
image from the rear view camera.
Distance warning uses two ultrasound sensors fitted by the

counterweight on the rear of the machine in order to measure the
distance to objects behind and warn the operator. The sensors are
activated during reversing.
Sensor, back-up warning device

9 Frame, body, cab and accessories – Cab structure and suspension 9:77
9.10 Cab structure and suspension

Structure and suspension, description
The cab has a flat floor with a bracket for the driver's seat. It is mounted
in a cab substructure via strong rubber dampers fitted on the underside
of the cab. This minimises vibrations from the frame to the cab. Each
damper mounting has one rubber bushing and one bolt.
9.10.1 Cab frame

Cab frame, description
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
9.10.2 Doors
Doors, description
The cab has two doors. The left-hand door is the driver's door and the
right-hand door is the emergency exit. The door has:
• support rail (inside)
• opening handle (inside and outside)
• door locks
The door locks have the same key code as the ignition key lock.
The cab can be equipped with unique key codes.
The doors can be equipped without key locks. In which case, there
are plastic plugs fitted in the recesses for the lock cylinders.
• opening window.
• gas spring damping that prevents the door from being damaged
when it is opened.
The cab can be equipped for different door opening angles. There
are two different lengths for gas springs. The long variant can allow
the door to open up to and including 180°. The shorter variant only
1. Lock, opening side window allows a limited opening angle.
2. Door lock with opening handle The cab can be equipped with a special door-open holder (normally
on left-hand side).
3. Support handle
4. Door compartment with bottle holder
Door, replacement

9:78 9 Frame, body, cab and accessories – Cab undercarriage
2 Remove the screws securing the roof.

3 Open the door
4 Remove spring clip that fastens gas damper in the door.
5 Detach the gas damper from the door.
6 Lift the roof slightly (40-50 mm) using an overhead crane.
7 Lift off the door in question by hand.
8 Replace the door.
9.10.3 Cab undercarriage

Cab substructure, description
The cab is mounted on a cab substructure via strong rubber insulators
fitted on the underside of the cab. This minimises vibrations from the
frame to the cab.
The cab substructure is available in two versions, normal and raised

cab. The cab substructure is secured in the body (frame) with bolts.
There are also steps fitted between body and cab substructure.

9 Frame, body, cab and accessories – Cab interior 9:79
9.11 Cab interior

Cab interior equipment, description
The cab is designed for optimum operator comfort. Switches, controls,
warning and indicator lamps are grouped on the dashboard panels to
provide the operator with a good driving environment.
Recyclable materials have been used for all parts.
• Dashboard panels
• Interior parts, plastic
• Interior parts, steel plate
• Insulation
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
The interior plastic components of the cab are made of recyclable
material.
Interior plastic components, replacement

See appropriate parts of the following instructions:
• Travel direction selector and parking brake, replacement, page 2:9
• Steering wheel, replacement, page 5:4
• Steering valve, replacement, page 5:8
• Wiper motor roof, replacement , page 9:51
• Wiper motor rear, replacement, page 9:52
• Dashboard panel, replacement, page 9:79
• Front floor panel, left, replacement, page 9:80
• Front floor panel, right, replacement, page 9:80
• Front floor panel, centre, replacement, page 9:80
• Front floor panel, accelerator pedal, replacement, page 9:80
• Rear panel, upper left, replacement, page 9:81
• Rear panel, upper right, replacement, page 9:81
• Rear floor panel, right, replacement, page 9:82
• Rear floor panel, centre, replacement, page 9:82
• Rear floor panel, left, replacement, page 9:81
• Panel, cab entry front, replacement, page 9:82
• Panel, cab entry rear, replacement, page 9:83
Dashboard panel, replacement

2 Remove the defroster nozzles, see Defroster nozzles,
3 Remove the clips that secure the dashboard panel.
NOTE
Reuse the clips by re-inserting the centre pin and pressing this
flush with the head on fitting.
a) Press in the centre pin on the clip approx. 3 mm to unlock the clip.
b) Carefully remove the clip.
4 Raise the dashboard panel slightly and unplug all electric
connectors. Then remove the dashboard panel.
5 If the dashboard panel shall be replaced:
Transfer the components to the new panel.

9:80 9 Frame, body, cab and accessories – Interior fittings, plastic
Front floor panel, left, replacement

2 Detach the dashboard panel so that it can be lifted, see Dashboard
panel, replacement, page 9:79.
3 Remove the clips and the screws securing the panel.
NOTE
Remove the clips that secure the panel as follows:

Front floor panel, centre, replacement

3 Remove the screws securing the panel.
Front floor panel, accelerator pedal, replacement

NOTE

Front floor panel, right, replacement

NOTE


9 Frame, body, cab and accessories – Interior fittings, plastic 9:81
Rear panel, upper left, replacement

2 Turn the screws that hold the panel 90° and raise them slightly.
3 Remove the panel.
Rear panel, upper right, replacement

3 Remove the panel.
Rear floor panel, left, replacement

2 Remove the upper panel, see Rear panel, upper left, replacement,
page 9:81.
4 Remove the panel.

9:82 9 Frame, body, cab and accessories – Interior fittings, plastic
Rear floor panel, right, replacement

2 Remove the upper panel, see Rear panel, upper right,
4 Remove the panel.
Rear floor panel, centre, replacement

2 Remove the upper left panel, see Rear panel, upper left,
3 Remove the upper right panel, see Rear panel, upper right,
4 Remove the left floor panel, see Rear floor panel, left, replacement,
page 9:81.
5 Remove the right floor panel, see Rear floor panel, right,
7 Remove the panel.
Panel, cab entry front, replacement

2 Remove the screws that hold the sill moulding in the cab entry,
and remove the sill moulding.
006652

9 Frame, body, cab and accessories – Interior fittings, textile 9:83
3 Left side:
Remove the handle from the A-pillar.
4 Right side:
Remove the bracket with safety chain from the A-pillar.
6 Remove the panel.
Panel, cab entry rear, replacement

2 Undo the screws which hold the sill moulding in the cab entry,
006652

4 Remove the panel.
9.11.3 Interior fittings, textile

Interior fittings, textile, description
The interior textile components of the cab are made of recyclable
material.

9:84 9 Frame, body, cab and accessories – Floor covering
Roof panel, front, replacement

3 Remove the roof panel.
006653 Roof panel, rear, replacement

2 Empty the roof compartment.
4 Hold the roof and disconnect the cable harness from the equipment
fitted in the roof (loudspeakers, lights, etc.).
5 Carefully remove the roof panel.
6 If the roof panel shall be replaced, transfer the components to
the new roof panel.
006654
Attaching bolts, rear roof panel
9.11.4 Floor covering

Floor covering, description
The floor covering is recyclable and is made of wear and water resistant
material.
Floor covering, replacement

2 Open the doors on both sides.
3 Undo the screws which hold the sill moulding in the cab entry,
4 Undo and remove all equipment in the cab which is screwed
through the floor matting, such as the seat and pedal base.
5 Replace the floor matting.
006652
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.
The insulation material consists of both self-adhesive foam plastic

material for noise and heat insulation and of self-adhesive matting
(heavy material for good sound insulation at low noise frequencies).

9 Frame, body, cab and accessories – Sun visors 9:85
9.11.6 Sun visors

Sun visors, description
Sun visors can be specified for the windscreen, roof window and the
rear window:
1. Sun visors, front and rear window: Adjustable up and down with
the cord on the right-hand side. Stops in the chosen position.
2. Sun visor, roof window: It is pulled out forwards. Stops in the
chosen position.
9.11.8 Writing panel and deed pigeon-hole

Writing desk, description
The function of the writing desk is to provide a work surface for a

writing and notes. It is located to the right of the steering wheel,
easily accessible for the operator. Also includes a deed pigeon-hole
and reading lamp.

9:86 9 Frame, body, cab and accessories – Frame
9.12 Frame
Frame, description
The body consists of two longitudinal frame sides. The mudguards,
footsteps, tanks and counterweights are bolted into the frame.
The frame contains attachment points for the steering axle and cab.
The brackets for engine, transmission, drive axle, fuel tank and
hydraulic oil tank are screwed into the chassis. The mudguards are
bolted into the frame.
The space in the rear section is welded to the longitudinal frame sides
and is used to contain the counterweights. The number and size of
counterweights is adapted to the machine in question.

9 Frame, body, cab and accessories – Body structure 9:87
9.13 Body structure

Body structure, description
The function of the body is to be part of the frame. There are fenders to
deflect dirt, footsteps and hand rails to facilitate access onto the body,
engine hood to deflect dirt and objects from the engine compartment
and a counterweight to balance the machine's lifting capacity.
The body is regarded as being the following:

• Wings
• Engine covers
• Footstep
• Counterweights
• Hydraulic oil tank
• Fuel tank
• Side panel
• Battery compartment
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by the
wheels during operation.
The wings can be equipped with extra mudguards when the

machine's work environment requires such.
9.13.2 Hood engine compartment

Hood engine compartment, description
The machine's engine compartment is protected by engine covers
consisting of tread plates with sound insulation that act as hoods. The
tread plates are divided into several sections, the hoods are secured
with rubber bushings or with screws. The tread plates are designed for
walking on and are ribbed to provide sure footing.
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
The machine's running boards are made of stamped stainless steel
plate that is designed to be walked on with footholds. The footsteps are
bolted into brackets on the frame.
There are hand rails by the cab steps for the cab and the platform
by the cab.

9:88 9 Frame, body, cab and accessories – Counterweight
9.13.4 Counterweight
Counterweights, description
The machine has counterweights to balance the machine\qs lifting
capacity and may therefore vary in quantity and weight.
The counterweights are located at the very back on the frame for
maximal leverage.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's characteristics.
The machine's handling characteristics change if the
counterweights are removed or added!
Never change the number of counterweights.
9.13.5 Battery compartment

Battery compartment, description
The battery compartment is located behind the cover lid on the rear
left-hand side of the machine (behind the fuel tank). The cover lid is
opened with a lockable T-handle.
The compartment has two sections separated by a fixed shelf. The

upper section contains the starter batteries. On machines with SCR
system, the lower section contains control electronics for emission
control. On machines without SCR system, the compartment can be
used for storage.
NOTE
The compartment with starter batteries must not be used as a
storage space.
1. Battery
2. Battery disconnector
9.13.8 Tool kit

Tool kit, description
The machine can be equipped with a tool kit.

9 Frame, body, cab and accessories – Lifting lugs 9:89
9.13.9 Lifting lugs

Lifting and lashing points, description
To transport the machine it is equipped with lifting points and lashing
points in several places:
• Rear of the frame at the steering axle (lashing point for securing on
a transport vehicle)
• Rear of the frame (welded lifting points for lifting the machine)
• Front of the frame above the drive axle (holes for securing on a
transport vehicle)
• Front of the frame above the drive axle (welded lifting points for
lifting the machine)

9:90 9 Frame, body, cab and accessories – Central lubrication
9.14 Central lubrication

Central lubrication, description
Central lubrication lubricates the machine's lubrication points

automatically during operation in accordance with pre-programmed
intervals and replaces parts of lubrication during preventive
maintenance. Central lubrication is activated and the time interval
starts when the engine is started and the speed is above 0.5 km/h, or
when a hydraulic function is active. When the time interval (pause) has
counted out, the pump unit is restarted and runs in accordance with a
predetermined running time.
The machine has two separate central lubrication systems, one for the
machine and one for the attachment.
Central lubrication consists of the following components:

• Pump unit (M6930), with lubricant reservoir.
• Distribution blocks, which distribute and doses the grease between
Example figure, components, central lubrication the different lubrication points.
1. Central lubrication sensor (B7242) The distribution blocks lubricate progressively, i.e. one point at a
time. If a point cannot be lubricated properly, e.g. due to a blocked
2. Grease nipple, manual lubrication of system
line, subsequent points will not be lubricated. The grease will be
3. Safety valve pushed out through the safety valve on the pump unit.
4. Lubricant nipple for filling • Lines, between main unit and distribution blocks and between
distribution blocks and grease nipples.
5. Distribution block
• Grease nipples, at the lubrication points.
• Central lubrication sensor (B7242).
The sensor is fitted on the distribution block at the pump unit and
sends signals to the control system. Faults in central lubrication
are indicated by error codes in the display.
Signals can be monitored with the diagnostic menu, see 9.14 Central
Lubr 1/XX DIAGNOSE, page 8:75.
NOTE
The central lubrication does not lubricate all lubrication points,
some still need to be lubricated during preventive maintenance.
9.14.1 Pump unit

Pump unit, description
The pump unit consists of a reservoir with agitator and filler nipple, as
well as pump housing with built-in motor and pump element.
The unit works by means of lubrication cycles (pause and run-time

and read time). A pressure relief valve is fitted to the pump element,
ensuring that the pressure in the system does not become too high.
Control of central lubrication is performed by the control system.

Signals can be monitored with the diagnostic menu, see 9.14 Central
Lubr 1/XX DIAGNOSE, page 8:75.
Pump unit, central lubrication

1. Safety valve
2. Lubricant nipple for filling

9 Frame, body, cab and accessories – Distribution block 9:91
9.14.2 Distribution block

Distribution block, description
The number of distribution blocks can vary depending on how many
(and which) lubrication points are selected. However, the first
distribution block (i.e. the block closest to the pump unit) is always
included.
The distribution blocks consist of progressively controlled pistons.

These are powered by the lubricant and have no springs and seals. The
lubricant is pressurised and then drives the pistons in the distributor.
The pistons move in a predetermined way, and this pattern of

movement is repeated time after time. Each piston must have complete
its movement before the next piston can move. The pistons are
interdependent. It is technically impossible for a connected lubrication
point to be missed.
Example figure, components, central lubrication

1. Central lubrication sensor (B7242)
3. Safety valve
9.14.3 Lines
Lines, description
The lubricant is carried to the lubrication points through hoses.
Example illustration, components, central lubrication

1. Lines, central lubrication
2. Lubricant nipples

9:92 9 Frame, body, cab and accessories – Lubricant nipples
9.14.4 Lubricant nipples

Lubrication points, description
The lubrication points have lubricant nipples with couplings to which
the lines are connected. The couplings can be straight or angled.
Example illustration, components, central lubrication

1. Lines, central lubrication
2. Lubricant nipples
9.14.5 Sensor, central lubrication

Sensor, central lubrication, description
Sensor, central lubrication (B7242), is fitted on the distribution block at
the pump unit and sends signals to the control system. Faults in central
lubrication are indicated by error codes.
Example figure, components, central lubrication

1. Central lubrication sensor (B7242)
3. Safety valve

9 Frame, body, cab and accessories – Paint/coatings 9:93
9.15 Paint/coatings
Paint/coatings, description
The machine is painted with paint which is applied by brush or spray.
For colour code (RAL), see machine card.
Check the machine frequently for stone chips, dents and paint
scratches, repair them at once to prevent corrosion on the metal
underneath. Only use touch-up paint for small stone chips and
scratches. More extensive paint damage should be repaired by a paint
workshop.
NOTE
Before performing touch-ups, the surface area must be carefully
cleaned.
Contact Cargotec for information about other surface treatment and

colours.

9:94

10:1
Contents 10 Common hydraulics

10 Common hydraulics ........................................................................................ 10:3
10.2 Safety valves..................................................................................................10:4
10.2.1 Accumulator drain valve ............................................................................10:4
10.2.2 Relief valve, attachment ............................................................................10:4
10.2.3 Pipes and hoses........................................................................................10:4
10.2.4 Pressure relief valve..................................................................................10:5
10.3 Tanks and accumulators ................................................................................10:6
10.3.1 Tank...........................................................................................................10:6
10.3.2 Accumulator ..............................................................................................10:6
10.3.4 Pipes and hoses........................................................................................10:6
10.4 Pumps............................................................................................................10:7
10.4.1 Gear pump with fixed displacement ..........................................................10:7
10.4.2 Axial piston pump with variable displacement...........................................10:8
10.4.3 Pipes and hoses......................................................................................10:18
10.5 Hoses, pipes and valves ..............................................................................10:19
10.5.1 Pipes and hoses......................................................................................10:19
10.5.2 Priority valve............................................................................................10:19
10.5.7 Valve block servo pressure .....................................................................10:20
10.5.8 Accumulator servo circuit ........................................................................10:22
10.5.9 Control valve, attachment .......................................................................10:23
10.5.10 Main valve ...............................................................................................10:23
10.6 Temperature control, cleaning and hydraulic oil...........................................10:25
10.6.1 Tank heater .............................................................................................10:26
10.6.2 Hydraulic oil cooler ..................................................................................10:26
10.6.3 Cooling fan ..............................................................................................10:27
10.6.4 Sensor hydraulic oil temperature.............................................................10:27
10.6.5 Bypass valve, hydraulic oil cooler ...........................................................10:28
10.6.6 Breather filter hydraulic oil tank ...............................................................10:29
10.6.7 Hydraulic oil filter .....................................................................................10:29
10.6.9 Fine filter hydraulic oil..............................................................................10:30
10.6.10 Pipes and hoses......................................................................................10:30
10.7 Other ............................................................................................................10:31
10.7.1 Hydraulic cylinders ..................................................................................10:31

10:2

10 Common hydraulics – Common hydraulics 10:3
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering
and certain cab functions with hydraulic pressure.
The brake system can be found under section 4 Brakes, see Brakes,
general, page 4:3.
Pressure plate
On the machine there is a pressure plate with the most important
pressure information stamped in. The pressure plate is fitted on the
left-hand side of the frame in front of the cab steps.
Pressure levels vary with the equipment and are therefore unique
to each machine. When checking the pressure, pressures must be
consistent with the values specified on the pressure plate.
1. Feed pressure control valve, attachment 5. Max. pressure hydraulic oil pumps
2. Max. brake pressure 6. Gas pressure servo accumulator
3. Gas pressure brake accumulators 7. Oil pressure steering
4. Servo pressure, lift and tilt

10:4 10 Common hydraulics – Safety valves
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
Relief valve brake system, drains the stored pressure in the brake
system's accumulators.
For information about depressurising the machine, see Hydraulic

The accumulator drain valve is fitted on the main valve. See Main
valve, description, page 10:23.
10.2.2 Relief valve, attachment

Relief valve attachment, description
Relief valve attachment, drains the pressure in the hydraulic line to the
attachment's pressure feed. This line is pressurised after the engine
has been switched off due to non-return valves in the hydraulic oil
pump. The valve must be closed during normal operation.
For information about depressurising the machine, see Hydraulic

The relief valve is fitted on the main valve. See Main valve, description,
page 10:23.


10 Common hydraulics – Pressure relief valve 10:5
10.2.4 Pressure relief valve

Pressure limiting valve, general
The pressure relief valve is fitted in valve block, servo pressure, which
is part of the main valve, see Valve block servo pressure, description,
page 10:20.

10:6 10 Common hydraulics – Tanks and accumulators
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
The hydraulic oil tank forms part of the side panel on the right-hand side
of the machine. The oil filters (position 2) for the working hydraulics
are fitted inside the tank. These are accessible through hatches on
top of the tank.
Hydraulic oil is filled directly into the tank through the filler plug (position
5). For oil capacity and grade, see section F Technical data. The whole
filter unit can be removed to facilitate access for cleaning. There is a
drain plug located at the bottom of the tank.
The tank has filtered venting (position 4) which allows changes in the
tank volume due to usage and temperature variations.
The oil level is checked on the level glass (position 1) on the tank's side
when all hydraulic cylinders are in the bottom position.
1. Sight glass hydraulic oil

2. Cleaning filter hydraulic oil
3. Filling point, spare
4. Breather filter
5. Filling point
10.3.2 Accumulator
Accumulator, general
See Accumulator, description, page 4:14.
See Accumulator servo circuit, description, page 10:22.


10 Common hydraulics – Pumps 10:7
10.4 Pumps
Pumps, general
The machine's hydraulics are supplied from three pumps. Two of them
for the working hydraulics and one for the brake system. The pumps
are mounted on the transmission's power take-off.
Hydraulic oil pump 1 (position 1) is assembled together with Oil pump

brake system (position 1) into one pump bank. Hydraulic oil pump 1
supplies the steering, the control valve for lift and tilt (part of the main
valve) as well as pressure feed to the attachment. The priority valve
ensures that there is always pressure for the steering, the residual
flow goes to the control valve for lift and tilt, as well as pressure feed
attachment. There is a non-return valve fitted on the pump's pressure
side which prevents the oil from being fed back through the pump
instead of out into the hydraulic system.
Hydraulic oil pump 2 (position 2) supplies the control valve for lift and
tilt (part of the main valve) as well as pressure feed to the servo circuits
and attachment. There is a non-return valve fitted on the pump's
pressure side which prevents the oil from being fed back through the
pump instead of out into the hydraulic system.
Return oil from hydraulic pump 1 and 2 passes through a filter before
1. Hydraulic oil pump 1 it reaches the hydraulic oil tank.
Oil pump brake system and cooling/cleaning (position 3) supplies
3. Oil pump brake system and cooling/cleaning the brake and cooling circuit over an accumulator charging valve (part
of the main valve), see Brake oil pump, description, page 4:8.
Oil pump brake system and cooling/cleaning continuously circulates

the hydraulic oil through the radiator and hydraulic oil filter, see
Temperature control system, hydraulic oil, description, page 10:25. A
fine filter is available as an option which is located on the return
from the brakes.
10.4.1 Gear pump with fixed displacement

Gear pump with fixed displacement, general

10:8 10 Common hydraulics – Axial piston pump with variable displacement
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
description
The hydraulic oil pumps are of the type variable axial piston pump, and
are controlled by load signals depending on the flow demand from
each function.
Hydraulic oil pump 1 (position 1) supplies the control system as

well as the control valve (part of the main valve) for lift/lower, tilt and
attachment. The priority valve ensures that there is always pressure
available for the steering system, the residual flow goes to the control
valve for lift, tilt and pressure feed attachment.
A block with a test outlet for measuring pump pressure and a non-return
valve are fitted on the connection from Hydraulic oil pump 1 (position
1).
Hydraulic oil pump 2 (position 2) supplies the control valve for lift
and tilt (part of the main valve) as well as pressure feed to the servo
circuits and attachment.
A block with a test outlet for measuring pump pressure and a non-return
valve are fitted on the connection from Hydraulic oil pump 2 (position
2).
3. Oil pump brake system and cooling/cleaning

10 Common hydraulics – Axial piston pump with variable displacement 10:9
Axial piston pump with variable displacement,

function description

1 The lift or tilt section of the main See pressure plate Servo Lifting/lowering, description, page 7:15
valve sends load signals to the servo pressure lift and tilt on left Tilt, description, page 7:62
pressure section when a function is frame member.
activated.
2 The load signal is sent onward to - Valve block servo pressure, description,
hydraulic oil pump 2 and the shuttle page 10:20
valve.
3 Hydraulic oil pump 2 increases the flow See pressure plate Max. Axial piston pump with variable displacement,
to the main valve. pressure hydraulic oil description, page 10:8
pumps on left frame
member.
4 The main valve's pressure reducer See pressure plate servo Valve block servo pressure, description,
reduces the feed pressure to servo pressure, on left frame page 10:20
pressure. member.
5 Accumulator servo pressure stores the See pressure plate servo Accumulator servo circuit, description, page
servo pressure. pressure, on left frame 10:22
member.
6 The shuttle valve (fitted on the See pressure plate Servo Valve block servo pressure, description,
connection for valve block servo pressure lift and extension page 10:20
pressure) forwards the load signal to on left frame member.
hydraulic oil pump 1.
7 Hydraulic oil pump 1 increases the flow See pressure plate Max. Axial piston pump with variable displacement,
to the servo valve. pressure hydraulic oil description, page 10:8
pumps on left frame
member.
8 The priority valve routes pressure from See pressure plate Priority valve, general, page 5:6
hydraulic oil pump 1 to the control valve Steering pressure, on left
or to the main valve. frame member.
9 The pressure limiting valve drains - Pressure limiting valve, general , page 10:5
pressure to tank if the pressure in the
hydraulic system becomes too high.
10 When any attachment function is U = 24 V 11.5.3.4 Control unit KFU (D7971), page
activated, Control unit KFU (D7971) 11:31
activates Solenoid valve, attachment D10: Diagnostic menu, see 10.4 Pumps
hydraulics (Y6003). 1/XX DIAGNOSE, page 8:76


11 Solenoid valve attachment hydraulics - Solenoid valve, engagement of hydraulics
(Y6003) controls an unloaded constant for top lift, page 10:20
pressure (which acts as a load signal)
to Control valve, attachment.
12 When Solenoid valve attachment - Valve block servo pressure, description,
hydraulics (Y6003) is not activated, the page 10:20
unloaded pressure is directed to tank.
13 The shuttle valve forwards the load See pressure plate Servo Valve block servo pressure, description,
signal to hydraulic oil pump 1. pressure lift and extension page 10:20
on left frame member.
14 Hydraulic oil pump 1 increases the flow - Axial piston pump with variable displacement,
to the priority valve. description, page 10:8
15 The priority valve routes pressure from See pressure plate Priority valve, general, page 5:6
hydraulic oil pump 1 to the control valve Steering pressure, on left
or to the main valve. frame member.
16 The main valve routes the pressure - Main valve, description, page 10:23
onward to control valve, attachment.
17 Control valve, attachment, routes - Attachment control valve, description, page
pressure to the desired attachment 7:50
function.
18 When the steering wheel is turned, the - Steering valve, description, page 5:8
steering valve sends load signals to the
main valve.
19 The main valve forwards the load - Valve block servo pressure, description,
signals to the shuttle valve. page 10:20
20 The shuttle valve forwards the load See pressure plate Servo Valve block servo pressure, description,
signal to hydraulic oil pump 1. pressure lift and extension page 10:20
on left frame member.
21 Hydraulic oil pump 1 increases the flow See pressure plate Axial piston pump with variable displacement,
to the priority valve. Steering pressure, on left description, page 10:8
frame member.
22 The priority valve routes the hydraulic See pressure plate Priority valve, general, page 5:6
pressure to control valve, steering. Steering pressure, on left
frame member.

machine, page E:4.

Axial piston pump, checking
NOTE
B Safety.
operating temperature, approx. 50 °C.
014520

3 Connect a pressure gauge to the measuring outlet on hydraulic

oil pump 1.
5 Check the stand-by pressure for one pump at a time in the
following order:
Hydraulic oil pump 1: 2.8 MPa
Hydraulic oil pump 2: 2.5 MPa
The settings apply to a standard machine, certain machines may
have higher standby pressure. For correct standby pressure, see
the pressure plate. However, the difference in pressure between
the different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run the extension
function against end-position (overflow).
1. Hydraulic oil pump 1 Run out the boom to max. and continue to request max. extension
with the control lever. This will cause the extension function to
a Adjusting screw, standby pressure overflow.
b Adjusting screw max. pressure
c Measurement connection
a Adjusting screw, standby pressure
b Adjusting screw max. pressure
c Measurement connection
7 Check the max. pressure on hydraulic oil pump 1, the pressure

should correspond with the value on the pressure plate.
All pumps should give the same max. pressure. The sequence
between pumps is not important.
9 Transfer the pressure gauge to hydraulic oil pump 2 and repeat
steps 3-8.
Pressure plate, maximum pressure hydraulic oil

pumps

Hydraulic oil pump 1, replacement
NOTE
B Safety.

2 Drain the oil from the hydraulic oil tank, see Maintenance manual.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump's suction
hose.
3 Switch off the system voltage.

NOTE
5 Release the oil pump for the brake system from hydraulic oil pump
1.
6 Hang up the oil pump for the brake system.
7 Protect the contact surface on the oil pump for the brake system
against dirt using a plastic bag or similar.


8 Mark up and detach the hydraulic hoses from hydraulic oil pump 1.
NOTE
from contaminants.
9 Attach hoisting equipment to the axial piston pump.
10 Remove the axial piston pump.

Remove the retaining bolts and lift the pump away.
11 Clean the flange on the transmission, removing all silicone
remnants.
CAUTION
Contaminants can damage the transmission.
Product damage.
Be careful and make sure that no gasket remains fall
down into the transmission.
12 Transfer the connection adapters to the new axial piston pump.
NOTE
correctly.
13 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.

14 Fit the axial piston pump in place.

Position the axial piston pump so that the pump shaft engages the
transmission's gearing. Fit the attaching bolts.
15 Brush sealing silicone onto the sealing face of the gear pump
against the spacer ring, see section F Technical data.
NOTE
Only use silicon on the side facing the gear pump.
16 Fit the gear pump in place.

Place the gear pump on the axial piston pump and install the
attaching bolts.
Exercise caution that the O-ring on the spacer ring is correctly
aligned and that the gear pump's shaft engages the axial piston
pump's output shaft.
17 Connect the suction hose to the axial piston pump.
NOTE
correctly.


18 Fill the pump with oil through the connections on the top.
CAUTION
The hydraulic oil pump will seize if the engine is started
before the pump is filled with oil.
Product damage.
Always fill the pump with oil before the upper
connection is fitted.
19 Connect the hydraulic hoses to the axial piston pump in

accordance with the marking.
NOTE
correctly.
20 Bleed the axial piston pump, see Axial piston pump with variable
displacement, venting, page 10:18.
CAUTION
Vent the axial piston pump before starting the engine.
The oil in the axial piston pump may cavitate and cause
product damage.
hydraulic system.
NOTE
the lock ring.

23 Check that the hose connections and seal between gear pump and
axial piston pump are airtight.
24 Check the pump pressures, see Axial piston pump, checking,
page 10:11.
manual.
Hydraulic oil pump 2, replacement
NOTE
B Safety.

CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump's suction
hose.

3 Switch off the system voltage.

NOTE
5 Mark up and detach the hydraulic hoses from hydraulic oil pump 2.
NOTE
from contaminants.
6 Attach hoisting equipment to the axial piston pump.

2. Pressure hose (to the priority valve)
7 Remove the attaching bolts and lift the axial piston pump away.
8 Clean the flange on the transmission, removing all silicone

remnants.
CAUTION
Contaminants can damage the transmission.
Product damage.
Be careful and make sure that no gasket remains fall
down into the transmission.
9 Transfer the connection adapters to the new axial piston pump.
NOTE
correctly.

10 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.
11 Fit the axial piston pump in place.

Position the axial piston pump so that the pump shaft engages the
transmission's gearing. Fit the attaching bolts.
12 Connect the hydraulic hoses to the axial piston pump in
accordance with the marking.
NOTE
correctly.
13 Fill the pump with oil through the opening on the top of the pump.
CAUTION
The hydraulic oil pump will seize if the engine is started
before the pump is filled with oil.
Product damage.
Always fill the pump with oil before the upper
connection is fitted.
14 Bleed the axial piston pump, see Axial piston pump with variable
displacement, venting, page 10:18.
CAUTION
Vent the axial piston pump before starting the engine.
The oil in the axial piston pump may cavitate and cause
product damage.
hydraulic system.
NOTE
the lock ring.

17 Check that the hose connections are sealed tightly.
18 Check the pump pressures, see Axial piston pump, checking,
page 10:11.

10:18 10 Common hydraulics – Pipes and hoses
manual.
Axial piston pump with variable displacement, venting
NOTE
Safety.
1 Remove the hydraulic oil tank breather filter.

2 Connect compressed air at max. pressure max. 10 kPa to the
hydraulic oil tank's connection for breather filter.
CAUTION
Excessive pressure in the hydraulic tank damages the
hydraulic system.
Product damage.
Ensure that the pressure does not become too high by
adjusting the pressure regulator on the compressed
air before the tank is pressurised.
3 Loosen the hoses to the hydraulic system's feed from the axial
piston pumps one at a time and let oil flow out. Tighten the
connections when oil free of air is flowing out.
4 Remove the compressed air from the tank and fit the breather filter.
6 Let the engine run at idle speed for at least one minute. Check that
all connections are sealed tightly.
7 Lower the lifting carriage and raise it again very slowly so that
the pump operates under minimum load while air pockets are
eliminated.


10 Common hydraulics – Hoses, pipes and valves 10:19
10.5 Hoses, pipes and valves

Hoses, pipes and valves, description
• Servo valve load handling and steering, incl. shuttle valves,
pressure reducers and solenoid valves. This converts pump
pressure to servo pressure and collects all control signals from the
different functions and prioritises between them in order to control
the hydraulic oil pumps in the best way.
• Collection block, unfiltered returns. This valve collects return
lines from different hydraulic valves that may not have any back
pressure and routes them directly to the tank.
• Priority valve. The priority valve ensures that the steering
function always has pressure before other hydraulic functions are
connected to the same hydraulic oil pump.

Hoses with ORFS couplings are used almost exclusively. For maximum
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. O-rings must not be oiled; O-rings must be dry during assembly.

Hose length
C/L Hose length

Hose length is measured on a hose laid out between the sealing
surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to a great
extent on how clean the hydraulic oil is. It is therefore very important to
prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.

• Always clean the area around a component before starting to work.
001015
• Plug hose connections immediately after disconnecting. If possible,

use correct plugs for the connection type. If plugs are missing, use
C/L line for measuring hose length clean plastic bags and cable ties or tape to seal the connection.
• Never re-use oil that has been drained from the machine.
10.5.2 Priority valve

Priority valve, description
See Priority valve, general, page 5:6.

10:20 10 Common hydraulics – Valve block servo pressure
10.5.7 Valve block servo pressure

Valve block servo pressure, description
page 7:64.
Valve block, servo pressure, handles load signals from Control valve
lift, lower and tilt, Control valve steering; and load signals to the
hydraulic oil pumps are handled in the servo valve.
Valve block servo pressure also supplies Control valve lift, lower and tilt
with servo pressure.
1. Load signal from control valve steering (LS2) The following functions are collected in Servo valve load handling and
2. Shuttle valve steering:
3. Pressure feed to control valve, attachment • Pressure reducer.
(OK)
• Solenoid valve, engagement of hydraulics for top lift (Y6003).
4. Load signal to hydraulic oil pump 1 (LS1).
• Shuttle valves.
5. Load signal to hydraulic oil pump 2 (PL).
• Pressure relief valve.
6. Pressure feed from hydraulic oil pump (P1)
7. Solenoid valve, engagement of hydraulics top
Pressure reducer
lift (Y6003) The pressure reducer reduces the pressure from the hydraulic oil
8. Return to tank (T3) pumps to servo pressure for the control valve.
9. Return to tank (T1)
The servo pressure is stored in accumulator, servo pressure, see
10. Measurement outlet, servo pressure () Accumulator servo circuit, description, page 10:22. A built-in non-return
11. Accumulator pressure (PS) valve prevents pressure leakage from the accumulator when the
machine is not in use.
Solenoid valve, engagement of hydraulics for top lift
Solenoid valve engagement of hydraulics for top lift (Y6003) routes an

unloaded constant pressure from the attachment's supply as a load
signal to hydraulic oil pump 1 when attachment functions are activated.
When the solenoid valve is activated, pressure from the supply for the
top lift hydraulics is routed through a shuttle valve, attachment in the
valve block, to hydraulic oil pump 1. When the solenoid valve is not
activated, the load signal is drained to the tank and the inlet from the
supply for the top lift hydraulics is closed.
The valve is controlled electrically by Solenoid valve engagement of

hydraulics for top lift (Y6003) which is activated by Control unit KFU
(D7971).
The signal can be checked with the diagnostic menu, see 10.4 Pumps

10 Common hydraulics – Valve block servo pressure 10:21
Shuttle valve
A shuttle valve chooses between two pressure signals and sends
the strongest. The shuttle valves are used to send load signals to
the hydraulic oil pumps. This means that the pumps are controlled
by the function that requires the highest pressure if several functions
are activated simultaneously. See Axial piston pump with variable
displacement, description, page 10:8.
The shuttle valves choose between the following pressure signals:

1. Shuttle valve pump 1 is fitted on the valve block's connection
(LS1) and selects between the pressure signal from Control valve
lift, lower and tilt, and the pressure signal from Control valve
steering, and sends the strongest pressure signal onward to
hydraulic oil pump 1.
2. Shuttle valve attachment is fitted on the valve block and selects
between the pressure signal from Control valve lift, lower and tilt
and the unloaded constant pressure from the attachment's feed
(through Solenoid valve engagement of hydraulics for top lift). The
strongest pressure signal is sent onward to hydraulic oil pump 2.
Pressure relief valve

The pressure relief valve protects the hydraulic system against
excessive feed pressure from the hydraulic oil pumps.
The pressure limiting valve leads too high pressure in the hydraulic
oil supply to tank, protecting the hydraulic system against excessive
pressures.
Servo pressure, check
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.
Use the operating menus transmission and hydraulics to check
3 Connect a pressure gauge (0–25 MPa) to the measuring outlet
on valve block, servo pressure.

10:22 10 Common hydraulics – Accumulator servo circuit
4 Start the engine and check the servo pressure. Compare with
the pressure plate.
Turn the steering wheel or activate a load handling function in
order to activate the hydraulic oil pumps. The servo pressure is
higher than the standby pressure of the hydraulic oil pumps.
measuring outlet.
Valve block servo pressure, replacement

See Main valve, replacement, page 10:24.
10.5.8 Accumulator servo circuit

Accumulator servo circuit, description
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is fitted
on Servo valve load handling and steering to the right on the lifting
beam in the engine compartment.
The accumulator is a diaphragm type and is divided into two spaces

by a diaphragm. One side of the diaphragm is pressurised by
nitrogen gas. The other side is pressurised by the hydraulic oil, which
compresses the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas

pressure and filling gas.
Accumulator servo circuit, replacement
NOTE
B Safety.

NOTE

10 Common hydraulics – Control valve, attachment 10:23
3 Detach the accumulator from its mounting.

4 Replace the accumulator.
hydraulic system.
NOTE
the lock ring.
7 Start the machine and carefully activate all load handling functions
one at a time
CAUTION
product damage.
Activate the functions carefully and operate at the
lowest possible speed a couple of times to avoid
cavitation.
manual.

See Attachment control valve, description, page 7:50.
10.5.10 Main valve

Main valve, description
page 7:64.
Main valve composition

1. Accumulator charging valve
2. Control valve, lift and tilt
3. Valve block servo pressure

10:24 10 Common hydraulics – Main valve
Main valve, replacement
NOTE
B Safety.

NOTE
3 Mark up and detach the cable harness from the main valve.
4 Mark up and detach the hydraulic hoses from the main valve.
NOTE
from contaminants.
5 Remove the main valve.

6 Transfer parts to the new main valve.
Main valve composition
1. Accumulator charging valve NOTE
2. Control valve, lift and tilt Transfer one connection at a time so that the marking is not
3. Valve block servo pressure mixed up.
7 Fit the new main valve and connect the hydraulic hoses and cable
harness in accordance with the marking
hydraulic system.
NOTE
the lock ring.
9 Start the machine and carefully activate all load handling functions
one at a time
CAUTION
product damage.
Activate the functions carefully and operate at the
lowest possible speed a couple of times to avoid
cavitation.
10 Switch off the machine and check that there is no leakage.

manual.

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:25
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control system, hydraulic oil,
description
The hydraulic system's oil is cooled by means of the brake oil pump
circulating the hydraulic oil through radiator and filter, see Temperature
control, cleaning and oil brake system, description, page 4:40.
The temperature control system consists of hydraulic oil tank, brake

oil pump, brake system oil filter (high pressure filter), accumulator
charging valve (part of the main valve), accumulator, wheel brake units,
radiator, temperature sensor and thermal bypass valve.
Cleaning of hydraulic oil, description

Two hydraulic oil filters are fitted on the hydraulic system's return
line, see Hydraulic oil filter, description, page 10:29. These clean the
hydraulic oil.
As an option, the machine can be equipped with a fine filter for the
hydraulic oil. The brake oil pump circulates the oil from the hydraulic
oil tank through the brake system and the fine filter and then back to
the hydraulic oil tank.

10:26 10 Common hydraulics – Tank heater
10.6.1 Tank heater

Tank heater, description
The machine can be equipped with electrically-driven tank heater in

different units together with electrical heater for the engine, oil tank and
preparation for cab fan. The tank heater heats the oil in the hydraulic
oil tank and is intended for use in cold climates.
The tank heater is supplied with high voltage from an external mains
cable is connected to the mains power connector. The sensor for the
start interlock function is an optical sensor that can react to objects
other than the connected power cable.
Tank 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 tank heater is
fitted in a cavity in the connection cover on the lower part of the tank's
short side.
The tank heater has an adjustable thermostat that keeps the
temperature at a constant level. The thermostat is fitted on the
heating element and is adjusted with a knob on the junction box. The
recommended temperature setting is 20-30 °C.
1. Mains power connector high voltage
2. Sensor, start interlock function CAUTION
3. Terminal box, start interlock, engine and cab
heater
4. Terminal box, heater hydraulic oil tank and oil The tank heater is connected to high voltage (110 - 400
tank brake system V).
5. Tank heater, hydraulic oil tank High voltage.
Installation and reconnection of the tank heater may
only be performed by personnel authorised for work
with high voltage.
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, description
The hydraulic oil cooler is located lowest down in the cooling unit
behind the engine, and a temperature-controlled bypass valve in the
cooler means that the oil comes up to operating temperature more
quickly. The cooler is the through-flow type and cools the hydraulic oil
in the working hydraulics and the brake system.
• Hydraulic oil.
• Engine coolant.
• Transmission oil, see Transmission oil cooler, description, page
2:13.
• Charge air (cooled in the upper part of the cooling unit), see
Intercooler, description, page 1:37.
The Volvo TAD8xxVE engine option has a separate intercooler on
the right-hand side of the machine.
• Refrigerant in the air conditioning unit .
Hydraulic oil cooler, replacement

See Radiator, replacement, page 1:43.

10 Common hydraulics – Cooling fan 10:27
10.6.3 Cooling fan

The hydraulic oil cooler is cooled by the engine's cooling fan, see
Cooling fan, description, page 1:44.
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
Hydraulic oil temperature sensor (B7760) detects the temperature of
the hydraulic oil. The sensor detects the oil temperature in the tank,
and therefore takes into account the accumulated heat in the hydraulic
oil. The sensor is located on the side of the hydraulic oil tank. The
signal is used to control the engine's cooling fan, see Cooling fan,
Sensor, hydraulic oil temperature (B7760) is supplied with voltage by,

and sends voltage signals proportional to the oil temperature to Control
unit KFU (D7971).
The signal can be checked with the diagnostic menu, see 10.6 Oil
Temp/Clean 1/XX DIAGNOSE, page 8:76.
Sensor, hydraulic oil temperature, (B7760)
Sensor, hydraulic oil temperature, replacement
NOTE
B Safety.

3 Disconnect the cable harness from Sensor, hydraulic oil
temperature (B7760).
4 Replace Sensor, hydraulic oil temperature (B7760).
NOTE
correctly.
5 Connect the cable harness to the sensor.

Sensor, hydraulic oil temperature, (B7760)
manual.

10:28 10 Common hydraulics – Bypass valve, hydraulic oil cooler
10.6.5 Bypass valve, hydraulic oil cooler

Bypass valve, hydraulic oil cooler, description
The bypass valve in the radiator is temperature-controlled and this
means that the oil reaches operating temperature more quickly. When
the oil is cold, the valve is open and releases the oil past the radiator.
When the oil is hot, the valve is closed the oil flows through the
hydraulic oil cooler. The valve starts to close at 55 °C and is fully
closed when the temperature reaches 65 °C.

2. 3. Bypass valve Volvo TAD8xxVE
3. 3. Bypass valve Cummins QSB6.7
Bypass valve, cooler, replacement
NOTE
B Safety.
1 Machine in service position, section B Safety.

3 Remove the bypass valve from the radiator.
4 Fit the new bypass valve.
manual.

2. 3. Bypass valve Volvo TAD8xxVE
3. 3. Bypass valve Cummins QSB6.7

10 Common hydraulics – Breather filter hydraulic oil tank 10:29
10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
A breather filter of insert type is mounted on the hydraulic oil tank to
protect the tank from impurities. On the top of the filter housing is an
indicator that shows when the filter is clogged and needs to be changed.

Hydraulic oil filter, description
The oil in the hydraulic system is cleaned by two return filters fitted
inside the hydraulic oil tank. The return oil from the load handling
functions, the main valve and the priority valve flows through the filters.

10:30 10 Common hydraulics – Fine filter hydraulic oil
Hydraulic oil filter, replacement

To replace the filter, see the Maintenance manual.
10.6.9 Fine filter hydraulic oil

Fine filter hydraulic oil, description
The fine filter is located on the front right-hand side in the engine
compartment. The filter is connected to the brake system's return line.
The brake oil pump circulates the oil from the hydraulic oil tank through
the brake system and 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.
Fine filter hydraulic oil, changing

To replace the filter, see the Maintenance manual.


10 Common hydraulics – Other 10:31
10.7 Other
10.7.1 Hydraulic cylinders
Fault tracing, leakage
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that internal
leakage can be detected. High pressure causes the
seals to close tighter, which prevents detection of
internal leakage.
1. Carefully check the source of the leakage before taking any action.
It may be possible to rectify the fault without disassembly.
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.
• 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 leakage. Pressurise the cylinder and check
whether the piston sinks back.
This could be due to a worn piston seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with support ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld

10:32 10 Common hydraulics – Hydraulic cylinders
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod is
clean and free from all residual paint. Also check that
connections and couplings are free from burrs and
impact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.

3 Remove the cylinder from its mounting and undo the connections.
4 Plug the cylinder connections and hoses without delay.
5 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
Inspect the sealing surfaces. Always bearing mind the function of the
seals and the type of sealing surfaces they have. See the following
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 cause leakage directly.
• 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:
Fit the cylinder head absolutely straight, ideally by
hand and do not hit with a mallet. If a mallet must be
used, use a plastic or rubber mallet and tap gently.
If the cylinder head is fitted crooked, the sealing lip
of the piston rod seal could be damaged, making an
improper seal. This applies to all types of piston rod
seals.

10 Common hydraulics – Hydraulic cylinders 10:33
Function and removal of the seals

Piston rod seal
Piston rod seal
2 The piston rod seal is the seal that sits in the groove in the cylinder
head and seals against the piston rod. This seal is very exposed to
wear since it is both a dynamic and a static seal, i.e. it seals against
1 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
• Pre-stressed V-seal with support ring
3 • Compressible seal
The single V-seal has a V-shaped section with two lips that seal
in opposite directions. The hydraulic pressure acts in the V-shape,
4 pressing the sealing lips out towards the sealing surfaces on the piston
6 rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V-shape so that
it cannot touch and thereby damage a sealing surface. A mark from
a screwdriver on a sealing surface can have a devastating effect and
cause major leakage.
001497
1. Hydraulic pressure
2. Seal lip pressed out toward piston rod
3. Seal lip pressed inward toward cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver

2 The pretensioned V-seal also has an O-ring in the seal's V-shaped

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
it cannot touch and thereby damage a sealing surface. A mark from
3 a screwdriver on a sealing surface can have a devastating effect and
7
cause major leakage.
6 4
001498
5
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
6. Screwdriver

Support ring and O-ring
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
not to damage the O-ring.
4
2
001506
1
2. O-ring
3. Support ring
Scraper
Scraper
The purpose of the scraper is to scrape the piston rod clean and
øD+10 prevent impurities from entering the cylinder barrel.
1
The scraper must be fitted with a special fitting tool. This tool must
have a greater outer diameter than the scraper so that the press force
against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal
2 capsule would be deformed (see lower illustration), which would impair
the function of the scraper.
4 To prevent the scraper from bottoming in its recess in the cylinder head,
the recess is slightly deeper than the width of the scraper.
3
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of
cylinder head recess
5. Incorrect assembly 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 then
2 prise out the scraper. Polish away any damage to the cylinder head.
CAUTION
No tool may be applied from the inside. This could
give rise to burrs on the cylinder head which could in
3 turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
2 On the single-acting V-seal it is always the long side that seals

against the fixed surface and the short side that seals against the
moving surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is always
inserted in the V-shape so that it cannot touch and thereby damage a
sealing surface. A mark from a screwdriver on a sealing surface can
have a devastating effect and cause major leakage.
3
6 4
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface, piston
6. Screwdriver

The seal must always be fitted as a single assembly together with the
support ring.
Always assemble by hand. No tools should be used as they could

easily 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
Double-acting piston seal
Double-acting piston seal

The double-acting seal functions with pressure from both sides, e.g. in
5 4 3 1 6
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
sure that the seal is not damaged by the cylinder barrel threads.
2
002951
1. Variable sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston
6. Cylinder barrel
Dismantling:
1 Remove guide rings and support rings.
2 Move the seal body over to one side of the sealing groove.
3 Press up the material so that there is a gap between seal 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 could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 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.

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylinder
barrel on steering cylinders. This is because the O-ring in the cylinder
head fastens in the lock ring groove in the cylinder barrel. It is therefore
best to remove the O-ring before trying to withdraw 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

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electric protection .......................................................................................... 11:4
11.2.1 Battery disconnector ................................................................................. 11:4
11.2.2 Fuses ........................................................................................................ 11:5
11.2.6 Control breaker ......................................................................................... 11:9
11.3 Batteries....................................................................................................... 11:10
11.3.1 Start battery............................................................................................. 11:10
11.4 Alternator ..................................................................................................... 11:12
11.4.1 Alternator................................................................................................. 11:12
11.5 Distribution of electricity ............................................................................... 11:13
11.5.1 Voltage feed ............................................................................................ 11:13
11.5.2 Electronic box.......................................................................................... 11:22
11.5.3 Control units ............................................................................................ 11:24
11.5.5 Cable harness ......................................................................................... 11:38
11.6 Communication ............................................................................................ 11:39
11.6.1 CAN bus .................................................................................................. 11:39
11.6.2 Redundant CAN bus ............................................................................... 11:42
11.6.3 CAN bus drive-train ................................................................................. 11:45
11.6.6 Communication with the machine ........................................................... 11:45
11.6.7 Smartfleet ................................................................................................ 11:47

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
Common electrics, general
Electrical functions that are common to several of the machine's main
functions are found under the function common electrics. For example,
voltage feed and CAN bus.

11:4 11 Common electrics – Electric protection
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
The starter batteries are connected to the machine's electrical system
via battery disconnector (S1440). The battery disconnector disconnects
all voltage feed from the batteries to the machine's electrical system
except that connected to the 50 A main fuse, see Fuses, description,
page 11:5.
For more information on the starter batteries, see Starter battery,

description, page 11:10
IMPORTANT
Never switch off the voltage with the battery
A. Battery disconnector disconnector when the engine is running. This could
B. Battery cover damage the alternator.
The battery disconnector must not be used as control
breaker!
Battery isolator, replacement

2 Open the battery cover.
3 Disconnect the negative cable and then the positive cable from
the battery.
WARNING
Be careful to keep the positive and negative cables
apart to avoid short circuiting.
4 Replace the battery isolator.


11 Common electrics – Fuses 11:5
11.2.2 Fuses
Fuses, description
CAUTION
Never use fuses with a too high amperage.
There is a risk of damage or fire on lines!
Follow the instructions on the fuse plate for the fuse
type and amperage.
The electrical system has two main circuits (30 and 15-voltage), see
Voltage feed, general, page 11:13. The main circuits are fuse-protected
several times with main fuses, distribution fuses and circuit fuses.
Main fuses
Main fuses
The main fuses splits the machine\qs voltage feed in smaller parts
to maintain as many functions as possible in case of damage in the
cabling.
The machine has two main fuses, 1 x 100 A that is supplied from
the battery disconnector and 1 x 50 A that is supplied directly from
the battery. Together, these two fuses disconnect all electrical power
to the machine.
1. Main fuse (100 A) (disconnected with the

battery disconnector)
2. Main fuse (50 A) (direct feed)

11:6 11 Common electrics – Fuses
Distribution fuses
Distribution fuses
The distribution fuses divide the machine's voltage feed in smaller
parts in order to maintain as many functions as possible in the event
of damage in the cable harness.
F9952-1 Distribution fuses battery voltage

F9954-1 Distribution fuses ignition voltage
X401 Distribution fuses attachment

11 Common electrics – Fuses 11:7
Circuit fuses
Circuit fuses
The fuses are grouped in fuse holders located in the electronic box in
the cab, which is located behind the rear panel, and in the electronic
box on the frame on the left-hand side of the machine.
There is a fuse plate by the electronic box that describes the various
fuses.
1. Circuit fuses cab (F9968)

2. Circuit fuses frame (F9958)
Main fuse, replacement

3 Disconnect the negative cables from the negative terminals of
the batteries.
4 Remove the plastic cover.
5 Check and replace fuses if necessary.
CAUTION
type and amperage.
6 Fit the protective cover.

7 Connect the negative cables to the negative terminals of the
batteries.
8 Switch on the system voltage with the battery disconnector
1. Main fuse (100 A) (disconnected with the

battery disconnector)
2. Main fuse (50 A) (direct feed)

11:8 11 Common electrics – Fuses
Distribution fuse, replacement

3 For fuses in the electronic box on the frame: Remove the electronic
box cover on the frame.
CAUTION
type and amperage.

7 For fuses in the electronic box on the frame: Fit the cover for the
electronic box on the frame.
F9952-2 Distribution fuses battery voltage

F9954-1 Distribution fuses ignition voltage

11 Common electrics – Control breaker 11:9
Circuit fuse, replacement

3 For fuses in the electronic box on the frame: Remove the electronic
box cover on the frame.
CAUTION
type and amperage.

7 For fuses in the electronic box on the frame: Fit the cover for the
electronic box on the frame.
1. Circuit fuses cab (F9968)

2. Circuit fuses frame (F9958)
11.2.6 Control breaker

Control breaker, description
The control breaker is located in the cab on the right dashboard panel,
front section.
See Control breaker voltage, function description, page 11:19.
When the switch is activated, all hydraulic functions are disconnected

and machine speed is limited.
016150
Control breaker placement

11:10 11 Common electrics – Batteries
11.3 Batteries
11.3.1 Start battery
Starter battery, description
Two series-connected batteries (G9930) are located behind a hatch on
the machine's rear left-hand side (by the fuel tank).
The battery's negative terminal is connected to the frame and the

positive terminal is connected to the battery isolator.
The batteries are charged by the alternator, see Alternator, description,

page 11:12.
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work
gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed
in the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the
batteries. Sparks could ignite the hydrogen gas,
causing an explosion. Disconnect the battery with the
battery disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (frame).

11 Common electrics – Start battery 11:11
Starter battery, replacement

2 Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
3 Replace the batteries.
4 Fit the tensioning strap back in the buckle in accordance with the
series of figures.
5 Connect the cables to the battery terminals. Connect the negative
cable last of all.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting.
018837

11:12 11 Common electrics – Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description
The alternator (G6600) generates current during operation and supplies
this to the batteries. The alternator produces AC current and has an
integrated charge regulator.
The alternator is driven by the engine via a belt. Any errors are
indicated by an error code for the charging system's voltage. Low
battery charge is indicated by the event menu for low battery charge.
The signal can be checked with the diagnostic menu, see 1.9
Control System 2/XX DIAGNOSE, page 8:25 or 11.4 Alternator 1/XX
Alternator, replacement
See Supplier documentation, engine.

11 Common electrics – Distribution of electricity 11:13
11.5 Distribution of electricity

Distribution of electricity, general
This section describes the distribution of electric power and
communication between the control units.
System communication has three main sections:

• Dual voltage supply of control units, where one voltage supply can
go down while maintaining the diagnosis function.
• Redundant CAN bus communication (one CAN bus loop can go
down without losing system functionality).
See 11.6.2 Redundant CAN bus, page 11:42.
• CAN bus communication for drive train (the drive train has its own
communication system).
See 11.6.3 CAN bus drive-train, page 11:45.
11.5.1 Voltage feed

Voltage feed, general
The machine's components are supplied with voltage at different times
depending on requirements, the machine has the following voltage
feeds:
• Battery voltage (30): see Battery voltage (30), description, page
11:14.
• Ignition voltage (15): see Ignition voltage (15), description, page
11:17.
• Redundant voltage feed: See Redundant voltage feed of control
units, description, page 11:15.
• Control breaker voltage: See Control breaker voltage, description,
page 11:18.
Start-up of electrical systems, description

When the machine is not in use, and no function is switched on, the
machine's electrical system is in a de-energised state, i.e. neither the
power electronics nor control units are energised. When starting the
machine the voltage supply is activated and the redundant CAN bus is
initiated. Start-up is managed by the KCU control unit (D7901). The
first prerequisite in order for the machine to perform the activity is to
first establish the redundant voltage supply for control units and then
establish CAN bus communication to manage the control signals for
functions.
Control units establish communication if any of the following happens.

• Driver's door opens
• Interior lighting comes on
• Warning lamp activates
• Ignition key lock in position I
• Operator in seat
• Diesel heater is started at the set time
• Courtesy lighting is switched on

11:14 11 Common electrics – Voltage feed
Start-up
On start-up the following happens.
1. Start-up signal to the KCU control unit (D7901).
2. Control unit KCU (D7901) initiates connection of the redundant
voltage feed, see Redundant voltage feed of control units, function
3. Control unit KCU (D7901) initiates ignition voltage, see Ignition
voltage (15), function description, page 11:17.
4. Control unit KCU (D7901) initiates redundant CAN bus, see
Redundant CAN bus, start-up, page 11:43.
5. Control unit KFU (D7971) initiates CAN bus drive-train, see 11.6.3
CAN bus drive-train, page 11:45.
11.5.1.1 Battery voltage (30)
Battery voltage (30), description

The battery voltage is supplied from the starter batteries when the
battery disconnector is in position I.
Red fuse holder contains circuit fuses for battery voltage. Black fuse
holder contains circuit fuses for ignition voltage. Green fuse holder in
electronic box frame contains circuit fuses that are supplied before
the battery disconnector. Green fuse holder in the cab holds fuses for
special functions and fuses that are supplied with ignition voltage.
Battery power voltage feeds:

• Control unit KCU (D7901)
• Starter motor (M6540)
• Relay, ignition key lock (K3150)
• Start-up functions
• Control breaker relay (S2500)
• Engine
• Transmission
• Radio (A9002)
Circuit fuses battery voltage
A few functions are also supplied with voltage when the battery
disconnector is in position 0 (Fuses GN5-GN8), these are:
• Control unit RMI (A9110)
• Timer diesel heater (D7440)
• Fire extinguishing system (A9630)
• Control unit diesel heater (E6690)
• Electric battery disconnector (S1440)
• Switch for engine compartment lighting (S1041) and Engine
compartment lighting (E4380-1 – E4380-5)

11 Common electrics – Voltage feed 11:15
11.5.1.2 Redundant voltage feed of control units
Redundant voltage feed of control units, description

The redundant voltage feed only supplies the control logic and buses
for the control units, and is wholly controlled by Control unit KCU
(D7901). The outputs for the control units remain de-energised and are
only supplied with voltage when the ignition voltage is activated.
The redundant voltage feed for each control unit is independent of

other control units. Control unit KCU (D7901) has four outputs for
voltage feed while other control units have two inputs for redundant
voltage feed. In the event of a malfunction of one voltage feed the
control unit is supplied by the other feed.
When all control units have redundant voltage feed and bus
communication, the system is ready to receive and process signals.
Redundant voltage feed is activated by:

• Switch interior lighting (S1160)
• Switch, flashing hazard lights (S1090)
• Switch, ignition key lock (S1500)
• Seat switch (B2300)
• Break contact (opening switch) driver's door left (S2660-LE) or
Break contact (opening switch) driver's door right (S2660-RI)
• Heater cab (E6690)
Redundant voltage feed of control units, function

description
The redundant voltage feed of control units consists of the special
redundant voltage feed and the normal ignition voltage, see 11.5.1.3
Ignition voltage (15), page 11:17.

Battery disconnector In position 1 Battery disconnector, description , page 11:4


1 On activation of the Interior lighting switch U = 24 V Lighting system, function description, page
(S1160) a voltage signal is sent to the KCU 9:54
control unit (D7901). D1: Diagnostic menu, see 9.6 Lighting Sys
2 On activation of the Warning light switch U = 24 V Lighting system, function description, page
(S1090) a voltage signal is sent to the KCU 9:54
control unit (D7901). D2: Diagnostic menu, see 9.7 Signalling
3 On turning the ignition key lock switch U = 24 V D3: Diagnostic menu, see 11.5 Distr of
(S1500) to position I a voltage signal is sent Electr 1/XX DIAGNOSE, page 8:78
to the KCU control unit (D7901).
4 On activation of the Seat switch (B2300) a U = 24 V Sensor operator in seat, description, page
voltage signal is sent to the KCU control unit 9:17
(D7901). D4: Diagnostic menu, see 9.3 Seat 1/XX
DIAGNOSE, page 8:58
5 On activation of the driver's door left break U = 24 V D5: Diagnostic menu, see 9.6 Lighting Sys
contact (S2660-LE) or driver's door right 18/XX DIAGNOSE, page 8:71
break contact (S2660-RI) a voltage signal is
sent to the KCU control unit (D7901).
6 On activation of the Cab heater switch U = 24 V Engine heater, description (electric engine
(E6690) a voltage signal is sent to the KCU heater), page 1:45
control unit (D7901). D6: Diagnostic menu, see 9.4 Climate
System 19/XX DIAGNOSE, page 8:64
7 On activation of the Instep lighting switch U = 24 V D7: Diagnostic menu, see 9.6 Lighting Sys
(S1410) a voltage signal is sent to the KCU 6/XX DIAGNOSE, page 8:69
8 Control unit KCU (D7901) activates the U = 24 V 11.5.3.1 Control unit KCU (D7901), page
output for CPU voltage supplying all the 11:25
control units. D8: Diagnostic menu, see 11.5 Distr of
9 Control unit KID (D7950) is supplied with - 11.5.3.3 Control unit, KID (D7950), page
CPU voltage and the control unit starts. 11:29
D9: Diagnostic menu, see 11.5 Distr of
10 Control unit KPU (D7902) is supplied with - 11.5.3.2 Control unit KPU (D7902), page
11 Control unit KFU (D7971) is supplied with - 11.5.3.4 Control unit KFU (D7971), page
Electr 4/XX DIAGNOSE, page 8:79.
12 Control unit KAU (D7911) is supplied with - 11.5.3.8 Control unit KAU (D7911), page
Electr 13/XX DIAGNOSE, page 8:79.

11.5.1.3 Ignition voltage (15)

Ignition voltage (15), description
The ignition voltage supplies most of the functions in the machine,
except for the components in the working hydraulics.
The ignition voltage is supplied by Relay ignition voltage (K3150) that

routes voltage from the battery on activation. Relay ignition voltage
(K3150) is controlled by Control unit KCU (D7901)
The green fuse holder in the cab is divided between fuses GN1-GN4,
which are fuses for special functions, and fuses GN5-GN8, which are
supplied with ignition voltage.
Ignition voltage is activated by:

• Switch, ignition key lock (S1500) to position I
• Switch, flashing hazard lights (S1090)
• Cab heater (E6690) (diesel heater)
Circuit fuses ignition voltage
Ignition voltage (15), function description

Battery disconnector In position 1 Battery disconnector, description , page 11:4
Redundant voltage feed Activated Redundant voltage feed of control units, function
description, page 11:15
Redundant CAN bus Communication established Redundant CAN bus, description, page 11:42

1 Ignition key lock switch (S1500) is turned to U = 24 V Cab overview, page 9:5
position I where after a voltage signal is sent D1: Diagnostic menu, see 11.5 Distr of
to KCU control unit (D7901). Electr 1/XX DIAGNOSE, page 8:78
2 Warning lamp activates where after a U = 24 V Lighting system, function description, page
voltage signal is sent to the KCU control unit 9:54
(D7901). D2: Diagnostic menu, see 9.7 Signalling


3 Cab heater (E6690) (diesel heater) is U = 24 V D3: Diagnostic menu, see 9.4 Climate
activated, on which a voltage signal is sent System 19/XX DIAGNOSE, page 8:64
to Control unit KCU (D7901).
4 Control unit KCU (D7901) supplies voltage U = 24 V 11.5.3.1 Control unit KCU (D7901), page
to the Ignition voltage relay (K3150). 11:25
5 Ignition voltage relay (K3150) supplies U = 24 V -
voltage to fuse holder in the cab electronic
box and in the frame electronic box.
6 The fuses feed voltage to control units, U = 24 V -
relays, solenoid valves and other electronic
components.
7 Control unit KCU (D7901) is supplied with U = 24 V 11.5.3.1 Control unit KCU (D7901), page
ignition voltage and activates outputs for 11:25
requested functions. D8: Diagnostic menu, see 11.5 Distr of
8 Control unit KID (D7950) is supplied with U = 24 V 11.5.3.3 Control unit, KID (D7950), page
ignition voltage and shows information from 11:29
the machine's subsystems. D9: Diagnostic menu, see 11.5 Distr of
9 Control unit KPU (D7902) is supplied with U = 24 V 11.5.3.2 Control unit KPU (D7902), page
10 Control unit KFU (D7971) is supplied with U = 24 V KFU control unit (D7971), description, page
11 Control unit KAU (D7911) is supplied with U = 24 V 11.5.3.8 Control unit KAU (D7911), page
12 Control unit KFU (D7971) sends signals U = 24 V KFU control unit (D7971), description, page
for ignition voltage to Control unit engine 11:31
(D7940) and Control unit transmission
(D7930)
13 Control unit transmission (D7930) is started U = 24 V 11.5.3.7 Control unit, transmission (D7930),
and establishes communication on CAN page 11:35
bus drive-train
14 Control unit engine (D7940) is started and U = 24 V 11.5.3.6 Control unit, engine (D7940), page
establishes communication on CAN bus 11:33
drive-train
11.5.1.4 Control breaker voltage

Control breaker voltage, description
Control breaker voltage supplies functions that require control breakers
e.g. working hydraulics.
Control breaker voltage is disconnected with Switch control breaker
(S2500). Control breaker voltage is controlled via the CAN bus by
Control unit KPU (D7902).
Conditions for activating control breaker voltage are:
• Start key in position I.
• Ignition voltage (15) activated.
• Switch control breaker (S2500) is not activated.
Switch safety switch (S2500)

Control breaker voltage, function description

Redundant voltage feed Activated Redundant voltage feed of control units, function description,
page 11:15
Ignition voltage Activated Ignition voltage (15), function description, page 11:17
Redundant CAN bus communication 11.6.2 Redundant CAN bus, page 11:42
established

1 Control breaker passive Control breaker in Control breaker, description, page 11:9
Switch, control breaker (S2500) sends home position U = 24 V D1: Diagnostic menu see 11.5 Distr of
voltage signals to Control unit KPU (D7902). Electr 24/XX DIAGNOSE, page 8:82
2 Control unit KPU (D7902) sends Control Checked by the control 11.5.3.2 Control unit KPU (D7902), page
breaker passive on the CAN bus. system; error shown 11:27
with error code.
3 Control unit KFU (D7971) and Control unit Checked by the control 11.5.3.4 Control unit KFU (D7971), page
KAU (D7911), allow the connections for system; error shown 11:31
PWM safety group 1 and PWM safety group with error code. 11.5.3.8 Control unit KAU (D7911), page
2 to be activated. 11:36
4 Control breaker activated Control breaker Control breaker, description, page 11:9
Switch, control breaker (S2500) stops depressed: U = 0 V D1: Diagnostic menu see 11.5 Distr of
sending voltage signals to Control unit KPU Electr 24/XX DIAGNOSE, page 8:82
(D7902).
5 Control unit KPU (D7902) sends Control Checked by the control 11.5.3.2 Control unit KPU (D7902), page
breaker activated via the CAN bus. At the system; error shown 11:27
same time, Control unit KPU (D7902) sends with error code.
a request for the functions that are acted on
by the control breaker.
6 Control unit KFU (D7971), stops activation Checked by the control 11.5.3.4 Control unit KFU (D7971), page
of connections connected to PWM safety system; error shown 11:31
group 1, PWM safety group 2 and PWM with error code. D6: Diagnostic menu see 11.5 Distr of
safety group 3. Electr 25/XX DIAGNOSE, page 8:82,
7 Functions connected to one of the safety I = 0 mA 11.5 Distr of Electr 26/XX DIAGNOSE,
groups are interrupted: page 8:83, 11.5 Distr of Electr 27/XX
DIAGNOSE, page 8:83, 11.5 Distr of Electr
• Lift or lower 28/XX DIAGNOSE, page 8:83 and 11.5
• Tilting Distr of Electr 29/XX DIAGNOSE, page
8:83


8 Control unit KAU (D7911) interrupts I = 0 mA 11.5.3.8 Control unit KAU (D7911), page
activation of connections connected to PWM 11:36
safety group 1, PWM safety group 2 and D8: Diagnostic menu, see 11.5 Distr of
PWM safety group 3. Electr 40/XX DIAGNOSE, page 8:84,
9 Functions connected to one of the safety 11.5 Distr of Electr 41/XX DIAGNOSE,
groups are interrupted: page 8:84, 11.5 Distr of Electr 42/XX
DIAGNOSE, page 8:84, 11.5 Distr of Electr
• Side shift 43/XX DIAGNOSE, page 8:84, 11.5 Distr of
• Spreading Electr 44/XX DIAGNOSE, page 8:85
• Twistlocks
10 Control unit KFU (D7971) sends request for Checked by the control 11.5.3.4 Control unit KFU (D7971), page
speed limitation on CAN bus drive-train. system; error shown 11:31
with error code.
11 Control unit, engine (D7940) limits the Checked by the control 11.5.3.6 Control unit, engine (D7940), page
engine speed. system; error shown 11:33
with error code.
12 Control unit transmission (D7940) limits the Checked by the control 11.5.3.7 Control unit, transmission (D7930),
gear range. system; error shown page 11:35
with error code.
13 Control unit KID (D7950) shows Event Checked by the control 11.5.3.3 Control unit, KID (D7950), page
menu, control breaker. system; error shown 11:29
with error code.

11.5.1.5 Voltage converter
Voltage converter, description

The voltage converter (U9010) is located under a protective cover to
the left behind the operator's seat.
The voltage converter converts 24 V to 12 V. 12 V power is available

for accessories through a connector in the cab electrical distribution
box and through two outlets in the cab.
The voltage converter is connected via four flat-pin terminals

XU9010:1, 24V primary side.
XU9010:2, ground.
XU9010:3, ground.
XU9010:4, 12V secondary side.
Voltage converter, replacement

2 Remove the left-hand panels behind the driver's seat, see Rear
panel, upper left, replacement, page 9:81 and Front floor panel,
left, replacement, page 9:80.
3 Mark up and disconnect the cable harness from the converter.
4 Replace the voltage converter.
5 Connect the cable harness in accordance with the marking.
Voltage converter

11:22 11 Common electrics – Electronic box
11.5.2 Electronic box

11.5.2.1 Electronic box, cab
Electronic box, cab, description
1 2 Electronic box, cab, is mounted on the rear wall of the cab, on the
left-hand side. Located there are:
• KCU control unit (D7901).
• Fuses.
• Connectors
8 3
• Relays.
4 • Voltage converter 24 V to 12 V
• Connector service contact (X050), see Communication with the
machine, description, page 11:45.
016132
• Connector customer accessories (X046) see below.

7 6 5
1. Terminal, frame-ground connections
2. Fuses
3. Connector X046
4. Connector X050
5. Connectors KCU control unit (D7901)
6. Power connection to KCU control unit (D7901)
7. Control unit KCU (D7901)
8. Connectors
Customer accessory connector (X046)
Customer accessory connector (X046)

Connector customer accessories (X046) is intended for connecting the
customer's own accessories so that they can be connected safely and
so that they do not interfere with other functions on the machine. The
connector is the type 9-pin Universal Mate-n-lock. For part number
see Spare parts catalogue.
The connector X046 contains the following connections:

1. 24 V ignition voltage 10 A
2. 24 V, battery voltage 10 A
9-pin Universal Mate-n-lock, pin numbers
3. Ground
4. 12 V, ignition voltage 20 A, when the machine is equipped with
a voltage converter
5. Ground
6. Ground
7. Empty
8. Empty
9. Empty

11 Common electrics – Electronic box 11:23
11.5.2.2 Electronic box frame
Electronic box, description

1. Circuit fuses battery voltage (F9958-RD)
2. Circuit fuses ignition voltage (F9958-BK)
3. Circuit fuses ignition voltage (F9958-GN)
4. Diagnostic socket CAN bus drive-train J1939
5. Diagnostic outlet Volvo
6. Diagnostic socket, transmission Dana
7. Control unit, transmission (D7930)
8. Distribution fuses ignition voltage (F9954-1)
9. Distribution fuses battery voltage (F9952-2)
10. Relay ignition voltage (K3150)
The electronic box is fitted on the side of the machine. Also located
there are:
• Fuses
• Outlet for programming Control unit, transmission (D7930)
• Distribution fuses
• Transmission control unit
• Power relays for voltage feed to the machine's functions

11:24 11 Common electrics – Control units
11.5.3 Control units

Control units, location
1. 11.5.3.8 Control unit KAU (D7911), page 11:36 7. Control unit, engine (D7940), description (engine
option Volvo), page 11:33
2. 11.5.3.3 Control unit, KID (D7950), page 11:29
8. Control unit, engine (D7940), description (engine option
3. 11.5.3.2 Control unit KPU (D7902), page 11:27
Cummins QSB6.7 engine), page 11:34
4. 11.5.3.1 Control unit KCU (D7901), page 11:25
9. 11.5.3.4 Control unit KFU (D7971), page 11:31
5. 11.5.3.7 Control unit, transmission (D7930), page 11:35
6. Control unit, after-treatment system (UDS)

11 Common electrics – Control units 11:25
11.5.3.1 Control unit KCU (D7901)
KCU control unit (D7901), description

KCU control unit (D7901) is the central control unit of the control
system. KCU control unit (D7901) sends activation signals to other
units, and controls and monitors their functions. It administrates work in
the control unit network.
KCU control unit (D7901) controls the redundant power supply and
manages communication via the redundant CAN bus. The KCU control
unit (D7901) receives, via KPU control unit (D7902), signals from the
switches in the cab.
The cab control unit has two LEDs that indicate the control unit's
function.
LED Status Description

Green Short flash The control unit is voltage fed by CPU
(1 Hz, 0.1 s) power.
Long flash Ignition key lock switch is in position I

1. Red LED (1 Hz, 0.5 s) and the Ignition voltage is switched on.
2. Green LED
Alternating If both CPU power and ignition power
3. Power supply connections short flash/long are switched on the LED flashes
flash with both short and long pulses
4. Connectors
simultaneously.
Lit The control unit is voltage fed.
Ignition key lock switch is in position I.
The display is lit and the system is
ready for the start of machine functions.
Red Short flash RedCAN wiring error on the unit.
(1 Hz, 0.1 s)
Long flash In the event of active error.
(1 Hz, 0.5 s)
Lit No CAN communication with other
control units, BusOff or Driver Error.
Green/red LED microcomputer start-up program

Green Flashes (2.5
Hz)
Unit with interrupted download.
Red Flashes (2.5
Hz)
Green Flashes (10 Hz) Unit has initiation error in the flash
loader and no application software is
Red Flashes (10 Hz) loaded.
Green Flashes
Download of HEX file (program flash).
Red Out
Green Lit
Download in progress (erase sector).
Red Out
Green Out Download in progress (erase sector
Red Out ready).
Green Out Download in progress (download

Red Out ready).

KCU control unit (D7901), replacement

1 Connect Kalmar Service Tool to the machine and select "Create
Machine Image". This saves the machine's settings and operating
data.
3 Remove the upper left panel behind the driver's seat, see Rear
panel, upper left, replacement, page 9:81.
4 Carefully fold out the rear panel.
Connection Kalmar Service Tool
4 5 Disconnect the cable harness from the control unit.

The two power cables are fitted with screws under the cable seals.
The multi-pole connectors are fitted with a screw in the centre
of each connector.
6 Remove the attaching bolts and the control unit.
7 Fit in the reverse order. Make sure that the correct torque is
used when tightening screws and nuts, take special care with the
fastening of power cables, which can break with a too large torque.
015797
1 2 3
1. Power cables
2. Connectors
3. Control unit KCU (D7901)
4. Screws
8 Connect Kalmar Service Tool to the machine and select "Repair

Machine Wizard". This programs the new control unit and resets
the settings.

11.5.3.2 Control unit KPU (D7902)
KPU control unit (D7902), description

KPU control unit (D7902) manages the functions of most switches in
the cab, such as the multi-function lever, direction indicator switches,
start button. It also manages the key panel for the control system and
its panel for warning and indicator lights.
function.

016044
1. Green LED Long flash Ignition key lock switch is in position I

(1 Hz, 0.5 s) and the Ignition voltage is switched on.
2. Red LED
short flash/long are switched on the LED flashes
simultaneously.
The display is lit and the system is
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

KPU control unit (D7902), replacement

data.
1 4 Open the cover.

015799
2
1. Screws
2. Cover lid
5 Mark up and detach the cable harness from the control unit.
6 Replace the control unit.
7 Fit in the reverse order. Check that all connectors are properly
inserted and all the pins are fitted in place in the connectors.
1
015798
2 3
1. Nut
2. Control unit KPU (D7902)
3. Connectors

the settings.

11.5.3.3 Control unit, KID (D7950)
KID control unit (D7950), description

Control unit KID (D7950) displays to the operator information sent by
the control system, such as speed, in the form of messages, status,
error indications, etc.
There is an indicator light for active errors on the steering panel, which
comes on when serious errors exist in the control system. Error codes,
event menus and information are shown on the display.
See the operator's manual for detailed information about the display.
016045
KID control unit (D7950), replacement

Machine Image". This creates and saves the machine's settings
and operating data.
3 Loosen the clamp and angle out Control unit KID.
Clamp


5 Separate the display casing carefully, both the display section
and the rear part loosen from the bracket when the screws are
loosened.
6 Disconnect the cable harnesses from the control unit.

7 Replace the control unit.
8 Fit in the reverse order. Check that all connectors are connected
and all the pins are fitted in place in the connectors.
015795

the settings.

11.5.3.4 Control unit KFU (D7971)
KFU control unit (D7971), description

KFU control unit (D7971) manages input data from sensors and sends
control signals to relays and solenoid valves for among others start-up,
hydraulic functions, parking brake, fans, central lubrication and lighting.
function.



simultaneously.
1. Red LED Lit The control unit is voltage fed.
2. Green LED Ignition key lock switch is in position I.
3. Power supply connections The display is lit and the system is
4. Connectors
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

KFU control unit (D7971), replacement

data.
3 Remove the hoods over the engine compartment.
4 Disconnect the cable harness from the control unit.

of each connector.

the settings.
8 Calibrate the following functions:
• Load sensor, see Load sensor, calibration, page 8:12.

11.5.3.6 Control unit, engine (D7940)
Control unit, engine (D7940), description (engine

option Volvo)
Control unit, engine, (D7940) is part of the drive-train control and
1 handles engine function, fuel injection, etc. On engine options with
after-treatment system for the exhaust gases, Control unit, engine
2 (D7940) is connected with Control unit, after-treatment system (UDS),
all communication with the machine is handled by Control unit, engine
(D7940).
3
Control unit engine (D7940) is connected to CAN bus drive-train,
together with the Control unit transmission (D7930) that is connected to
Control unit KFU (D7971). In turn, Control unit KFU (D7971) forwards
drive-train information to other units.
007424
The control unit is fitted on the engine has no function keys or display.
Engine control unit All functions are controlled via the CAN bus and an external control
1. Cooling duct for control unit (fuel) system.
2. Connector A (black) The diagnostic socket for communication directly with the engine via the
3. Connector B (grey) diagnostic tool is located in electronic box, frame, see Communication
with the machine, description, page 11:45.
The control unit monitors the following values in order to optimise

engine performance.
• engine speed
• camshaft position
• boost pressure
• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level
• AdBlue temperature
• Control unit, after-treatment system (UDS)
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
For more information, see supplier documentation.

Control unit, engine (D7940), description (engine

option Cummins QSB6.7 engine)
Control unit, engine, (D7940) is part of drive-train control and handles

engine function, fuel injection, etc.
Control unit engine (D7940) is connected to CAN bus drive-train,

together with the Control unit transmission (D7930) that is connected to
Control unit KFU (D7971). In turn, Control unit KFU (D7971) forwards
drive-train information to other units.
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
system.
The diagnostic socket for communication directly with the engine via the
diagnostic tool is located in electronic box, frame, see Communication
with the machine, description, page 11:45.
The control unit monitors the following values in order to optimise

engine performance.
• engine speed
• boost pressure
• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• coolant level
• water in fuel
• air pressure
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
Control unit, engine (D7940), replacement

See supplier documentation engine.

11.5.3.7 Control unit, transmission (D7930)
Transmission control unit (D7930), description

Control unit, transmission (D7930) is fitted in electronic box, frame,
and is part of drive-train control and handles transmission function,
selection of gear at load and engine speed, etc.
Control unit, transmission (D7930) is connected via a separate CAN

bus (CAN bus drive-train) communication to the engine, which is
connected to Control unit KFU (D7901). In turn, Control unit KFU
(D7901) forwards drive-train information to other units.
Control unit, transmission, replacement

2 Open the cover lid on electronic box, frame.
3 Remove the outer attaching bolts for Control unit, transmission
(D7930).
4 Lift up the intermediate plate so that the rear of the control unit is
visible.
5 Disconnect the cable harness from Control unit, transmission
(D7930).
6 Remove the inner attaching bolt and remove the control unit.
7 Fit the new the control unit and fit the rear attaching bolt.
8 Connect the cable harness to Control unit transmission (D7930).
9 Lift the intermediate wall into place.
10 Fit the outer attaching bolts for Control unit, transmission (D7930).
11 Calibrate the transmission, see Transmission, calibration, page
2:17.

11.5.3.8 Control unit KAU (D7911)
Control unit KAU (D7911), description

Control unit KAU (D7911) processes input data from sensors and
sends control signals to lights and solenoid valves on the attachment.
The control unit is fitted by Control valve attachment on the rear section
of the attachment.
function.



1. Red LED
simultaneously.
2. Green LED
3. Power supply connections
4. Connectors The display is lit and the system is
(1 Hz, 0.1 s)
(1 Hz, 0.5 s)

Green Flashes (2.5
Hz)
Red Flashes (2.5
Hz)
Green Flashes
Red Out
Green Lit
Red Out
Red Out ready).

Red Out ready).

Control unit KAU (D7911), replacement

data.
3 Disconnect the cable harness from the control unit.

of each connector.
Control unit KAU (D7911)

1. Power cables
2. Multi-pole connectors
3. Attaching bolts

the settings.

11:38 11 Common electrics – Cable harness
11.5.5 Cable harness

Cables, description
The cables are drawn in a cable harness along the side of the frame
and held in place with straps, belts and rubber clamps.
There are very few joints in the cables between the consumers and the
fuse box. The intention is to reduce the risk of faults.
When working on the machine, the following points must be followed in

order to maintain the function and safety of the machine:
• Disconnect the voltage with the battery disconnector or by
detaching the negative terminal from the batteries before working
on the electrical system. Note that there are functions that are
supplied directly from the battery.
• A cable harness that is exposed or replaced must be routed and
clamped in the same way as from the factory. The routing and
clamping of the cable harness are fully tested, and deviation from
this may result in damage to the machine or cable harness.
• Never clamp a cable harness to fuel pipes, fuel hoses, hydraulic
pipes or hydraulic hoses.
DANGER
Incorrect clamping of a cable harness.
Fire hazard
Never clamp a cable harness to fuel pipes, fuel hoses,
hydraulic pipes or hydraulic hoses. Chafing damage
may result in leakage, short circuit and fire.
• Never route the cable harness so that it runs over sharp edges
or where it is exposed to radiant heat from hot components or
exhaust gases.
• Make it a habit to inspect the cable harness in conjunction with
repairs. Repair damaged cable harnesses immediately to avoid
bigger problems.
• When repairing the cable harness, use the intended tools for
separating connectors and crimping the contacts.
IMPORTANT
AdBlue on wiring.
be replaced.

11 Common electrics – Communication 11:39
11.6 Communication
Communication, general
The machine communications are managed by a CAN bus system. The
CAN bus system consists of control units connected into a network.
The idea of a network is to share information. Signal values are sent

to the control unit, which for example, is connected to a sensor, other
control units can use the signal for their functions.
The network consists of control units and segments. Segments are the
CAN bus between the control units.
11.6.1 CAN bus

CAN bus, description
1 2 Communication between the control units takes place using so-called

"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
120 ohm 120 ohm

The CAN bus is a fast control bus with logical hardware circuits. A
simple technology that is highly reliable (low error frequency), which is
a requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
5 5 CAN specifies:
• that the signal traffic is carried by "twisted pair" cables.
3
• that termination resistors (position 1) are necessary (adapted to
4 cables' impedance) so that the pulse train (position 4) should
2 obtain a sharp signal.
U [V]
• that the signal valve is given as the potential difference between

the cables, CAN + and CAN - (position 2 and 3).
3
• form of signal messages.
000026
t [S]
Messages are sequential and signal is high (voltage

high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit

11:40 11 Common electrics – CAN bus
Message
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 complete
000027
message is approx. 100 bits long. The illustration depicts how a
t [S] message is structured.
Messages are sequential and signal is high (voltage Start bit (B)
high) or low (voltage low).
A. Length message Indicates that the transmission of a frame, i.e. a message, is now
beginning.
B. Start bit
Identity field (C)
C. Identity field/Priority
D. Control field (length of data segment) Indicates what kind of information the message contains, e.g.
E. Data segment measurement information on engine speed.
F. Checksum for error detection Does not indicate address to control unit. CAN does not work with
G. Acknowledge bit addressing. All control units receive messages and send them on.
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 logical one (1) when the
message is sent. The first control unit to receive the message sends it
on and sets the bit to logical zero (0).

11 Common electrics – CAN bus 11:41
Communication
Communication
The CAN network consists of control units and segments. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logical zero and logical one. The
illustration depicts an approved interval according to the standard for
potential levels. CAN + has a recommended value of 3.5 V and CAN
- has 1.5 V. As a worst case scenario, the potential difference can be
U [V]
0,5 V only 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 an

1,5 V analogue or digital multimeter.
When a message is sent, all control units in the network listen.

Messages are saved in the control unit and relevant information is
processed. The control unit that receives the message first confirms
receipt (sets an acknowledge bit). The transmitting control unit then
000028
t [S] knows that the message has been received by at least one control unit.
Potential levels CAN + and CAN - One control unit at a time sends the message. Other control units listen
and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest priority
(highest value in identity field) is concluded. This means that messages
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).
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
protocol 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

11:42 11 Common electrics – Redundant CAN bus
11.6.2 Redundant CAN bus

Redundant CAN bus, description
Redundant CAN bus means that each control unit has two connections
for communication, CAN-N (normal) and CAN-R (redundant). The CAN
bus is connected in series between the control units. This means the
CAN bus can handle the loss of a segment. If several segments fail
then one or several of the control units lose contact with the network
and work independently, but usually with limited capacity to perform
their function. The signals can be checked with diagnostic menu.
The network is based on a node being central, in this case DynRedCAN

King KCU D7901, and the governing unit (master). This node has
lowest node number. Other nodes in the network are secondary
(slaves) and manage dedicated areas, e.g. hydraulic unit.
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. The machine can still be
run, in some cases with a limited function.
A condition for communication is that the ignition voltage is active.
The following occurs:

• Most suitable route for an enclosed communication system is
analysed.
• Communication is established segment for segment.
NOTE
The number of active segments depends on the number of control
units that are active in the machine in question, which depends on
the machine's equipment level (option).
• Termination resistors in the control nodes ensure communication

segment by segment. This is indicated as a rapid clicking sound
when starting (key to position I in the ignition key lock) that can be
heard in the operator's station.
• When all nodes and segments have closed loops then the
communication is established in the system.
The redundant CAN bus can handle the loss of a segment. The link
is analysed during start-up and continuously during operation. If a
segment is incorrect, the message is sent another way. If several
segments are lost, one or more control units lose communication
and work independently, often with significantly limited functionality.
CAN bus faults are indicated with an error code and a warning in the
display. The communication loop can be disrupted by cable damage
for example, and then communication is established via an alternative
route. Open circuits and errors are shown in the diagnostic menus for
RedCAN, diagnostic menu 1 – 9
Technical specification:
• 11 bit identity field
• 250 kbit/s
• Termination 120 Ohm (in the control units)

11 Common electrics – Redundant CAN bus 11:43
Redundant CAN bus, start-up
Condition Refer- Reference

ence
value
Battery disconnector In position Battery disconnector, description , page 11:4.
1
Redundant voltage feed Activated Redundant voltage feed of control units, function description, page 11:15.
The illustration shows two alternatives for how the couplings are
changed depending on the number of control units on the machine:
Solid lines show the CAN-bus with a minimal number of control units.
Dotted lines show the CAN-bus with a maximal number of control units.

1 Control unit KCU (D7901) establishes Checked by control 11.5.3.1 Control unit KCU (D7901), page
redundant CAN bus communication by system, error shown 11:25
sending a request on the CAN bus via with error code.
CAN-N to Control unit KFU (D7971).
Termination resistor in the control unit
protects against interference in the event
of open circuit in the segment and thereby
ensures communication on the second CAN
connection.
2 Control unit KFU (D7971) responds with Checked by control 11.5.3.4 Control unit KFU (D7971), page
node number (Node 2) to Control unit KCU system, error shown 11:31
(D7901) via CAN-R and sends the request with error code.
onward via CAN-N.
Depending on the machine's equipment, the
control unit that is next in the loop varies.
connection.
3 Control unit KAU (D7911) responds with Checked by control 11.5.3.8 Control unit KAU (D7911), page
node number (Node 7) via CAN-R and system, error shown 11:36
sends the request onward to Control unit with error code.
KPU (D7902) via CAN-N.
connection.

11:44 11 Common electrics – Redundant CAN bus

4 Control unit KPU (D7902 ) responds with Checked by control 11.5.3.2 Control unit KPU (D7902), page
node number (Node 11) to Control unit KAU system, error shown 11:27
onward to Control unit KID (D7950) via
CAN-N.
connection.
5 Control unit KID (D7950) responds with Checked by control 11.5.3.3 Control unit, KID (D7950), page
node number (Node 12) Control unit KPU system, error shown 11:29
onward to Control unit KCU (D7901) via
CAN-N.
connection.
6 Control unit KCU (D7901) receives Checked by control 11.5.3.1 Control unit KCU (D7901), page
information about the control units that system, error shown 11:25
responded and the order in which they with error code. Diagnostic menu, see 11.6 Communication
responded. The information is compared 1/XX, page 8:85, 11.6 Communication
with the set-up file and if the information 2/XX, page 8:86, 11.6 Communication
is correct the CAN bus is signalled as 3/XX, page 8:86, 11.6 Communication
functioning and the control units are allowed 4/XX, page 8:86, 11.6 Communication
to communicate with each other. 5/XX, page 8:86 and 11.6 Communication
If a control unit has not responded, then 6/XX, page 8:87.
Control unit KCU (D7901) uses both CAN-R
and CAN-N to keep communication open
and an error code is set.
7 Each time a control unit requests information Checked by control Diagnostic menu, see 11.6 Communication
from another control unit, a response is sent system, error shown 7/XX, page 8:87, 11.6 Communication
that the information is received. If a control with error code. 8/XX, page 8:87 and 11.6 Communication
unit is not responding then an error message 9/XX, page 8:88.
is sent to Control unit KCU (D7901).
In the event of errors, as the first action,
Control unit KCU (D7901) attempts to
re-establish communication with a new
request.

11 Common electrics – CAN bus drive-train 11:45
11.6.3 CAN bus drive-train

CAN bus for drive-train, description
1 2 Communication with Control unit engine (D7940) and Control unit

transmission (D7930) is separated from the redundant CAN bus.
Control unit KFU (D7971) forwards the communication between the
machine's control system and engine and transmission.
3 4 5
The CAN bus for the drive-train is based on the standard SAE J1939
where selected messages are used to control the engine and
D7971 D7940 D7930 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.
The engine and transmission control units are supplied by respective

engine and transmission suppliers. The machine can be equipped
with different transmission and engine models. Messages from the
transmission and engine are built up according to a standard structure.
The signals from Control unit transmission (D7930) can be checked

016151
6 7 with the diagnostic menus 2.8 Control System 1/XX DIAGNOSE, page
8:30.
1. Engine
The signals from Control unit engine (D7940) can be checked with the
2. Transmission diagnostic menus 1.9 Control System 1/XX DIAGNOSE, page 8:25, 1.9
3. Control unit KFU (D7971) Control System 2/XX DIAGNOSE, page 8:25, 1.9 Control System 3/XX
4. Control unit, engine (D7940) DIAGNOSE, page 8:25 and 1.9 Control System 4/XX DIAGNOSE,
page 8:25.
5. Control unit, transmission (D7930)
6. Redundant CAN bus
7. CAN bus for drive-train
11.6.6 Communication with the machine

Communication with the machine, description
Diagnostic socket, machine
Diagnostic socket, machine

The machine has an outlet for communication between control units
and a PC.
The rear of the cover on Control unit KID (D7950) includes a USB port
for connecting a computer with Kalmar Service Tool (KST). Kalmar
Service Tool is used for resetting the service interval, upgrading
and reprogramming the machine's control units (not engine and
transmission).
Diagnostic socket, drive-train

Electronic box frame contains diagnostic socket for CAN bus drive-train
(J1939), engine and transmission.

11:46 11 Common electrics – Communication with the machine
Service contact (X050)
Service contact (X050)

Connector service contact (X050) is fitted in electronic box, cab. The
connector can be used for connecting service tools or troubleshooting
the machine.
The connector is the type 9-pin Universal Mate-n-lock. For part number
see Spare parts catalogue.
Connector service contact (X050) contains the following connections:

1. CAN bus option (R+)
2. CAN bus option (R-)
016169
3. Ignition voltage, 24 V 10 A
4. Battery voltage, 24 V 10 A
Service contact X050
5. Ground
6. Searchlight (E4370)
7. Searchlight (E4370)
8. Status signal, relay ignition voltage (K3150)
9. Status signal, redundant voltage feed CPU Power
9-pin Universal Mate-n-lock, pin numbers
Vehicle Data Interface (VDI) (X039)
Vehicle Data Interface (VDI) (X039)
As an option, the machine can be prepared for connection of external

systems for communication with the machine (for example, Smartfleet
and radio control). Connection of external systems is made to the
Vehicle Data Interface (VDI) connector (X039).
VDI is a connector of the 9-pin Universal mate-n-lock type in the

electronic box in the cab. For part number, see the spare parts
catalogue.
Connector VDI (X039) contains the following connections:

1. CAN bus option (R+)
2. CAN bus option (R-)
3. Ignition voltage, 24 V 10 A
4. Battery voltage, 24 V 10 A
5. Ground
6. Not connected
7. Not connected
8. Not connected
9. Battery voltage before battery disconnector, 24 V 10 A (may
require extra installation on the machine)

11 Common electrics – Smartfleet 11:47
11.6.7 Smartfleet
Smartfleet, description
Smartfleet is an option for process automation. Smartfleet reads

and sends operating data from the machine and creates advanced
functions for statistics and load data. The information can be sent
wirelessly to a central server for further processing.
The functions for Smartfleet in the machine are handled by the Machine
Telematic Unit (MTU), see Machine Telematic Unit (MTU), description,
page 11:47.
11.6.7.1 Machine Telematic Unit (MTU)
Machine Telematic Unit (MTU), description
Machine Telematic Unit (MTU) is the control unit for Smartfleet

functions and equipment in the machine. MTU handles communication
between machine and other components that are connected to MTU.
The Smartfleet control unit is connected to the machine via Vehicle
Data Interface (VDI) (connector X039 in the wiring diagram).
MTU communicates wirelessly with equipment on the machine and

central servers via antennas on the rear window and an antenna on
the cab's roof.
Equipment is connected to MTU via USB and physical inputs:
Examples of equipment connected to MTU:

• RFid reader for operator identification, see RFid reader, description,
page 11:47.
11.6.7.2 RFid reader
RFid reader, description
Smartfleet can connect the operator to stored operating data and save
operator-specific settings from the machine, such as speed limitation.
The operator uses an RFid tag to identify him/herself.
The RFid reader is fitted on the left-hand side of the cab’s rear panel.
The RFid reader is connected directly to MTU, see Machine Telematic
Unit (MTU), description, page 11:47.

11:48

D:1
D Error codes
Contents D Error codes

Error codes ........................................................................................................D:3
Engine........................................................................................................... D:11
Error codes engine (engine options Volvo TAD572VE and
TAD871VE) .............................................................................................. D:11
Error codes engine (engine option Cummins QSB6.7) ...............................:61
Transmission....................................................................................................:79
Error codes transmission.............................................................................:79
Machine .........................................................................................................:170
Error codes machine .................................................................................:170

D:2

D Error codes – Error codes D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:

• Code, error code's number, shown in field d on the display.
• Node, specifies which control unit generated the error. See Table
Node, explanation, page :170.
d • Description, explanation of the error code and when it\qs
generated.
• Limitation, in case of certain error codes certain functions are
impaired or limited to protect the machine and operator.
• Action, information of what should be checked to find the cause
of the error code.
016080
• Diagnostic menu, reference to suitable diagnostic menu to rectify

the problem, read signal value or check the function.
Active error codes shown in Active errors
In addition to the explanation of the display figure, the description
Field d: Error code. 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.
• The reference leads to the function or component that the error
code is linked to, this field should be used to seek more information
d if necessary. Various types of information can be located via each
reference.
d Sections 0-12 contain a description of the function and its
components, component locations and work instructions for
different tasks.
d
016081
Inactive and active error codes are shown in Error

history
Field d: Error code.

D:4 D Error codes – Error codes
Error code menu, description

The control and monitoring system's display is divided into a number of
fields where the information is shown (see the figures to the left).
• Field a: Error code level. Shown with a symbol.
• Field b: Operator action. Shown with a symbol.
• Field c: Component that generated the error code. Shown with
a symbol.
• Field d: Error code.
• Field e: Number of errors. For Error history the number of errors
is limited to the last 50 errors.
• Field f: Number of errors on each error code level.
• Field g: Date and time.
Field a: Error code level

e
f The control and monitoring system gives error code information in three
levels which are indicated with a symbol in the display unit.
d
Symbol Action
STOP
a b c
Indicates a serious malfunction that may
jeopardise the operator's safety or cause machine
015229
failure. The error code must be attended to

immediately.
WARNING
Indicates malfunction in machine that should be
taken care of as soon as possible.
e
f
d INFORMATION
a g c
Information to the operator that something should
be rectified, e.g. broken bulb. Rectify the cause
at a suitable opportunity. Instructions for action
are normally found in Operator's manual, chapter
6 Inspection and maintenance.
015230
Field b: Operator action
Inactive error codes are shown in Error history The control system provides information about what action the operator
should carry out. The information is indicated with a symbol on the
display unit.
Symbol Action
Carry out action in accordance with daily
inspection, see Operator's manual, chapter 6
Inspection and maintenance.
Error requires action by trained personnel.

One of the functions of the machine is not working
fully.
Critical error.
Errors that may jeopardise the machine or safety,
such as low oil pressure or overload. Stop the
machine and safeguard the error.
Read the operator's manual.

Field c: Affected function
Symbol Function Symbol Function Symbol Function

Engine Fuel level AdBlue level
Temperature electric Temperature electric Particulate filters

motor drive motor hydraulics
Exhaust temperature Air filter Engine coolant level
Coolant temperature Engine oil level Preheating engine

engine
Transmission Oil temperature torque Lock-up, torque converter

converter
Differential locks Transmission oil level Oil pressure, transmission
Oil temperature Driveline/Axle Tyre pressure

transmission
Regulator (inverter) Brakes Brake pressure
Parking brake Oil temperature brake Steering

system
Suspension Load handling Control levers
Lift/lower Lift/lower Extension
Side shift Side shift Spreading
Spreading Rotation Tilt
Tilt lock Tilt Levelling

Symbol Function Symbol Function Symbol Function

Levelling lock Levelling Contact twistlocks
Locked twistlocks Unlocked twistlocks Contact top lift attachment
Contact side-lift Bottom lift attachment Support jacks

attachment
Control system Boom angle Boom length
Scales Overload system Overload system
Height limit Frame, body, cab and Hour meter (operating

accessories hours)
Seat Revolving driver's seat Air conditioning unit
ECH, ECC Fresh air filter Pause heater
Temperature water heater Recirculation Washer fluid
Wipers Revolving or flashing Lighting

beacon
Horn Heating rear Cab sliding length

windscreen/rear view
mirrors
Vertically adjustable cab Tiltable cab Central lubrication
Hydraulic oil filter Hydraulic oil temperature Battery charging
CAN bus CAN bus drivetrain

Field d: Error code number
Field d: Error code number

The control system gives error codes from the machine's sub-systems:
1 2 3 Unit number (AAA)

The first part of the error code indicates the unit that generated the
error. The following units can generate error codes:
Unit number Unit

1–99 Units in the RedCAN system
Component type (B)

A letter before the numbers in the component number indicates the
015233
component in question. There is no component type (B) for error codes
from the engine and transmission.
Example figure error codes The following component types can be identified:
1. Unit number (AAA)
2. Component number (SPN) (BCCCC-DD)
3. Type of error (FMI) (E)
Prefix Description
A Control panel Drive-train/Wiper
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 White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
Q Battery disconnector
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
V Diode
W Antenna
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Component (CCCC)
The numbers are a unique number (SPN) to locate the faulty
component.

Component location (DD)

In cases where multiple components have the same component
number, two letters or the serial number 1-9 are added to make the
error code unique. The letters often specify a location on the machine.
There is no component location (DD) for error codes from the engine
and transmission.
The following locations are used:
Letters Location
10 Left
20 Right
30 Upper
40 Lower
100 Front
110 Left front
120 Right front
200 Rear
210 Left rear
220 Right rear
Type of error (EE)

The FMI code indicates the type of error.
Table Specifications FMI
FMI Description SAE text

0 Value too high. Data valid, but higher than normal operating range.
1 Value too low. 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 Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
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 Value too high. Data valid but higher than normal operating range: The least serious
level.
16 Value too high. Data valid but higher than normal operating range: Moderately
serious level.
17 Value too low. Data valid but under normal operating range: The least serious level.

FMI Description SAE text

18 Value too low. Data valid but under normal operating range: Moderately serious
level.
19 Communication error. Received network data incorrect.
20 Data too high. Data valid but higher than normal value.
21 Data too low. Data valid but lower than normal value.
22-30 Reserved for SAE allocation.
31 FMI not available or the condition Not available or the condition exists.
indicated by SPN exists.
32 Electrical problem. Abnormally high resistance or short-circuit to higher voltage.
33 Electrical problem. Abnormally low resistance or short-circuit to lower voltage.
34 Time exceeded. Time exceeded.
35 Communication error. CAN bus error.
36 Communication error. Driver error.
37 Communication error. Over flow.
38 Communication error. Error passive stat.
39 Communication error. Baud rate.
40 Communication error. Control unit disappears (stop sending messages) after start up.
41 Communication error. Control unit missing on start up.
42 Communication error. CAN-bus segment after the control unit is faulty. Normal side.
43 Communication error. CAN-bus segment after the control unit is faulty. RedCAN side.
44 Communication error. Control unit incorrectly positioned RedCAN circuit.
45 Communication error. Checksum error in the control unit.
Field e: Number of error codes

Specifies the number of menu pages with active fault codes in Active
errors and the number of menu pages with inactive error codes Error
history.
Field f: Number of errors on each error code level

Specifies the number of active error codes on each error code level.
Field g: Date and time

Specifies the date and time when the error code was confirmed.
Reading out error code
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 ignition key lock 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 Select the menu for ACTIVE ERRORS or ERROR HISTORY with

or and confirm with .
014978
e
f
d
a b c
015229

3 The error code list is shown on the display. Error code is shown on
e the display where the field d shows the error code number together
f with field e that shows the number of errors.
d Navigate the error code list with the function keys and . Leave
a g c the error code list by pressing the function key .
NOTE
If error code isn't included in the error code list, it may be due to
the following:
015230
– condition for error detection no longer exists, e.g., control

lever is released or engine is off.
Inactive error codes are shown in Error history – loose connection/poor contact.
Error codes disappear from the list when the cause has been
remedied.
4 Note error code number (field d) to avoid forgetting.
5 Use the error code tables to find more information about the error
code.
6 After the remedial action, check that no active error codes remain
for the function in question.

D Error codes – Engine D:11
D.1 Engine
Error codes engine (engine options Volvo
TAD572VE and TAD871VE)
The error codes for the engine are sorted in numerical order. The table
contains the following information:
• SPN - Specifies component, SPN is the error code that is shown in
the machine, in accordance with SAE J1939.
• FMI - Denotes the type of error, see Table Specifications FMI,
page D:8.
• Supplier code - Specifies the error code in accordance with the
supplier's specification.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Specifies recommended action in summarised form with
the troubleshooting action that should be taken first.
• Connection and component - Specifies component number and
connector pin on the control unit and component for additional
troubleshooting with the wiring diagram.
• Diagnostic menu - Specifies which diagnostic menu can be used to
show the signal in the display's diagnostic menus.
Note that the engine also shows error codes for Control unit
after-treatment system (UDS). Certain components are connected to
this control unit, which is shown by "UDS" being first in the "Connection
and component" field.

VDU01.01GB
D:12
Table Error codes, engine (engine option Volvo)
SPN FMI Supplier Description Limitation Action Connections Diagnostic

code and menu
components
28 2 - + switch, no or weak signal. No limitation. Check the cable harness - -
between control unit and
component.
Check the component.
29 2 - Signal from accelerator pedal, Accelerator pedal Check the cable harness D7940/A:2 -
no or weak signal. connected to A:2 not between control unit and
working correctly. component.
abnormally high voltage or short connected to A:2 not between control unit and
Workshop Manual DCU80–100
circuit to higher voltage. working correctly. component.

abnormally low voltage or short connected to A:2 not between control unit and
circuit to lower voltage. working correctly. component.
abnormally low current or open connected to A:2 not between control unit and
circuit. working correctly. component.
51 3 P02E612 Sensor damper position, Engine speed limited to Check the cable harness D7940/B:24 -
abnormally high voltage or short idling speed. between control unit and
circuit to higher voltage. component.
51 5 P02E613 Sensor damper position, Engine speed limited to Check the cable harness D7940/B:17 -
abnormally low current or open idling speed. between control unit and
circuit. component. D7940/B:18
Check the component. D7940/B:24

Table Error codes, engine (engine option Volvo) (continued)

code and menu
components
51 7 P02E699 Sensor damper position, Throttle not working. Check that the throttle is not D7940/B:17 -
calibration error. binding during opening and
closing. D7940/B:18
Check that throttle movement D7940/B:24

runs smoothly without jerking
during self-calibration which
takes place during ignition.
Check the sensor.
51 12 P02E601 Sensor damper position, general No limitation. Check the cable harness D7940/B:17 -
electrical problem. between control unit and
component. D7940/B:18
D Error codes – Engine

Check the component. D7940/B:24
51 13 P02E697 Sensor damper position, Engine speed limited to Check that the throttle is not D7940/B:17 -
mechanical defect. idling speed. binding during opening and
closing. D7940/B:18
Engine difficult to start or
does not start at all. Check that throttle movement D7940/B:24
Check the sensor.
91 0 P012085 Signal from accelerator pedal, Speed limitation. Check error codes for D7940/A:1 1.1 Controls
value too high. accelerator pedal and CAN & Instr 1/XX
communication in the machine. DIAGNOSE,
page 8:21
91 2 - Signal from accelerator pedal, Accelerator pedal Check the cable harness D7940/A:1 1.1 Controls
no or weak signal. connected to A:1 not between control unit and & Instr 1/XX
working correctly. component. DIAGNOSE,
page 8:21
abnormally high voltage or short connected to A:1 not between control unit and & Instr 1/XX
circuit to higher voltage. working correctly. component. DIAGNOSE,
page 8:21
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D:13
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code and menu
components
abnormally low voltage or short connected to A:1 not between control unit and & Instr 1/XX
circuit to lower voltage. working correctly. component. DIAGNOSE,
page 8:21
abnormally low current or open connected to A:1 not between control unit and & Instr 1/XX
circuit. working correctly. component. DIAGNOSE,
page 8:21
91 9 P012082 Signal from accelerator pedal, No limitation. Check error codes for D7940/A:1 1.1 Controls
communication error. accelerator pedal and CAN & Instr 1/XX

page 8:21
91 19 P012083 Signal from accelerator pedal, Speed limitation. Check error codes for D7940/A:1 1.1 Controls
signal error. accelerator pedal and CAN & Instr 1/XX
page 8:21
94 0 P008B97 High fuel pressure. No limitation. Check if: D7940/B:16 -
• fuel filter is clogged.
• fuel pressure sensor is
faulty.
• strainer/filter in
high-pressure pump fuel
inlet (from fuel filter) is
clogged.
94 3 P253912 Sensor fuel pressure, No limitation. Check the cable harness D7940/B:16 -
abnormally high voltage or between control unit and
short circuit to higher voltage. component.
Check the sensor.
94 5 P253913 Sensor fuel pressure, No limitation. Check the cable harness D7940/B:16 -
abnormally low current or between control unit and
open circuit. component.
Check the sensor.

code and menu
components
94 12 P253901 Sensor fuel pressure, general No limitation. Check the cable harness D7940/B:16 -
component.
Check the sensor.
94 18 P008A00 Sensor fuel pressure, low fuel Reduced output and Check the fuel level in the tank. D7940/- -
pressure. torque.
Troubleshoot the fuel system
Error code for imbalance after leakage or trapped fuel
between cylinders. lines.
Change the fuel filter.
Check sensor fuel pressure.

Remove and clean the safety
valve in the feed pump.
97 0 P226985 Water in fuel. No limitation. Drain water separator. D7940/- -
97 4 P226411 Sensor water in fuel, abnormally No limitation. Check the cable harness D7940/B:8 -
low voltage or short circuit to between control unit and
lower voltage. component.
97 12 P226401 Sensor water in fuel, general No limitation. Check the cable harness D7940/B:8 -
component.
98 1 P250F00 Low oil level engine. Warning indication. Check the oil level in the engine. D7940/-
Check that there is no oil
leakage.
Check sensor oil level engine.
98 4 P250A11 Sensor oil level engine, No limitation. Check the cable harness D7940/B:4
abnormally low voltage or short between control unit and
circuit to lower voltage. component.
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98 5 P250A13 Sensor oil level engine, No limitation. Check the cable harness D7940/B:4
abnormally low current or open between control unit and
D:15
circuit. component.
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code and menu
components
98 18 P108600 Low oil level engine. Warning for low oil level. Check the oil level in the engine. D7940/-
Check that there is no oil
leakage.
Check sensor oil level engine.
100 1 P052400 Oil pressure in engine too low. Reduced engine power or Check the engine oil level and D7940/- 1.8 Lubrication
engine is turned off. oil quality. 1/XX
DIAGNOSE,
Change the engine oil and oil page 8:24
filter.
Check sensor oil pressure.

Replace the pressure control
valve at the oil pump.
Replace oil pump.
100 3 P052012 Sensor oil pressure, abnormally No limitation. Check the cable harness D7940/B:11 1.8 Lubrication
high voltage or short circuit to between control unit and 1/XX
higher voltage. component. DIAGNOSE,
page 8:24
100 5 P052013 Sensor oil pressure, abnormally No limitation. Check the cable harness D7940/B:11 1.8 Lubrication
low current or open circuit. between control unit and 1/XX
component. DIAGNOSE,
page 8:24
100 18 P109300 Low oil pressure in engine. Warning for low oil Check the engine oil level and D7940/- 1.8 Lubrication
pressure. oil quality. 1/XX
DIAGNOSE,
Change the engine oil and oil page 8:24
filter.
Check sensor oil pressure.
Replace the pressure control
valve at the oil pump.
Replace oil pump.

code and menu
components
102 0 P111800 Boost pressure too high. Reduced engine power. Check hoses and connections D7940/- 1.6 Intake
for the control of charge air Exhaust 3/XX
pressure. Leakage causes DIAGNOSE,
increased charge air pressure. page 8:22
Check the lever movement on
the wastegate valve
Check the charge air pressure
sensor.
Check solenoid valve charge air
pressure control.
Check the turbo.

102 3 P010512 Sensor charge air pressure, Engine power is limited Check the cable harness D7940/A:22 -
abnormally high voltage or short gradually depending on between control unit and
circuit to higher voltage. measurement values from component.
other sensors.
102 5 P010513 Sensor charge air pressure, Engine power is limited Check the cable harness D7940/A:22 -
abnormally low current or open gradually depending on between control unit and
circuit. measurement values from component.
other sensors.
102 16 P111600 High charge-air pressure. No limitation. Check hoses and connections D7940/- 1.6 Intake
for the control of charge air Exhaust 3/XX
pressure. Leakage causes DIAGNOSE,
increased charge air pressure. page 8:22
Check the lever movement on 1.7 Cooling
the wastegate valve system 8/XX
DIAGNOSE,
Check the charge air pressure page 8:24
sensor.
Check solenoid valve charge air
pressure control.
Check the turbo.
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code and menu
components
105 0 P111A00 Boost temperature too high. Reduced engine power. Check that the engine D7940/- 1.6 Intake
temperature is normal. Exhaust 3/XX
DIAGNOSE,
Check the coolant level. page 8:22
Clean the intercooler and 1.7 Cooling
radiator. system 8/XX
DIAGNOSE,
Check the charge air page 8:24
temperature sensor.
105 4 P011011 Sensor charge air temperature, No limitation. Check the cable harness D7940/A:47 1.6 Intake
abnormally high current, low between control unit and Exhaust 3/XX
voltage or short circuit to ground. component. DIAGNOSE,

page 8:22

Check the sensor.
105 5 P011013 Sensor charge air temperature, No limitation. Check the cable harness D7940/A:47 1.6 Intake
abnormally low current or open between control unit and Exhaust 3/XX
circuit. component. D7940/A:11 DIAGNOSE,
page 8:22
Check the sensor.
105 16 P111900 High boost temperature. No limitation. Check that the engine D7940/- 1.6 Intake
temperature is normal. Exhaust 3/XX
DIAGNOSE,
Check the coolant level. page 8:22
Clean the intercooler and 1.7 Cooling
radiator. system 8/XX
DIAGNOSE,
Check the charge air page 8:24
temperature sensor.
107 0 P10F800 Low pressure between air filter No limitation. Change the air filter. D7940/- -
and turbo.
107 3 P100712 Sensor air pressure intake, No limitation. Check the cable harness D7940/A:29 -
abnormally high voltage or short between control unit and
Check the sensor.
abnormally high current, low between control unit and
voltage or short circuit to ground. component.

code and menu
components
circuit. component.
Check the sensor.
general electrical problem. between control unit and
component.
Check the sensor.
108 5 P222613 Sensor air pressure (in control No limitation. Replace control unit engine D7940/- -
unit engine), abnormally low (D7940).
current or open circuit.

110 0 P021700 Coolant temperature too high. Reduced engine power. Check the coolant level. D7940/-
Check the drive of the cooling
fans.
Check that radiator is clean.
Check the condition and tension
of the drive belts.
Bleed the cooling system.
Check or change the thermostat
coolant.
Check sensor coolant
temperature.
Replace the pressure cap on the
expansion tank.
Clean the cooling system.
Replace the coolant pump.
110 4 P011511 Sensor coolant temperature, Engine hard to start. Check the cable harness D7940/B:27 -
Idle control reduced.
VDU01.01GB

Check the sensor.
D:19
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code and menu
components
110 5 P011513 Sensor coolant temperature, Engine hard to start. Check the cable harness D7940/B:27 -
circuit. Idle control reduced. component.
110 16 P111E00 High coolant temperature. No limitation. Check the coolant level. D7940/-
Check the drive of the cooling
fans.
Check that radiator is clean.
Check the condition and tension
of the drive belts.

Bleed the cooling system.
Check or change the thermostat
coolant.
Check sensor coolant
temperature.
Replace the pressure cap on the
expansion tank.
Clean the cooling system.
Replace the coolant pump.
111 1 P256000 Low coolant level. No limitation. Check the coolant level; fill if D7940/- -
necessary.
If the coolant level is low,
pressure test the cooling system
to find leakage.
Check the cable harness
component.
111 3 P255612 Sensor coolant level, abnormally No limitation. Check the cable harness D7940/B:23 -
high voltage or short circuit to between control unit and
higher voltage. component.

code and menu
components
high current, low voltage or short between control unit and
circuit to ground. component.
low current or open circuit. between control unit and
component.
111 18 P111D00 Low coolant level. No limitation. Check the coolant level; fill if D7940/- -
necessary.
If the coolant level is low,
pressure test the cooling system

to find leakage.
component.
131 3 P047012 Pressure sensor exhaust gases, Engine brake, low Check the cable harness D7940/B:12 -
abnormally high voltage or short performance. between control unit and
circuit to higher voltage component.
131 5 P047013 Pressure sensor exhaust gases, Engine brake, low Check the cable harness D7940/B:12 -
abnormally low current or open performance. between control unit and
circuit. component.
131 12 P047001 Pressure sensor exhaust gases, - Check the cable harness D7940/B:12 -
component.
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code and menu
components
157 0 P008800 Fuel pressure, too high. Reduced engine power. Check the cable harness - -
between control unit and fuel
pressure regulator (MPROP).
Check the fuel pressure
regulator's signal with an
oscilloscope.
between control unit and ePRV.
Check ePRV's signal with an
oscilloscope.

pressure sensor. Check the
fuel pressure with VODIA or by
measuring the voltage.

code and menu
components
157 1 P008700 Fuel pressure, too low. The engine can be Check that the fuel inlet valve is - -
switched off. The engine open and that the fuel lines are
turns over but does not correctly connected. Carry out
start. a visual inspection of the fuel
system for trapped hoses/pipes
and for leakage. Check the fuel
filters. Bleed the fuel system.
Run the engine from a separate
stand-alone fuel tank. Check for
inward leakage of air between
the high-pressure pump and the
tank. Check for air leakage.

fuel pressure with VODIA or
by measuring the voltage. P
(normal at idle) = 30-40 MPa,
P (start) approximately 20-30
MPa. If the engine can be
started, check at which fuel
pressure the error code occurs.
If the engine cannot be started,
check the fuel pressure when
the engine turns over.
oscilloscope.
oscilloscope.
157 4 P019011 Pressure sensor fuel, Reduced engine power. Check the cable harness D7940/A:19 -
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abnormally high current, between control unit and

low voltage or short circuit to component.
D:23
ground.
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code and menu
components
abnormally low current or between control unit and
mechanical problem. between control unit and
component.
157 12 P019001 Pressure sensor fuel, general Reduced engine power. Check the cable harness D7940/A:19 -
component.


code and menu
components
157 14 P00C600 Pressure sensor fuel, fuel The engine turns over but Check that the fuel inlet valve is - -
pressure too low when engine does not start. open and that the fuel lines are
turns over. correctly connected. Carry out
a visual inspection of the fuel
system for trapped hoses/pipes
and for leakage. Check the fuel
filters. Bleed the fuel system.

MPa. If the engine can be
started, check at which fuel
pressure the error code occurs.
If the engine cannot be started,
check the fuel pressure when
the engine turns over.
oscilloscope.
oscilloscope.
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code and menu
components
157 16 P114700 Pressure sensor fuel, fuel Reduced engine power. Check the cable harness - -
pressure too high. between control unit and fuel
MPa.

oscilloscope.
oscilloscope.
If the high-pressure pump has
been removed/replaced, check
the installation of the pump.
158 2 P05611F Voltage feed Control unit engine Uneven torque. Perform a correct shutdown. - -
(D7940).
between control unit and battery.
Clean the connection points.
Check that there are no voltage
losses between batteries and
control unit.
Check the battery disconnector.
158 3 - Voltage feed, Control unit Voltage feed from control Check the cable harness - -
engine (D7940), abnormally unit may be affected. between the control unit and its
high voltage or short circuit to power supply.
higher voltage.
Check that the control unit has
the correct power supply.

code and menu
components
158 4 - Voltage feed, Control unit Voltage feed from control Check the cable harness - -
engine (D7940), abnormally unit may be affected. between the control unit and its
high current, low voltage or short power supply.
circuit to ground.
Check that the control unit has
the correct power supply.
172 4 P00D911 Sensor ambient temperature, Engine difficult to start at Check the cable harness D7940/B:31 -
abnormally high current, low low temperatures. between control unit and
172 5 P00D913 Sensor ambient temperature, Engine difficult to start at Check the cable harness D7940/B:31 -
abnormally low current or open low temperatures. between control unit and

circuit. component.
173 0 P242800 Exhaust temperature too high. Reduced engine power. Check that the exhaust pipe D7940/- -
has not been damaged and that
there are no restrictions.
Check the sensor.
Check the exhaust system's
back pressure.
173 16 P112E00 High exhaust temperature. No limitation. Check that the exhaust pipe D7940/- -
has not been damaged and that
there are no restrictions.
Check the sensor.
Check the exhaust system's
back pressure.
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code and menu
components
175 0 P029800 Oil temperature too high. Reduced engine power. Check the oil level in the engine D7940/- 1.8 Lubrication
and that there is no leakage. 1/XX
DIAGNOSE,
Check the coolant level and page 8:24
engine temperature.
Clean the lubrication system.
Replace the drain valve for the
oil cooler.
Check the sensor.
175 4 P019511 Sensor oil temperature, Speed limitation. Check the cable harness D7940/A:31 1.8 Lubrication
abnormally high current, between control unit and 1/XX

low voltage or short circuit to component. DIAGNOSE,
ground. page 8:24
175 5 P019513 Sensor oil temperature, No limitation. Check the cable harness D7940/A:31 1.8 Lubrication
abnormally low current or between control unit and 1/XX
open circuit. component. DIAGNOSE,
page 8:24
175 16 P112500 High oil temperature. No limitation. Check the oil level in the engine D7940/- 1.8 Lubrication
and that there is no leakage. 1/XX
DIAGNOSE,
Check the coolant level and page 8:24
engine temperature.
Clean the lubrication system.
Replace the drain valve for the
oil cooler.
Check the sensor.
190 0 P021900 Engine speed too high. Engine speed is limited Stop the machine and switch D7940/- 1.9 Control
off the engine. Investigate the System 1/XX
cause of the high engine speed DIAGNOSE,
when the engine has been page 8:25
stopped.

code and menu
components
190 16 P119D00 Engine speed too high. Engine speed is limited Stop the machine and switch D7940/- 1.9 Control
off the engine. Investigate the System 1/XX
cause of the high engine speed DIAGNOSE,
when the engine has been page 8:25
stopped.
411 3 P040912 Pressure sensor, exhaust gas EGR valve closed. Check the cable harness D7940/A:21 -
recirculation (EGR), abnormally between control unit and
high voltage or short circuit to component.
higher voltage.
411 5 P040913 Pressure sensor, exhaust gas EGR valve closed. Check the cable harness D7940/A:21 -
recirculation (EGR), abnormally between control unit and

low current or open circuit. component.

411 12 P040901 Pressure sensor, exhaust gas - Check the cable harness D7940/A:21 -
recirculation (EGR), general between control unit and
electrical problem. component.
412 0 P112100 EGR temperature too high. Reduced engine power. Clean the EGR cooler. - -
412 4 P040A11 Temperature sensor, exhaust - Check the cable harness D7940/B:48 -
gas recirculation (EGR), between control unit and
abnormally high current, low component.
voltage or short circuit to ground.
gas recirculation (EGR), between control unit and
abnormally low current or open component.
circuit.
gas recirculation (EGR), general between control unit and
electrical problem. component.
VDU01.01GB
412 16 P112200 EGR temperature higher than Reduced engine power. Clean the EGR cooler. - -
normal.
D:29
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code and menu
components
626 2 - Signal from start button, no or Start button has jammed. Check the cable harness - 1.11 Start &
weak signal. between control unit and Stop 2/XX
page 8:26
626 3 P100212 Relay preheating, abnormally Engine difficult to start at Check the cable harness D7940/B:25 -
high voltage or short circuit to low temperatures. between control unit and
high current, low voltage or short low temperatures. between control unit and
circuit to ground. component.

low current or open circuit. low temperatures. between control unit and
component.
628 2 P060741 Memory error in Control unit Engine does not start. Reprogram the control unit. D7940/- -
engine (D7940).
Replace the control unit.
628 2 - Control unit, engine (D7940), Engine does not start. Reprogram the control unit. D7940/- -
program memory
program memory
program memory
program memory
program memory

code and menu
components
636 7 P001676 Sensor rpm camshaft, incorrect The engine takes longer to Check the cable harness D7940/A:45 -
assembly. The signal does not start than normal or does between control unit and
correspond with the signal from not start at all. component. D7940/A:46
sensor rpm crankshaft.
Rough running. Check the component's
assembly.
High fuel consumption.
Check the signal from the
component with an oscilloscope.
Compare the signals from
sensor rpm camshaft and
sensor rpm crankshaft with an
oscilloscope.

636 8 P034038 Sensor speed, camshaft, The engine takes longer to Check the cable harness D7940/A:45 -
abnormal frequency. start than normal. between control unit and
component. D7940/A:46
Check the component's

assembly.
636 9 P034031 Sensor rotation speed camshaft, The engine takes longer to Check the cable harness D7940/A:45 -
no signal. start than normal. between control unit and
component. D7940/A:46

637 2 P03351F Sensor rpm crankshaft, no or The engine takes longer to Check the component's D7940/A:37 1.9 Control
weak signal. start than normal. assembly. System 1/XX
D7940/A:38 DIAGNOSE,
Reduced torque. Check the signal from the page 8:25
Rough running.
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code and menu
components
637 8 P033538 Sensor speed, crankshaft, The engine takes longer to Check the component's D7940/A:37 1.9 Control
abnormal frequency. start than normal. assembly. System 1/XX
D7940/A:38 DIAGNOSE,
Reduced torque. Clean the component. page 8:25
Rough running. Check the signal from the
637 9 P033531 Sensor rotation speed flywheel, The engine takes longer to Check the cable harness D7940/A:37 1.9 Control
no signal. start than normal. between control unit and System 1/XX
component. D7940/A:38 DIAGNOSE,
Reduced torque. page 8:25
Rough running. component with an oscilloscope.

High fuel consumption. Check the component.
639 2 U001088 Communication error (Backbone Engine shut-off: the engine Check all data links between D7940/B:51 -
1) Control unit engine. cannot be started. machine, transmission, engine
and after-treatment system. D7940/B:55
Engine running: the engine
can only be stopped by UDS/B:10
using the emergency stop.
UDS/B:14
No engine information is
shown in the machine.
639 2 - Communication error (Backbone Engine shut-off: the engine Check all data links between D7940/B:51 -
1) Control unit engine. cannot be started. control unit engine and
Backbone 1. D7940/B:55
Engine running: the engine
can only be stopped by UDS/B:10
using the emergency stop.
UDS/B:14
639 9 - Communication error (Backbone Engine shut-off: the engine Check the fuse on control unit D7940/B:51 -
1) Control unit engine. cannot be started. engine.
D7940/B:55
Engine running: the engine Check the cable harness
can only be stopped by between control unit and "smart UDS/B:10
using the emergency stop. relay" module.
UDS/B:14

code and menu
components
641 0 P004577 Variable turbo geometry too high Reduced engine power. Check the movement of the - -
value. control lever on the VGT
actuator.
Check the VGT actuator.
641 2 P256214 Actuator variable turbo Reduced engine power. Replace the VGT unit. - -
geometry.
641 3 P006E17 Actuator variable turbo Reduced engine power. Check the cable harness - -
geometry, abnormally high between control unit and
voltage or short circuit to higher component.
voltage.
Replace the VGT actuator.

641 5 P004513 Actuator variable turbo Reduced engine power. Check the cable harness - -
geometry, abnormally low between control unit and
amperage or open circuit. component.
641 6 P004519 Actuator variable turbo Reduced engine power. Check the cable harness - -
geometry, abnormally high between control unit and
current. component.
641 9 U010C00 Communication error between Reduced engine power. Check the engine's CAN - -
actuator variable turbo geometry communication.
and control unit, engine (D7940).
Check the voltage feed to the
VGT unit.
641 11 P004592 Actuator variable turbo Reduced engine power. Replace the VGT actuator. - -
geometry, no measurement
values.
641 17 P112B00 Variable turbo geometry Reduced engine power. Check the heat radiation that - -
temperature higher than normal. may affect the VGT unit.
Replace the VGT unit.
647 3 P048012 Magnetic clutch cooling fan, Cooling fan drive locked at Check the cable harness D7940/B:49 -
abnormally high voltage or short 100%. between control unit and
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code and menu
components
647 4 P048011 Magnetic clutch cooling fan, Cooling fan drive Check the cable harness D7940/B:49 -
abnormally high current, low not working, risk of between control unit and
voltage or short circuit to ground. overheating. component.
647 5 P048013 Magnetic clutch cooling fan, Cooling fan drive locked at Check the cable harness D7940/B:49 -
abnormally low amperage or 100%. between control unit and
651 3 P020112 Injector cylinder 1, abnormally Engine only runs on 5 Check the cable harness D7940/A:56 -
high voltage or short circuit to cylinders, sounds rough between control unit and
higher voltage. and has reduced power. component. D7940/A:59
Protected mode Check the component.

Limp-home on other
injectors.
high current, low voltage or short cylinders, sounds rough between control unit and
circuit to ground. and has reduced power. component. D7940/A:59

Limp-home on other
injectors.
low current or open circuit. cylinders, sounds rough between control unit and
and has reduced power. component. D7940/A:59

Limp-home on other
injectors.

Limp-home on other
injectors.

code and menu
components

Limp-home on other
injectors.

Limp-home on other
injectors.

Limp-home on other
injectors.

Limp-home on other
injectors.
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D:35
VDU01.01GB
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code and menu
components

Limp-home on other
injectors.

Limp-home on other

injectors.

Limp-home on other
injectors.

Limp-home on other
injectors.
677 3 P061512 Starter relay on the starter Engine does not start. Check the cable harness D7940/B:29 -
motor, abnormally high voltage between control unit and
or short circuit to higher voltage. component. D7940/B:37
677 4 P061511 Start relay on starter motor, Engine does not start. Check the cable harness D7940/B:29 -
voltage or short circuit to ground. component. D7940/B:37

code and menu
components
677 5 P061513 Starter relay on the starter Engine does not start. Check the starter relay on the D7940/B:29 -
motor, abnormally high voltage starter motor.
or short circuit to higher voltage. D7940/B:37
component.
677 6 P061519 Start relay on starter motor, Engine does not start. Check the cable harness D7940/B:29 -
abnormally high current. between control unit and
component. D7940/B:37
679 3 P009012 Fuel pressure regulator Reduced engine power. Check the cable harness D7940/A:12 -
(MPROP), abnormally high between control unit and
Open ePRV. D7940/A:16
voltage or short circuit to higher component.

voltage.

regulator (MPROP) with an
oscilloscope.
current, low voltage or short Open ePRV. component. D7940/A:16
circuit to ground.
oscilloscope.
voltage or short circuit to higher Open ePRV. component. D7940/A:16
voltage.
oscilloscope.
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D:37
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code and menu
components
679 7 P228D72 Fuel pressure regulator Reduced engine power. Check the cable harness D7940/A:12 -
(MPROP), mechanical problem, between control unit and fuel
stuck in open position. pressure sensor. Check the D7940/A:16
(normal at idle) = 30-40 MPa.
Check at which fuel pressure
the error code occurs.

oscilloscope.
729 5 P054013 Preheating element, abnormally Engine difficult to start at Check the fuse for the D7940/B:7 -
low current or open circuit. low temperatures. component.
component.
729 6 P054070 Relay preheating, mechanical Engine difficult to start at Check the cable harness D7940/B:7 -
problem, locked in engaged low temperatures. between control unit and
mode. component. D7940/B:25

729 7 P05407F Relay preheating, mechanical Engine difficult to start at Check the cable harness D7940/B:7 -
problem, locked in disengaged low temperatures. between control unit and
mode. component.
729 12 P054001 Preheating element, general Preheating cannot be Check the fuse for the D7940/B:7 -
electrical problem. activated, starting problems component.
in cold weather.
component.

code and menu
components
970 3 P100112 Stop button on engine, The engine is switched off Check the cable harness D7940/A:27 -
abnormally high voltage or and cannot be started. between control unit and
short circuit to higher voltage. component.
abnormally high current, and cannot be started. between control unit and
ground.
abnormally low current or and cannot be started. between control unit and
970 11 P100192 Stop button on engine, activated. Engine cannot be started. Reset the switch and switch the D7940/A:27 -
ignition on and off.

Check the cable harness to A27
on the control unit.
970 14 P100190 Stop button on engine, Engine cannot be started. Check the Stop button. D7940/A:27 -
mechanical problem. Jammed
in depressed position. Check the cable harness to A27
on the control unit.
1188 3 P024312 Actuator intercooler pressure Reduced engine power. Check the cable harness D7940/B:38 -
control, abnormally high voltage between control unit and
or short circuit to higher voltage. component.
control, abnormally high current, between control unit and
ground.
control, abnormally low current between control unit and
or open circuit. component.
VDU01.01GB
D:39
VDU01.01GB
D:40

code and menu
components
1239 14 P009400 Less fuel leakage. - Check the high-pressure system - -
for leakage.
oscilloscope. Check the return
line from ePRV.
fuel pressure with VODIA or by
measuring the voltage.

1347 7 P06279C Fuel pressure pump, low flow Reduced engine power. Check for other error codes that - -
may be the cause.
1485 7 P068573 Engine relay active. ECM relay activated. Replace main relay. - -
Battery is discharged.
1639 3 P052612 Sensor fan speed, abnormally The cooling fan does not Check the cable harness D7940/A:35 -
high voltage or short circuit to disengage. between control unit and
1668 2 U008088 Communication error (Engine No limitation. Check the cable harness - -
subnet) control unit engine, between the control unit and
unreasonable signal. components on Engine subnet.
1761 3 P203A12 Sensor AdBlue level, abnormally No limitation. Check the cable harness UDS/B:46 1.6 Intake
high voltage or short circuit to between Control unit Exhaust 4/XX
P203A86 higher voltage. after-treatment system (UDS) DIAGNOSE,
and the component. page 8:22
1761 5 P203A13 Sensor AdBlue level, abnormally No limitation. Check the cable harness UDS/B:46 1.6 Intake
low current or open circuit. between Control unit Exhaust 4/XX
May also generate error after-treatment system (UDS) UDS/B:51 DIAGNOSE,
code SPN 1761/12 and and the component. page 8:22
3510/4

code and menu
components
1761 12 P203A01 Sensor AdBlue level, general Reduced engine power. Check the cable harness D7940/- 1.6 Intake
electrical problem. between control unit and Exhaust 4/XX
P203A86 May also generate error component. DIAGNOSE,
code SPN 1761/3 and page 8:22
1761/5. Check and rectify other error
codes.
1761 17 P114500 AdBlue level low. No limitation. Fill AdBlue. D7940/- 1.6 Intake
Exhaust 4/XX
DIAGNOSE,
page 8:22
1761 18 P203F00 AdBlue level too low. Reduced engine power. Fill AdBlue. D7940/- 1.6 Intake
Exhaust 4/XX
No AdBlue additive. DIAGNOSE,

page 8:22
2000 9 U010000 Communication error between No limitation. Check fuses for Control unit UDS/- -
Control unit after-treatment after-treatment system (UDS).
system (UDS) and Control unit
engine (D7940). Check the cable harness
between Control unit
after-treatment system (UDS)
and Control unit engine (D7940).
Check that the software
corresponds between Control
unit after-treatment system
(UDS) and Control unit engine
(D7940).
2017 9 U014100 Communication error with No limitation Check the cable harness - -
machine. between engine and machine.
2036 9 U117100 Communication error with No limitation Check the cable harness - -
machine. between engine and machine.
2659 10 P04007C EGR system, slow response. No limitation. Check the function of the EGR D7940/-
valve.
2659 18 P04009C EGR system, flow too low. No limitation. Check that there are no D7940/- -
blockages in the EGR system.
VDU01.01GB
Check the function of the EGR

valve.
D:41
VDU01.01GB
D:42

code and menu
components
2791 2 P048613 EGR position sensor, no or Reduced engine power. Check the cable harness - -
weak signal. between control unit and
component.
Check the EGR unit.
2791 3 P041A12 EGR unit, abnormally high Reduced engine power. Replace the EGR unit. - -
voltage or short circuit to higher
voltage.
2791 4 P041A11 EGR unit, abnormally high Reduced engine power. Replace the EGR unit. - -
current, low voltage or short
circuit to ground.
2791 5 P040313 EGR unit, abnormally high Reduced engine power. Check the cable harness - -

current, cable open circuit or between control unit and EGR
short circuit to ground. unit.
Replace the EGR unit.
2791 6 P040312 EGR unit, abnormally high Reduced engine power. Check the cable harness - -
current. between control unit and EGR
unit.
2791 7 P040371 EGR valve, incorrect response Reduced engine power. Check the function of the EGR D7940/- -
from mechanical system. valve.
Replace the EGR control.
2791 9 U010A00 Communication error between No limitation. Check the engine's CAN D7940/- -
EGR unit and Control unit communication.
engine (D7940).
Check the voltage feed to the
EGR unit.
2791 11 P040392 EGR valve, no measurement Reduced engine power. Check the cable harness D7940/- -
values. between control unit and EGR
unit.
2791 12 P040341 EGR valve, general electrical Reduced engine power. Replace the EGR unit. D7940/- -
problem.

code and menu
components
2791 17 P114E00 EGR valve, temperature higher Reduced engine power. Check the heat radiation that - -
than normal. may affect the EGR unit.
3031 0 P24FF00 AdBlue tank, temperature too No limitation. Carry out a test with Vodia in - 1.6 Intake
high. order to check the function of Exhaust 4/XX
the tank's heating valve. DIAGNOSE,
page 8:22
Check the temperature sensor.
3031 4 P205A11 Sensor temperature AdBlue No limitation. Check the cable harness D7940/B18 -
tank, abnormally high current, between control unit UDS and
low voltage or short circuit to the component.
ground.

Check and rectify other error
codes.
3031 5 P205A13 Sensor temperature AdBlue No limitation. Check the cable harness D7940/B18 -
tank, abnormally low current or between control unit UDS and
open circuit. the component.
codes.
3031 12 P205A86 Sensor temperature AdBlue Reduced engine power. Check the cable harness D7940/- -
tank, general electrical problem. between control unit and
P205A01 May also generate error component.
code SPN 3519/4 and
3519/5. Check and rectify other error
codes.
3216 2 P220064 NOx sensor before catalyst, No limitation. Replace the component. D7940/- -
unreasonable signal.
abnormally high voltage or short
circuit to higher voltage.
abnormally low current or open
circuit.
VDU01.01GB
D:43
VDU01.01GB
D:44

code and menu
components
3216 9 U029D00 NOx sensor before catalyst, no Reduced engine power. Check the cable harness UDS/B:49 -
signal. between engine and control unit
May also generate error for after-treatment system.
code SPN 3226/9 and
520416/9. Check the cable harness
component.
Check all cable harnesses for
Engine subnet.
codes.
3216 11 P225D00 NOx sensor before catalyst, no Reduced engine power. Check that the sensor is clean. D7940/- -

measurement values.
Check that the sensor is fitted
correctly.
component.
Check that the exhaust system
has no leaks.
Check the sensor.
3216 12 P22FB92 NOx sensor before catalyst, No limitation. Replace the component. D7940/- -
unreasonable measurement
values.
internal error during start-up.
3216 14 P22001C NOx sensor before catalyst, No limitation. Replace the component. D7940/- -
internal supply voltage too high.
3226 2 P229E64 NOx sensor after catalyst, No limitation. Replace the component. D7940/- -
unreasonable signal.
3226 3 P229E12 NOx sensor after catalyst, Reduced engine power. Replace the component. D7940/- -
abnormally high voltage or short
circuit to higher voltage.
3226 5 P229E13 NOx sensor after catalyst, Reduced engine power. Replace the component. D7940/- -
abnormally low current or open
circuit.

code and menu
components
3226 7 P225F00 NOx sensor after catalyst, Reduced engine power. Check that the sensor is clean. D7940/- -
mechanical problem.
Check that the sensor is fitted
correctly.
component.
Check that the exhaust system
has no leaks.
Check that the intake system
has no leaks.

Check the sensor.
3226 9 U029E00 NOx sensor after catalyst, no Reduced engine power. Check the cable harness UDS/B:49 -
signal. between engine and control unit
May also generate error for after-treatment system.
code SPN 3216/9 and
520416/9. Check the cable harness
component.
Engine subnet.
codes.
3226 12 P22FE00 NOx sensor after catalyst, No limitation. Replace the component. D7940/- -
unreasonable measurement
values.
3226 13 P229E93 NOx sensor after catalyst, No limitation. Replace the component. D7940/- -
internal error during start-up.
3226 14 P229E1C NOx sensor after catalyst, No limitation. Replace the component. D7940/- -
internal supply voltage too high.
3241 4 P054411 Sensor exhaust gas temperature No limitation. Check the cable harness UDS/B:39 -
1, abnormally high current, low between Control unit
VDU01.01GB
voltage or short circuit to ground. after-treatment system (UDS)

and the component.
D:45
VDU01.01GB
D:46

code and menu
components
1, cable open circuit or short between Control unit
circuit to ground. May also generate error after-treatment system (UDS)
code SPN 3241/19. and the component.
Check the sensor.
1, general electrical problem. between Control unit
and the component.
Check the sensor.
3241 19 P054486 Sensor exhaust gas temperature Reduced engine power. Check and rectify other error UDS/B:39 -

1, incorrect value from the codes.
after-treatment system. May also generate error
code SPN 3241/5.
3361 12 P204F93 Metering error AdBlue. Reduced engine power. Check and rectify other error D7940/- -
codes.
No AdBlue additive.
Check the injection unit for
May also generate error AdBlue.
code SPN 4376/4, 4334/4,
4334/5, 5394/5, 5394/4 Check the AdBlue pump.
and 520416/9.
3361 12 P208A86 AdBlue pump, general electrical Reduced engine power. Check and rectify other error D7940/- -
problem. codes.
May also generate error
code SPN 4334/4, 4334/5,
5392/31 and 5485/14.
3363 3 P20B112 Heating valve AdBlue tank, Risk that AdBlue freezes in Check the cable harness UDS/B:4 -
abnormally high voltage or short the tank. between Control unit
circuit to higher voltage. after-treatment system (UDS)
and the component.
abnormally high current, low the tank. between Control unit
and the component.
abnormally low current or open the tank. between Control unit
circuit. after-treatment system (UDS)
and the component.

code and menu
components
3364 17 P207F9A Incorrect AdBlue quality. Reduced conversion of Check AdBlue quality. D7940/- -
NOx.
3464 3 P02E012 Actuator motor throttle, The throttle is set in open Check the cable harness D7940/B:1 1.1 Controls
abnormally high voltage or position. between control unit and & Instr 1/XX
short circuit to higher voltage. component. D7940/B:5 DIAGNOSE,
page 8:21
3464 4 P02E011 Actuator motor accelerator The throttle is set in open Check the cable harness D7940/B:1 1.1 Controls
control, abnormally high current, position. between control unit and & Instr 1/XX
low voltage or short circuit to component. D7940/B:5 DIAGNOSE,
ground. page 8:21

3464 5 P02E013 Actuator motor accelerator The throttle is set in open Check the cable harness D7940/B:1 1.1 Controls
control, abnormally low current position. between control unit and & Instr 1/XX
or open circuit. component. D7940/B:5 DIAGNOSE,
page 8:21
3464 7 P02E09C Actuator motor accelerator - Clean the throttle. D7940/- 1.1 Controls
control, flow too low. & Instr 1/XX
Check that the throttle is not DIAGNOSE,
binding during opening and page 8:21
closing.
Check that throttle movement
Check sensor damper position.
3464 10 P02E07C Actuator motor accelerator Poor throttle response. Clean the throttle. D7940/- 1.1 Controls
control, calibration error. & Instr 1/XX
closing.
VDU01.01GB
D:47
VDU01.01GB
D:48

code and menu
components
3464 12 P02E09B Actuator motor accelerator Low exhaust gas Clean the throttle. D7940/- 1.1 Controls
control, flow too high. temperature. & Instr 1/XX
closing.
- - -
3468 2 P018564 Fuel temperature manifold, Check the cable harness

defective sensor between control unit and

component.
3468 4 P018511 Fuel temperature sensor, - Check the cable harness - -
circuit. component.
component.

code and menu
components
3468 16 P016800 Fuel temperature too high. Reduced engine power. Check the fuel level, fill the tank - -
with fuel.
NOTE
High temperature due to fast
return flow of fuel to the tank
being reduced if there is a lot of
fuel in the tank.
Check the installation of the fuel
tank and the fuel lines. Check
if anything is radiating heat
against the fuel system.

Check the fuel temperature
sensor.
line from ePRV.
3509 3 P06B017 Voltage feed sensor A, Sensor supplied by output Check the cable harness D7940/A:7 -
abnormally high voltage or A:7 may show incorrect between the control unit and the
short circuit to higher voltage. values and generate other components.
error codes.
3509 4 P06B016 Voltage feed sensor A, Sensor supplied by output Check the cable harness D7940/A:7 -
abnormally high current, A:7 may show incorrect between the control unit and the
low voltage or short circuit to values and generate other components.
ground. error codes.
3510 3 P06B317 Voltage feed sensor B, Sensor supplied by output Check the cable harness D7940/B:17 -
abnormally high voltage or B:17 may show incorrect between the control unit and the
short circuit to higher voltage. values. components.
code SPN 100/3.
3510 3 P06B317 Voltage feed sensor B, No pressure measurement Check the cable harness UDS/B:51 -
VDU01.01GB
abnormally high voltage or in AdBlue pump unit. between the control unit and the
short circuit to higher voltage. components.
D:49
VDU01.01GB
D:50

code and menu
components
3510 4 P06B316 Voltage feed sensor B, Sensor supplied by output Check the cable harness D7940/B:17 -
abnormally high current, B:17 may show incorrect between the control unit and the
low voltage or short circuit to values. components.
ground.
code SPN 100/5.
3510 4 P06B316 Voltage feed sensor B, No pressure measurement Check the cable harness UDS/B:51 -
abnormally high current, in AdBlue pump unit. between Control unit
low voltage or short circuit to after-treatment system (UDS)
ground. May also generate error and the AdBlue pump unit.
code SPN 1761/12 and
1761/5. Check the component.
3511 3 P06E617 Voltage feed sensor C, Sensor supplied by output Check the cable harness D7940/A:1 -

abnormally high voltage or A:1 may show incorrect between the control unit and the
short circuit to higher voltage. values and generate other components.
error codes.
3511 4 P06E616 Voltage feed sensor C, Sensor supplied by output Check the cable harness D7940/A:1 -
abnormally high current, A:1 may show incorrect between the control unit and the
low voltage or short circuit to values and generate other components.
ground. error codes.
3597 3 P065712 AdBlue pump unit voltage feed No AdBlue additive. Check the cable harness UDS/B:62 -
A, abnormally high voltage or between Control unit
short circuit to higher voltage. AdBlue pump unit not after-treatment system (UDS)
working. and the components.
3597 4 P065711 AdBlue pump unit voltage feed No AdBlue additive. Check the cable harness UDS/B:62 -
A, abnormally high current, low between Control unit
voltage or short circuit to ground. AdBlue pump unit not after-treatment system (UDS)
working. and the components.
3598 3 P266912 AdBlue pump unit voltage feed Risk that AdBlue freezes. Check the cable harness UDS/B:59 -
B, abnormally high current, low between Control unit
and the components.
3598 4 P266911 AdBlue pump unit voltage feed Risk that AdBlue freezes. Check the cable harness UDS/B:59 -
B, abnormally high current, low between Control unit
and the components.

code and menu
components
4334 4 P204A11 Pressure sensor AdBlue pump Reduced engine power. Check the cable harness UDS/B:30 -
unit, abnormally high current, between Control unit
ground. and the component.
4334 5 P204A13 Pressure sensor AdBlue pump Reduced engine power. Check the cable harness UDS/B:30 -
unit, abnormally low current or between Control unit
open circuit. after-treatment system (UDS)
and the component.
4354 3 P20B912 Hose heater A AdBlue, Risk that AdBlue freezes in Check the cable harness UDS/B:32 -

abnormally high voltage or the hose. between Control unit
short circuit to higher voltage. after-treatment system (UDS)
and the component.
abnormally high current, the hose. between Control unit
abnormally low current or the hose. between Control unit
and the component.
4355 3 P20BD12 Hose heater B AdBlue, Risk that AdBlue freezes in Check the cable harness UDS/B:28 -
and the component.
and the component.
VDU01.01GB
D:51
VDU01.01GB
D:52

code and menu
components
4356 3 P20C112 Hose heater C AdBlue, Risk that AdBlue freezes in Check the cable harness UDS/B:24 -
and the component.
and the component.

4366 14 P20B992 Hose heater A AdBlue, special Risk that AdBlue freezes in Check the hose connections UDS/- -
instructions. the hose. from and to the engine's cooling
system.
Check the heating valve for the
AdBlue system.
Check error codes for the
preheating element.
4374 0 P202D7A AdBlue system, pressure No limitation. Check that the AdBlue hoses UDS/- -
leakage. are not damaged.
Check that the injection unit
is not leaking, see supplier
documentation.
4374 1 P208A92 AdBlue pump unit, motor speed No AdBlue additive. Troubleshoot in accordance with UDS/- -
too low. supplier documentation.
code SPN 5485/14 and
5392/31.
4375 0 P10AD12 Motor AdBlue pump unit, No limitation. Check the cable harness UDS/B:8 -
abnormally high voltage between Control unit
or ground connection after-treatment system (UDS)
short-circuited to voltage. and the component.
abnormally low current or ground between Control unit
connection short-circuited to after-treatment system (UDS)

code and menu
components
4375 3 P208A12 Motor AdBlue pump unit, No limitation. Check the cable harness UDS/B:7 -
abnormally high voltage or short between Control unit
circuit to higher voltage. after-treatment system (UDS) UDS/B:8
and the component.
UDS/B:12
UDS/B:62
abnormally high current, low between Control unit
and the component.
abnormally low current or open between Control unit

circuit. after-treatment system (UDS) UDS/B:8
and the component.
UDS/B:12
UDS/B:62
abnormally low current or open between Control unit
circuit on ground connection. after-treatment system (UDS)
and the component.
4375 14 P21CAA1 AdBlue pump unit, incorrect No limitation. Check the cable harness UDS/- -
supply voltage. between Control unit
and the component.
4376 3 P20A012 Directional control valve AdBlue AdBlue is not pumped back Check the cable harness UDS/B:12 -
pump unit, abnormally high to the tank when the engine between Control unit
voltage or short circuit to higher is switched off. after-treatment system (UDS)
voltage. and the component.
pump unit, abnormally high to the tank when the engine between Control unit
current, low voltage or short is switched off. after-treatment system (UDS)
circuit to ground. and the component.
pump unit, abnormally low to the tank when the engine between Control unit
VDU01.01GB
current or open circuit. is switched off. after-treatment system (UDS)

and the component.
D:53
VDU01.01GB
D:54

code and menu
components
4376 7 P20A007 Directional control valve AdBlue, AdBlue is not pumped back Test by starting the engine, run UDS/- -
mechanical problem. to the tank when the engine it at idling speed for five minutes
is switched off. and then switch off the engine.
Check if the fault remains.
Replace AdBlue pump unit.
Note that the AdBlue system
is pressurised!
4752 7 P245700 EGR cooler, temperature - Clean the EGR cooler. - -
deviation.
5016 4 P26E711 AdBlue pump unit voltage feed No limitation. Check the cable harness UDS/B:49 -
D, abnormally high current, low between Control unit

and the components.
5392 31 P20E892 Low AdBlue pressure. Reduced engine power. Check the level in the AdBlue - -
tank.
Troubleshoot in accordance with
supplier documentation.
5394 3 P204712 AdBlue injection unit, abnormally No AdBlue additive. Check the cable harness UDS/B:40 -
high voltage or short circuit to between Control unit
higher voltage. after-treatment system (UDS) UDS/B:44
and the component.
high current, low voltage or short between Control unit
circuit to ground. after-treatment system (UDS) UDS/B:44
and the component.
low current or open circuit. between Control unit
after-treatment system (UDS) UDS/B:44
and the component.

code and menu
components
5394 12 P204786 AdBlue injection unit, general No limitation. Check the cable harness D7940/- -
electrical problem. between the control unit and the
components.
5394 14 P204773 AdBlue injection unit, jammed in No AdBlue additive. Troubleshoot in accordance with UDS/B:40 -
closed position. supplier documentation.
UDS/B:44
5435 14 P204F94 AdBlue system, active error No limitation. Rectify other error codes for the UDS/- -
codes generated. after-treatment system.
5485 14 P10CE97 AdBlue pump unit, no return No limitation. Check that the AdBlue hoses UDS/- -
flow. are not trapped or damaged.

Check that the outlet from the
AdBlue pump unit is not clogged.
Troubleshoot in accordance with
supplier documentation.
5765 10 P041A2A EGR temperature sensor, slow Reduced engine power. Replace the EGR unit. - -
response.
520244 3 P009B12 Fuel pressure relief valve, Reduced engine power. Check the cable harness D7940/A:28 -
abnormally high voltage or short between control unit and ePRV.
circuit to higher voltage. Check ePRV's signal with an D7940/A:62
oscilloscope.
abnormally high current, low between control unit and ePRV.
voltage or short circuit to ground. Check ePRV's signal with an D7940/A:62
oscilloscope.
abnormally low current or open between control unit and ePRV.
circuit. Check ePRV's signal with an D7940/A:62
oscilloscope.
520244 7 P009B73 Fuel pressure relief valve, Reduced engine power. Check the cable harness - -
mechanical problem. between control unit and ePRV.
VDU01.01GB
oscilloscope.
D:55
VDU01.01GB
D:56

code and menu
components
520244 12 P018F00 Fuel pressure relief valve, Reduced engine power. Check the cable harness - -
general electrical problem. between control unit and fuel

oscilloscope.
520245 0 P016E00 Fuel pressure, too high. Reduced engine power. Check the cable harness - -
line from ePRV.
oscilloscope.

code and menu
components
520245 1 P016F00 Fuel pressure, too low. Reduced engine power. Check the fuel level. Check - -
hoses and fuel filter for leakage.
Check that fuel hoses are not
trapped or clogged. Change
the fuel filters. Bleed the fuel
system.

(normal at idle) = 30-40 MPa. If
the engine can be started, check
at which fuel pressure the error
code occurs.
line from ePRV.
oscilloscope.
VDU01.01GB
D:57
VDU01.01GB
D:58

code and menu
components
520245 16 P228F00 Fuel pressure above normal Reduced engine power. Check the cable harness - -
level. between control unit and fuel
code occurs.

line from ePRV.
oscilloscope.

code and menu
components
520245 18 P228E00 Fuel pressure below normal - Check the cable harness - -
level. between control unit and fuel
code occurs.

line from ePRV.
oscilloscope.
520335 5 U300001 Control unit engine (D7940), Engine does not start. Replace the component. D7940/- -
internal fault in voltage feed.
520416 9 U116F00 Communication error Control No AdBlue additive. Check fuses for Control unit D7940/- -
unit after-treatment system after-treatment system (UDS).
(UDS). May also generate error
code SPN 3216/9 and Check the cable harness
3226/9. between the control unit and
metering valve AdBlue.
Engine subnet.
codes.
VDU01.01GB
D:59
VDU01.01GB
D:60

code and menu
components
520688 0 P11A600 Exhaust temperature too high. No limitation. Check that the exhaust pipe is - -
not damaged and that it is not
clogged.
Check sensor exhaust gas
temperature.
Check the back pressure.
520688 3 P11A412 Sensor exhaust gas No limitation. Check the cable harness D7940/B:44 -
temperature, abnormally between the control unit and the
high voltage or short circuit to components.
higher voltage.

high current, low voltage or components.
short circuit to ground.
low current or open circuit. components.
520688 16 P11A500 Exhaust temperature higher No limitation. Check that the exhaust pipe is - -
than normal. not damaged and that it is not
clogged.
Check sensor exhaust gas
temperature.
Check the back pressure.
D Error codes – Engine :61
Error codes engine (engine option Cummins

QSB6.7)
The error codes for the engine are sorted in numerical order. The table
contains the following information:
page D:8.
in question.

VDU01.01GB
D:62
Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3)

code and menu
components
91 3 131 Accelerator pedal or lever Major decrease in engine Check the cable harness - 1.1 Controls
position sensor circuit. High power. Only emergency between control unit and & Instr 1/XX
voltage detected in accelerator operation possible. component. DIAGNOSE,
pedal or lever position circuit. page 8:21.
91 4 132 Accelerator pedal or lever Major decrease in engine Check the cable harness - 1.1 Controls
position sensor circuit. Low power. Only emergency between control unit and & Instr 1/XX
voltage detected in accelerator operation possible. component. DIAGNOSE,
pedal or lever position signal page 8:21.
circuit. Check the component.
91 9 3326 SAE J1939 multiplexing, system Engine speed limited to Use diagnostic menu to find - -
error accelerator pedal sensor. idling speed. incorrect segment.
94 3 546 Sensor, injection pressure. - Check the cable harness - -

component.
94 4 547 Sensor, injection pressure. - Check the cable harness - -
component.
94 15 2261 Fuel pressure. Least serious Decrease in engine power. Check whether the fuel filter is - -
level. clogged.
Check for damaged fuel pipes.
94 17 2262 Fuel pressure. Least serious Engine difficult to start. Check whether the fuel filter is - -
level. Decrease in engine power. clogged.
Check if the fuel pump gives low
flow.
Check if there is air in the fuel.
94 18 559 Fuel pump feed pressure. No noise or possible noise - - -
Moderately severe level. D7940 from the engine associated
2215 has detected that the fuel with higher injection
pressure in the fuel rail is higher pressure (particularly while
than the requested pressure. idling or with a high load).
Engine power decreases.
Table Error codes engine (engine option Cummins QSB6.7 Stage 3A/Tier 3) (continued)

code and menu
components
97 3 428 Sensor circuit for water in fuel None on performance. Check the cable harness - -
indicator. High voltage detected No water in fuel warning between control unit and
1845 in the water in the fuel circuit. available. component.
Check the sensor.
97 4 429 Sensor circuit for water in fuel None on performance. Check the cable harness - -
indicator. Low voltage detected No water in fuel warning between control unit and
1846 in the water in the fuel circuit. available. component.
Check the sensor.
97 15 418 Water in fuel indicator: The least Possible white smoke, Drain water separator. - -
serious level. Water has been power reduction or difficult
detected in the fuel filter. to start.

97 16 1852 Water in fuel indicator. Possible white smoke, Drain water separator. - -
Moderately serious level. power reduction or difficult
to start. Check the sensor.
100 1 415 Engine oil duct pressure. The Progressive power Check the oil level in the engine; - 1.8 Lubrication
most serious level. The oil reduction that increases fill if necessary. 1/XX
pressure signal indicates that with time after the warning. DIAGNOSE,
the oil pressure is lower than If the Engine protection page 8:24.
the critical limit for the engine's shutdown function is
protection. activated, the engine is
switched off 30 seconds
after the red STOP light
starts to flash.
100 2 435 Oil pressure switch sensor None on performance. No Check the cable harness - 1.8 Lubrication
circuit. An error in the engine oil engine protection for the oil between control unit and 1/XX
pressure switch signal has been pressure. component. DIAGNOSE,
detected by D7940. page 8:24.
Check the sensor.
100 3 135 Oil pressure sensor circuit. None on performance. No Check the cable harness - 1.8 Lubrication
High signal voltage detected in engine protection for the oil between control unit and 1/XX
engine oil pressure circuit. pressure. component. DIAGNOSE,
page 8:24.
Check the sensor.
100 4 141 Oil pressure sensor circuit. None on performance. No Check the cable harness - 1.8 Lubrication
VDU01.01GB
Low signal voltage detected in engine protection for the oil between control unit and 1/XX
engine oil pressure circuit. pressure. component. DIAGNOSE,
D:63
page 8:24.
Check the sensor.
VDU01.01GB
D:64

code and menu
components
100 18 143 Engine oil duct pressure. None on performance. Check the oil level in the engine; - 1.8 Lubrication
Moderately serious level. fill if necessary. 1/XX
Engine oil pressure signal DIAGNOSE,
indicates that the engine oil page 8:24.
pressure is lower than the limit
for engine protection warning.
101 0 556 Crankcase pressure. The engine is switched off. Check the following: Crankcase - -
ventilation filter needs to be
replaced.
Damage to crankcase pressure
sensor.

Clogged oil separator for
crankcase ventilation
Clogged oil drainage pipe or
non-return valve for crankcase
ventilation.
Clogged suction pipe for
crankcase ventilation.
Frozen or clogged crankcase
ventilation pipe.
101 2 1942 Crankcase pressure. - Check the cable harness - -
component.
Check the sensor.
component.
Check the sensor.
component.
Check the sensor.

code and menu
components
101 16 555 Crankcase pressure. None on performance. Check the following: Crankcase - -
ventilation filter needs to be
1974 replaced.
Damage to crankcase pressure
sensor.
Clogged oil separator for
crankcase ventilation
Clogged oil drainage pipe or
non-return valve for crankcase
ventilation.
Clogged suction pipe for

crankcase ventilation.
Frozen or clogged crankcase
ventilation pipe.
102 2 2973 Intake manifold pressure sensor Engine power decreases. Check the cable harness - .
circuit. D7940 has detected an between control unit and
intake manifold pressure signal component.
that is too high or too low for
the engine's current operating Check the sensor.
conditions.
102 3 122 Intake manifold pressure sensor Decrease in engine power. Check the cable harness - .
circuit. High signal voltage between control unit and
detected in the intake manifold component.
pressure circuit.
Check the sensor.
102 4 123 Intake manifold pressure sensor Decrease in engine power. Check the cable harness - .
circuit. Low signal voltage between control unit and
detected in the intake manifold component.
pressure circuit.
Check the sensor.
VDU01.01GB
D:65
VDU01.01GB
D:66

code and menu
components
105 0 155 Intake manifold temperature 1: Progressive power Check the coolant level in the - .
The most severe level. The reduction that increases engine; fill if necessary.
intake manifold air temperature with time after the warning.
signal indicates that the air If the Engine protection Check that the charge air cooler
temperature in the intake shutdown function is is clean, clean if necessary.
manifold is higher than the activated, the engine is
critical limit for engine protection. switched off 30 seconds Check that the fan belts are
after the red STOP light intact. Check the sensor.
starts to flash.
105 3 153 Temperature inlet manifold. Possible white smoke. Fan Check cable harness between - .
High signal voltage detected will stay ON if controlled control unit and component.
in the intake manifold air by the D7940. No engine
temperature circuit. protection for the intake Check the sensor.

manifold's air temperature.
105 4 154 Temperature inlet manifold. Low Possible white smoke. Fan Check cable harness between - .
signal voltage detected in the will stay ON if controlled control unit and component.
intake manifold air temperature by the D7940. No engine
circuit. protection for the intake Check the sensor.
manifold's air temperature.
105 10 783 Temperature inlet manifold. The engine is switched off. Check that the charge air cooler - -
is clean, clean if necessary.
Check the temperature after the
turbo.
105 16 488 Circuit, temperature sensor inlet - -
manifold.
108 2 295 Barometric pressure. The - Check cable harness between - -
pressure sensor for the ambient control unit and component.
air pressure reads an erratic
value on power-up. Check the sensor.
108 3 221 Barometric pressure sensor Engine power decreases. Check cable harness between - -
circuit. High signal voltage control unit and component.
detected in barometric pressure
sensor circuit. Check the sensor.
108 4 222 Barometric pressure sensor Engine power decreases. Check cable harness between - -
circuit. Low signal voltage control unit and component.
detected in barometric pressure
sensor circuit. Check the sensor.

code and menu
components
109 1 228 Sensor coolant pressure. Most The engine is switched off. Check cable harness between - -
serious level. control unit and component.
Check the sensor.
109 3 231 Sensor coolant pressure. No limitation. Check the cable harness - -
component.
Check the sensor.
109 4 232 Sensor coolant pressure. No limitation. Check the cable harness - -
component.

Check the sensor.
110 0 151 Engine coolant temperature. Progressive power Check the coolant level. -
The most serious level. The reduction that increases
engine coolant temperature with time after the warning. Check that radiator is clean.
signal indicates that the coolant If the Engine protection
temperature is higher than the shutdown function is Check if there is air in coolant
critical limit for engine protection. activated, the engine is system.
switched off 30 seconds Check the cap on the expansion
after the red STOP light tank.
starts to flash.
Check the sensor.
Check the thermostat.
110 3 144 Engine coolant temperature Possible white smoke. Fan Check cable harness between D7940
sensor circuit 1. High will stay ON if controlled control unit and component.
signal voltage or open circuit by the D7940. No engine
detected in the engine coolant protection for the engine Check the sensor.
temperature circuit. coolant temperature.
110 4 145 Engine coolant temperature Possible white smoke. Fan Check cable harness between D7940
sensor circuit 1. Low signal will stay ON if controlled control unit and component.
voltage detected in the engine by the D7940. No engine
coolant temperature circuit. protection for the engine Check the sensor.
coolant temperature.
VDU01.01GB
110 14 1847 Engine coolant temperature. The engine is switched off. Check cable harness between D7940
control unit and component.
D:67
Check the sensor.
VDU01.01GB
D:68

code and menu
components
110 16 146 Engine coolant temperature. Progressive power Check the coolant level. D7940
Moderately serious level. The reduction that increases
engine coolant temperature with time after the warning. Check that radiator is clean.
signal indicates that the coolant
temperature is higher than Check if there is air in coolant
the warning limit for engine system.
protection. Check the cap on the expansion
tank.
Check the sensor.
Check the thermostat.
111 1 235 Coolant level. The most Progressive power Check the coolant level; fill if - -

serious level. Low coolant level reduction that increases necessary.
detected. with time after the warning.
If the Engine protection Check the sensor.
shutdown function is
activated, the engine is
switched off for 30 seconds
starts to flash.
111 2 422 Coolant level. The engine is switched off. Check cable harness between - -
Check the sensor.
111 3 195 Coolant level sensor circuit. None on performance. Check cable harness between D7940 -
High signal voltage detected in control unit and component.
the engine coolant level circuit.
Check the sensor.
111 4 196 Coolant level sensor circuit. None on performance. Check cable harness between D7940 -
Low signal voltage detected in control unit and component.
the engine coolant level circuit.
Check the sensor.
111 18 197 Coolant level. The most Progressive power Check the coolant level; fill if - -
serious level. Low coolant level reduction that increases necessary.
detected. with time after the warning.
If the Engine protection Check the sensor.
shutdown function is
activated, the engine is
switched off for 30 seconds
starts to flash.

code and menu
components
157 0 449 Injector measurement, pressure No noise or possible noise - D7940 -
channel number. Moderately from the engine associated
1911 severe level. D7940 has with higher injection
detected that the fuel pressure pressure (particularly while
in the fuel rail is higher than the idling or with a high load).
requested pressure. Engine power decreases.
157 1 2249 Injector measurement, pressure No noise or possible noise - D7940 -
channel number 1. The most from the engine associated
severe level. D7940 has with higher injection
in the fuel rail is higher than the idling or with a high load).
requested pressure. Engine power decreases.
- -

157 2 554 Injector measurement, pressure D7940 will estimate fuel D7940
number 1. D7940 has detected pressure, and power is
that the fuel pressure signal has reduced.
not changed.
157 3 451 Injector measurement, channel Power and/or speed - D7940 -
number 1, pressure sensor reduction.
circuit. High signal voltage
detected in the fuel rail fuel
pressure sensor circuit.
157 4 452 Injector measurement, channel Power and/or speed - D7940 -
number 1, pressure sensor reduction.
circuit. Low signal voltage
detected in the fuel rail fuel
pressure sensor circuit.
157 16 553 Injector measurement, channel No noise or possible noise - D7940 -
number 1, pressure. Moderately from the engine associated
severe level. D7940 has with higher injection
is higher than the requested idling or with a high load).
pressure. Engine power decreases.
166 2 951 Imbalance between cylinders. Possible low power or Check cylinders and valves. - -
rough running or misfiring.
168 16 442 Voltage battery 1. Moderately Possible electrical damage Check the fuses. Check D7940 -
VDU01.01GB
serious level. Voltage feed to to all electrical components. batteries and alternator.
D7940 is higher than the highest
D:69
system voltage level.
VDU01.01GB
D:70

code and menu
components
168 18 441 Voltage battery 1. Moderately Engine may stop running Check the fuses. Check D7940 -
serious level. Voltage feed to or be difficult to start. batteries and alternator.
D7940 is lower than the lowest
system voltage level.
173 0 2737 Exhaust temperature sensor. - Check the sensor. - -
173 16 248 Exhaust temperature sensor. - Check the sensor. - -
175 0 214 High engine oil temperature. Power and/or speed Check the oil level in the engine.
reduction.
Check the coolant level and
engine temperature.
Check that no leakage occurs.

Check the sensor.
175 3 212 Sensor, oil temperature. No limitation. Check the cable harness
component.
Check the sensor.
175 4 213 Sensor, oil temperature. No limitation. Check the cable harness
component.
Check the sensor.
175 16 421 High engine oil temperature. The engine is switched off. Check the oil level in the engine.
Check the coolant level and
engine temperature.
Check that no leakage occurs.
Check the sensor.
190 0 234 Engine crankshaft Fuel injection disabled until Ease off the throttle or select - -
speed/position. The most engine speed fails below higher gear.
serious level. Engine speed the overspeed limit.
signal indicates engine speed
above engine protection limit.

code and menu
components
190 2 689 Engine's crankshaft The engine may misfire Check cable harness between D7940 -
speed/position. Engine speed when steering switches control unit and component.
2321 sensor at the crankshaft from the primary to the
unevenly synchronised. backup speed sensor. The Check the sensor.
engine power derates while
the engine is driven with
the backup speed sensor.
190 16 1992 Engine crankshaft Fuel injection disabled until Check cable harness between - -
speed/position. Moderately engine speed fails below control unit and component.
serious level. Engine speed the overspeed limit.
signal indicates engine speed Check the sensor.
above engine protection limit.

441 3 293 Auxiliary temperature sensor None on performance. Check cable harness between D7940
input signal 1. High signal control unit and component.
voltage or open circuit detected
in the OEM auxiliary temperature Check the sensor.
circuit.
441 4 294 Auxiliary temperature sensor None on performance. Check cable harness between D7940 -
input signal 1. Low signal control unit and component.
voltage detected in the OEM
auxiliary temperature circuit. Check the sensor.
441 14 292 Ambient temperature 1. Possibly reduced engine - -

power.
611 4 238 Voltage feed no. 3, sensor. - Check cable harness between - -
Check component.
611 16 2292 Measuring device fuel inlet. Engine may be difficult Check additional error codes - -
Moderately serious level. to start. Engine power is related to the fuel system.
reduced.
Check the fuel system's
components.
611 18 2293 Fuel injection unit. Moderately The engine has lower Check the fuel injection unit. - -
serious level. power output.
611 31 757 Control unit engine (D7940). Engine may be difficult to Check cable harness between - -
VDU01.01GB
start. control unit and component.
D:71
Check component.
VDU01.01GB
D:72

code and menu
components
612 2 115 Engine magnetic crankshaft The fuel to the injectors Check cable harness between D7940 -
speed/position sensor has lost is shut-off and the engine control unit and component.
425 both of two signals. D7940 has cannot be started.
detected that the primary engine Check component.
speed sensor and the backup
engine speed sensor signals are
reversed.
627 2 1117 No power supply with the ignition Possibly no noticeable Check the fuses. Check D7940 -
on. Supply voltage to D7940 fell performance impact, or the batteries and alternator.
below 6.2 VDC momentarily, or engine stops or is difficult to
D7940 was not allowed to power start. Incorrect information,
down correctly (retain battery release information and
voltage for 30 seconds after key maintenance monitoring

OFF). data may be incorrect.
627 12 351 Voltage feed to injectors. D7940 Possible smoke, low power Check the fuses. Check D7940 -
measured that injector boost output, engine misfiring, batteries and alternator.
voltage is low. and/or engine will not start.
629 12 111 Engine control unit. Error Engine might not start. Check the control unit. D7940 -
internally in D7940 related to
1597 memory hardware failures or
internal D7940 voltage feed
circuits.
630 12 3697 Engine control unit memory Engine may not be able to Check the control unit. D7940 -
error. start.
633 31 2311 Fuelling Actuator Number 1 Possible low power. - D7940 -
Circuit Error Conditions Exist.
Fuel pump actuator circuit
resistance too high or too low.
639 2 426 SAE J1939. Link error between One or more multiplexed Use diagnostic menu to find - -
Control unit engine (D7940) and units not working correctly. incorrect segment.
other units in SAE J1939. One or more symptoms
may occur.
639 9 285 Timeout error for SAE J1939 One or more multiplexed Use diagnostic menu to find - -
multiplexer-PNG: Abnormal units not working correctly. incorrect segment.
update rate. Cummins D7940 One or more symptoms
did not receive a multiplexed may occur.
message from an OEM-VECU
by the time limit or not at all.

code and menu
components
639 13 286 SAE J1939 Multiplexing At least one multiplexed Use diagnostic menu to find - -
Configuration Error - Out of devices will not operate incorrect segment.
Calibration. D7940 expected properly.
information from a multiplexed
device but only received
a portion of the necessary
information.
644 2 237 Input signal from external speed Primary or secondary Check cable harness between - -
request (synchronisation of motors may be shut down. control unit and component.
several units). The accelerator
control's input signal to the Check component.
primary or secondary motor
for synchronisation of multiple

devices is less than 3 percent or
greater than 97 percent.
651 5 322 Injector Solenoid Driver Cylinder The engine may misfire or Check cable harness between D7940 -
1 Circuit. High resistance or no run rough. control unit and component.
current detected at Number 1
injector DRIVER or RETURN Check the injector.
pin.
651 7 1139 Injector Solenoid Driver Cylinder The engine is switched off. Check cable harness between D7940 -
1 Circuit. Accidental fuel supply control unit and component.
detected in cylinder no. 1.
Check the injector.
pin.
Check the injector.
VDU01.01GB

pin.
D:73
VDU01.01GB
D:74

code and menu
components
Check the injector.
pin.

Check the injector.

pin.
Check the injector.
pin.
Check the injector.
697 3 2557 Auxiliary PWM drive no. 1. High Cannot control - D7940 -
signal voltage detected in the transmission.
analogue torque circuit.
697 4 2558 Auxiliary PWM drive no. 1. Low Cannot control - D7940 -
signal voltage detected in the transmission.
analogue torque circuit.

code and menu
components
723 2 778 Engine's spare crankshaft Possible low power. Check cable harness between D7940 -
speed/position sensor no. control unit and component.
2322 2. Engine speed sensor
at the crankshaft unevenly Check the sensor.
synchronised.
723 2 1376 Error in the engine speed sensor Possibly difficult to start. Check cable harness between D7940 -
(camshaft). D7940 has detected Engine power decreases. control unit and component.
an error in the camshaft position
sensor signal. Check the sensor.
723 7 731 Engine speed/position sensor Engine runs at low power Check cable harness between D7940 -
camshaft and crankshaft, output. Abnormal smoke, control unit and component.
misaligned. Mechanical difficult to start and erratic

Check the sensor.

misalignment between the idling can occur.
crankshaft and camshaft speed
sensors.
974 3 133 Circuit for remote accelerator Remote accelerator pedal Check cable harness between D7940 -
pedal or lever position sensor 1. not working. Remote control unit and component.
High voltage detected in remote accelerator pedal position
accelerator pedal position set to zero percent. Check component.
circuit.
974 4 134 Circuit for remote accelerator Remote accelerator pedal Check cable harness between D7940 -
pedal or lever position sensor 1. not working. Remote control unit and component.
Low voltage detected in remote accelerator pedal position
accelerator pedal position set to zero percent. Check component.
signal.
1075 3 2265 Electric lift pump for the engine's The engine may be difficult Check cable harness between D7940 -
fuel feed circuit. High signal to start. control unit and component.
voltage or open circuit detected
in the fuel lift pump's signal Check component.
circuit.
1075 4 2266 Electric lift pump for the engine's The engine may be difficult Check cable harness between D7940 -
fuel feed circuit. Low signal to start. control unit and component.
voltage detected in fuel lift pump
circuit. Check component.
1079 3 386 Voltage feed no. 1, sensor. The engine may be difficult Check cable harness between - -
VDU01.01GB
to start. control unit and component.

Check Control unit, engine
D:75
(D7940).
VDU01.01GB
D:76

code and menu
components
1079 4 352 Voltage feed no. 1, sensor. The engine may be difficult Check cable harness between - -
to start. control unit and component.
(D7940).
1080 3 227 Voltage feed no. 2, sensor Engine power decreases. Check cable harness between - -
circuit. control unit and component.
(D7940).

(D7940).
1172 3 691 Intake temperature sensor Engine power decreases. - D7940 -
circuit for compressor
turbocharger no 1. High signal
voltage detected at the intake
air temperature sensor circuit of
the turbocharger compressor.
1172 4 1172 Intake temperature sensor Engine power decreases. - D7940 -
circuit for compressor
turbocharger no 1. Low signal
voltage detected at the intake
air temperature sensor circuit of
the turbocharger compressor.
1347 3 272 Circuit for fuel high pressure Engine runs badly and with - D7940 -
solenoid valve. Electronic fuel derated power. Fuel rail
control actuator short-circuited pressure becomes higher
high. than requested.
1347 4 271 Circuit for fuel high pressure The engine runs poorly - D7940 -
solenoid valve. Electronic fuel when idling and has low
control actuator short-circuited power. Fuel pressure
low. becomes higher than
requested.
1347 7 281 Fuel pump element no. 1 (front). Engine will not run or - D7940 -
possible low power.
1388 14 296a Circuit for auxiliary pressure Possibly reduced engine - -
sensor. power.

code and menu
components
Check ECM.
3511 3 239 Voltage feed no. 3, sensor Possibly difficult to start the Check cable harness between - -
circuit. engine and rough running. control unit and component.
Check component.
3512 3 2185 Voltage feed no. 4, sensor Engine only running at idle. Check cable harness between - -
Check component.
- -

3512 4 2186 Voltage feed no. 4, sensor Engine only running at idle. Check cable harness between
Check component.
3513 3 1695 Voltage feed no. 5, sensor. Major decrease in engine Check cable harness between - -
power. Only emergency control unit and component.
operation possible.
Check component.
3513 4 1696 Voltage feed no. 5, sensor. Engine power decreases. Check cable harness between - -
Check component.
Check component.
Check component.
3938 3 1978 Speed/load. - Check cable harness between - -
Check component.
VDU01.01GB
3938 4 1979 Speed/load. - Check cable harness between - -

D:77
Check component.
VDU01.01GB
D:78

code and menu
components
4182 3 1411 Frequency potentiometer. - Check cable harness between - -
Check component.
4182 4 3695 Frequency potentiometer. - Check cable harness between - -
Check component.
4183 3 1412 Potentiometer (Droop Adjust - Check cable harness between - -
Potentiometer). control unit and component.
Check component.
- - -

4183 4 3696 Potentiometer (Droop Adjust Check cable harness between
Potentiometer). control unit and component.
Check component.
5571 0 3741 Common rail relief valve. Most Engine coughing / stops / Check if: - -
serious level. does not start / difficult to
• there is a blockage in the
start.
high-pressure drain pipe.
• the fuel pump is leaking or
the actuator is sodden.
• there is air in the fuel.
• the assembly adapter on
the fuel pump's actuator is
clogged.
5571 7 3727 Common rail relief valve. Reduced performance. Low fuel pressure. - -
D Error codes – Transmission :79
D.2 Transmission
Error codes transmission
Error codes for the transmission are sorted in numerical order. The
table contains the following information:
page D:8.
• Supplier code 2 - Specifies the error code in accordance with the
supplier's specification in alternative format.
in question.
In the event of serious faults in the transmission, the control unit

uses four conditions with reduced functionality in order to protect the
transmission from damage. These are:
• "Substitute clutch control"
In this mode the operator can use the machine as usual. However,
gear shifting and change of direction do not take place under the
control of normal modulation. The control unit uses the default
values for the modulation of the clutches.
• "Limp home"
In this mode, the operator can use one of the transmission gears
in each direction, and in some cases only in one direction. To
continue to drive in the event of a fault with the "Limp home"
restriction, the machine must be stopped to a standstill and the gear
selector moved to neutral before the gear can be selected again.
• "Transmission shut down"
In this mode, the transmission is permanently in neutral position as
the solenoid valves for the clutches and parts of the power supply
to the transmission are shut off. Park the machine and switch off
the engine.

VDU01.01GB
D:80
Table Error codes transmission Dana TE14000
SPN FMI Supplier Supplier Description Limitation Action Connections Diagnostic

code code 2 and menu
components
520304 0 0A.00 520304/0 Pressure sensor clutch Transmission in Check the clutch pressure in D7930/A9 - 2.8 Control
forward (B7653), pressure locked neutral position neutral position at idle. B7653/A System 22/XX
too high. (Shutdown). DIAGNOSE,
Check the clutch pressure page 8:33
with gear selected at idle.
520304 1 0A.01 520304/1 Pressure sensor clutch Transmission in Check the transmission oil D7930/A9 - 2.8 Control
forward (B7653), pressure locked neutral position level. B7653/A System 22/XX
too low. (Shutdown). DIAGNOSE,
Check the clutch pressure in page 8:33
neutral position at idle.
Check the clutch pressure
520304 3 0A.03 520304/3 Pressure sensor clutch Transmission in Check the cable harness D7930/A9 - 2.8 Control
forward (B7653), open circuit locked neutral position between Control unit, B7653/A System 22/XX
or short circuit to voltage. (Shutdown). transmission (7930) and DIAGNOSE,
the sensor. page 8:33
Check the sensor.
forward (B7653), short circuit locked neutral position between Control unit, B7653/A System 22/XX
to ground. (Shutdown). transmission (7930) and DIAGNOSE,
Check the sensor.
forward (B7653), signal error locked neutral position between machine and B7653/A System 22/XX
CAN bus drive-train. (Shutdown). Control unit transmission DIAGNOSE,
(D7930). page 8:33
forward (B7653), signal error locked neutral position between machine and B7653/A System 22/XX
CAN bus drive-train. (Shutdown). Control unit transmission DIAGNOSE,
(D7930). page 8:33
520305 0 0B.00 520305/0 Pressure sensor clutch Transmission in Check the clutch pressure in D7930/B5 - 2.8 Control
backward (B7654), pressure locked neutral position neutral position at idle. B7654/A System 22/XX
Table Error codes transmission Dana TE14000 (continued)

components
520305 1 0B.01 520305/1 Pressure sensor clutch Transmission in Check the transmission oil D7930/B5 - 2.8 Control
backward (B7654), pressure locked neutral position level. B7654/A System 22/XX
520305 3 0B.03 520305/3 Pressure sensor clutch Transmission in Check the cable harness D7930/B5 - 2.8 Control
backward (B7654), open locked neutral position between Control unit, B7654/A System 22/XX
circuit or short circuit to (Shutdown). transmission (7930) and DIAGNOSE,
voltage. the sensor. page 8:33
D Error codes – Transmission

Check the sensor.
backward (B7654), short locked neutral position between Control unit, B7654/A System 22/XX
circuit to ground. (Shutdown). transmission (7930) and DIAGNOSE,
Check the sensor.
backward (B7654), signal locked neutral position between machine and B7654/A System 22/XX
error CAN bus drive-train. (Shutdown). Control unit transmission DIAGNOSE,
(D7930). page 8:33
backward (B7654), signal locked neutral position between machine and B7654/A System 22/XX
error CAN bus drive-train. (Shutdown). Control unit transmission DIAGNOSE,
(D7930). page 8:33
520306 0 0C.00 520306/0 Input signal clutch pressure Transmission in Check the clutch pressure in - -
high gear, pressure too high. locked neutral position neutral position at idle.
(Shutdown).
520306 1 0C.01 520306/1 Input signal clutch pressure Transmission in Check the transmission oil - -
high gear, pressure too low. locked neutral position level.
(Shutdown).
Check the clutch pressure in
VDU01.01GB
D:81
VDU01.01GB
D:82

components
520306 3 0C.03 520306/3 Input signal clutch pressure Transmission in Check the cable harness - -
high gear, open circuit or locked neutral position between Control unit,
short circuit to voltage. (Shutdown). transmission (7930) and
the sensor.
Check the sensor.
high gear, short circuit to locked neutral position between Control unit,
ground. (Shutdown). transmission (7930) and
the sensor.
Check the sensor.

high gear, signal error CAN locked neutral position between machine and
bus drive-train. (Shutdown). Control unit transmission
(D7930).
high gear, signal error CAN locked neutral position between machine and
bus drive-train. (Shutdown). Control unit transmission
(D7930).
520307 0 0D.00 520307/0 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/A11 - 2.8 Control
1/3 (B7651), pressure too locked neutral position neutral position at idle. B7651/A System 22/XX
high. (Shutdown). DIAGNOSE,
520307 1 0D.01 520307/1 Pressure sensor clutch gear Transmission in Check the transmission oil D7930/A11 - 2.8 Control
1/3 (B7651), pressure too locked neutral position level. B7651/A System 22/XX
low. (Shutdown). DIAGNOSE,

components
520307 3 0D.03 520307/3 Pressure sensor clutch gear Transmission in Check the cable harness D7930/A11 - 2.8 Control
1/3 (B7651), open circuit or locked neutral position between Control unit, B7651/A System 19/XX
short circuit to voltage. (Shutdown). transmission (7930) and DIAGNOSE,
Check the sensor. 2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
1/3 (B7651), short circuit to locked neutral position between Control unit, B7651/A System 19/XX
ground. (Shutdown). transmission (7930) and DIAGNOSE,

System 22/XX
DIAGNOSE,
page 8:33
1/3 (B7651), signal error CAN locked neutral position between machine and B7651/A System 19/XX
bus drive-train. (Shutdown). Control unit transmission DIAGNOSE,
(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
520308 0 0E.00 520308/0 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/B3 - 2.8 Control
VDU01.01GB

D:83
VDU01.01GB
D:84

components
520308 1 0E.01 520308/1 Pressure sensor clutch gear Transmission in Check the transmission oil D7930/B3 - 2.8 Control
520308 3 0E.03 520308/3 Pressure sensor clutch gear Transmission in Check the cable harness D7930/B3 - 2.8 Control


System 22/XX
DIAGNOSE,
page 8:33
System 22/XX
DIAGNOSE,
page 8:33
(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33

components
(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
520309 0 0F.00 520309/0 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/A11 - 2.8 Control

520309 1 0F.01 520309/1 Pressure sensor clutch gear Transmission in Check the transmission oil D7930/A11 - 2.8 Control
520309 3 0F.03 520309/3 Pressure sensor clutch gear Transmission in Check the cable harness D7930/A11 - 2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
System 22/XX
VDU01.01GB
DIAGNOSE,
page 8:33
D:85
VDU01.01GB
D:86

components
(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33

(D7930). page 8:32

2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
520310 0 10.00 520310/0 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/B3 - 2.8 Control
520310 1 10.01 520310/1 Pressure sensor clutch gear Transmission in Check the transmission oil D7930/B3 - 2.8 Control
520310 3 10.03 520310/3 Pressure sensor clutch gear Transmission in Check the cable harness D7930/B3 - 2.8 Control
System 22/XX
DIAGNOSE,
page 8:33

components
System 22/XX
DIAGNOSE,
page 8:33

(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
(D7930). page 8:32
2.8 Control
System 22/XX
DIAGNOSE,
page 8:33
520297 0 15.00 520297/0 Pressure sensor clutch Transmission in Check the clutch pressure in D7930/A9 - 2.8 Control
520297 1 15.01 520297/1 Pressure sensor clutch Transmission in Check the transmission oil D7930/A9 - 2.8 Control
VDU01.01GB

D:87
VDU01.01GB
D:88

components
520297 3 15.03 520297/3 Pressure sensor clutch Transmission in Check the cable harness D7930/A9 - 2.8 Control
forward (B7653), open circuit locked neutral position between Control unit, B7653/A System 19/XX
or short circuit to voltage. (Shutdown). transmission (7930) and DIAGNOSE,
System 22/XX
DIAGNOSE,
page 8:33
520297 4 15.04 520297/4 Pressure sensor clutch Transmission in Check the cable harness D7930/A9 - 2.8 Control
forward (B7653), short circuit locked neutral position between Control unit, B7653/A System 19/XX
to ground. (Shutdown). transmission (7930) and DIAGNOSE,


System 22/XX
DIAGNOSE,
page 8:33
520297 15 15.0F 520297/15 Pressure sensor clutch Transmission in Check the clutch pressure in D7930/A9 - 2.8 Control
above normal. (Shutdown). DIAGNOSE,
520297 17 15.11 520297/17 Pressure sensor clutch Transmission in Check the transmission oil D7930/A9 - 2.8 Control
below normal. (Shutdown). DIAGNOSE,
520298 0 16.00 520298/0 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/A11 - 2.8 Control

components
520298 1 16.01 520298/1 Pressure sensor clutch gear Transmission in Check the transmission oil D7930/A11 - 2.8 Control
520298 3 16.03 520298/3 Pressure sensor clutch gear Transmission in Check the cable harness D7930/A11 - 2.8 Control

Check the sensor.
520298 4 16.04 520298/4 Pressure sensor clutch gear Transmission in Check the cable harness D7930/A11 - 2.8 Control
Check the sensor.
520298 15 16.0F 520298/15 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/A11 - 2.8 Control
1/3 (B7651), pressure above locked neutral position neutral position at idle. B7651/A System 22/XX
normal. (Shutdown). DIAGNOSE,
520298 17 16.11 520298/17 Pressure sensor clutch gear Transmission in Check the transmission oil D7930/A11 - 2.8 Control
1/3 (B7651), pressure below locked neutral position level. B7651/A System 22/XX
520299 0 17.00 520299/0 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/B3 - 2.8 Control
VDU01.01GB
D:89
VDU01.01GB
D:90

components

Check the sensor.

Check the sensor.
520299 15 17.0F 520299/15 Pressure sensor clutch gear Transmission in Check the clutch pressure in D7930/B3 - 2.8 Control
2/4 (B7652), pressure above locked neutral position neutral position at idle. B7652/A System 22/XX
2/4 (B7652), pressure below locked neutral position level. B7652/A System 22/XX
520300 0 18.00 520300/0 Pressure sensor clutch Transmission in Check the clutch pressure in D7930/B5 - 2.8 Control

components
520300 1 18.01 520300/1 Pressure sensor clutch Transmission in Check the transmission oil D7930/B5 - 2.8 Control
520300 3 18.03 520300/3 Pressure sensor clutch Transmission in Check the cable harness D7930/B5 - 2.8 Control
backward (B7654), open locked neutral position between Control unit, B7654/A System 22/XX
circuit or short circuit to (Shutdown). transmission (7930) and DIAGNOSE,
voltage. the sensor. page 8:33

Check the sensor.
520300 4 18.04 520300/4 Pressure sensor clutch Transmission in Check the cable harness D7930/B5 - 2.8 Control
backward (B7654), short locked neutral position between Control unit, B7654/A System 22/XX
circuit to ground. (Shutdown). transmission (7930) and DIAGNOSE,
Check the sensor.
520300 15 18.0F 520300/15 Pressure sensor clutch Transmission in Check the clutch pressure in D7930/B5 - 2.8 Control
above normal. (Shutdown). DIAGNOSE,
520300 17 18.11 520300/17 Pressure sensor clutch Transmission in Check the transmission oil D7930/B5 - 2.8 Control
below normal. (Shutdown). DIAGNOSE,
520301 0 19.00 520301/0 Analogue input signal B4, No limitation. Check the cable harness - -
value too high. between Control unit,
transmission (D7930) and
transmission.
VDU01.01GB
value too low. between Control unit,
D:91
transmission.
VDU01.01GB
D:92

components
short circuit to voltage. between Control unit,
transmission.
short circuit to ground. between Control unit,
transmission.
520301 15 19.0F 520301/15 Analogue input signal B4, No limitation. Check the cable harness - -
above normal value. between Control unit,

transmission.
below normal value. between Control unit,
transmission.
520368 0 1E.00 520368/0 Voltage feed to Control unit Transmission locked Checks that start assistance D7930/A2 2.8 Control
transmission (D7930) above (Recovery mode). is not engaged. System 20/XX
32 V. D7930/A4 DIAGNOSE,
Check the alternator and page 8:32
battery charging. D7930/A7
Check the cable harness D7930/A13 -

between machine and D7971/1:49
Control unit transmission
(D7930). D7930/B7
D7930/B9
520368 1 1E.01 520368/1 Voltage feed to Control unit Transmission locked Check the alternator and D7930/A2 2.8 Control
transmission (D7930) below (Recovery mode). battery charging. System 20/XX
10 V. D7930/A4 DIAGNOSE,
Check the cable harness page 8:32
between machine and D7930/A7
(D7930). D7930/A13 -
D7971/1:49
D7930/B7
D7930/B9

components
520368 15 1E.0F 520368/15 Voltage feed to Control unit No limitation. Checks that start assistance D7930/A2 2.8 Control
transmission (D7930) above is not engaged. System 20/XX
normal level. D7930/A4 DIAGNOSE,
Check the alternator and page 8:32
battery charging. D7930/A7
Check the cable harness D7930/A13 -

between machine and D7971/1:49
(D7930). D7930/B7
D7930/B9
520368 17 1E.11 520368/17 Voltage feed to Control unit No limitation. Check the alternator and D7930/A2 2.8 Control

transmission (D7930) below battery charging. System 20/XX
normal level. D7930/A4 DIAGNOSE,
(D7930). D7930/A13 -
D7971/1:49
D7930/B7
D7930/B9
520368 31 1E.1F 520368/31 Voltage feed to Control unit, Transmission locked Check the alternator and D7930/A2 2.8 Control
transmission (D7930). to gear 1 and 2 battery charging. System 20/XX
(Limp-home). D7930/A4 DIAGNOSE,
(D7930). D7930/A13 -
D7971/1:49
D7930/B7
D7930/B9
520369 0 1F.00 520369/0 Reference voltage to sensor, Transmission locked Check Control unit, D7930/B10 2.8 Control
above 8.8 V. to gear 1 and 2 transmission (D7930). System 20/XX
(Limp-home). DIAGNOSE,
page 8:32
VDU01.01GB
520369 1 1F.01 520369/1 Reference voltage to sensor, Transmission locked Check Control unit, D7930/B10 2.8 Control
below 7.2 V. to gear 1 and 2 transmission (D7930). System 20/XX
D:93
(Limp-home). DIAGNOSE,
page 8:32
VDU01.01GB
D:94

components
520340 9 26.09 520340/9 Message error for 4WD/2WD No limitation. Check the cable harness D7930/B1 - 2.8 Control
selector on CAN bus between machine and D7971/1:31 System 11/XX
drive-train. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520340 15 26.0F 520340/15 Message error for 4WD/2WD No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32


(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
520342 0 27.00 520342/0 Message error high/low No limitation. Check the cable harness D7930/B1 - 2.8 Control
drivetrain. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32

components
520342 15 27.0F 520342/15 Message error high/low No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32

(D7930). D7930/B2 - page 8:31
D7971/1:32
520286 2 28.02 520286/2 Message error for travel Transmission in Check the cable harness D7930/B1 - 2.8 Control
direction on CAN bus locked neutral position between machine and D7971/1:31 System 11/XX
drivetrain. (Shutdown). Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB

(D7930). D7930/B2 - page 8:31
D:95
D7971/1:32
VDU01.01GB
D:96

components
(D7930). D7930/B2 - page 8:31
D7971/1:32
520320 0 2A.00 520320/0 Actual gear ratio too high. Transmission in Check the oil level. - 2.8 Control
One or more clutches are locked neutral position System 22/XX
slipping. (Shutdown). Check the system pressure in DIAGNOSE,
the transmission. page 8:33
on all clutches with different

gears selected.
Stall speed is checked.
Check the speed sensors.
520320 1 2A.01 520320/1 Actual gear ratio too high. Transmission in Check the oil level. - 2.8 Control
One or more clutches are locked neutral position System 22/XX
slipping. (Shutdown). Check the system pressure in DIAGNOSE,
the transmission. page 8:33
on all clutches with different
gears selected.
Stall speed is checked.
Check the speed sensors.
520325 0 2B.00 520325/0 Sensor, temperature The engine speed is Check the transmission oil - 2.8 Control
torque converter (B7661), limited to 1500 rpm. cooler. System 23/XX
temperature too high. DIAGNOSE,
Check the function of the page 8:33
cooling fan.
520325 3 2B.03 520325/3 Sensor, temperature torque No limitation. Check the cable harness D7930/B32 - 2.8 Control
converter (B7661), short between Control unit, B7661/1 System 23/XX
circuit to voltage. transmission (7930) and DIAGNOSE,
the sensor page 8:33
Check the sensor.
Check other error codes for
the sensor.

components
converter (B7661), open between Control unit, B7661/1 System 23/XX
circuit or short circuit to transmission (7930) and DIAGNOSE,
ground. the sensor page 8:33
Check the sensor.
the sensor.
520325 15 2B.0F 520325/15 Sensor, temperature torque No limitation. Check all temperature D7930/B32 - 2.8 Control
converter (B7661), above sensors. B7661/1 System 23/XX
normal level. DIAGNOSE,

page 8:33
converter (B7661), below between Control unit, B7661/1 System 23/XX
normal level. transmission (7930) and DIAGNOSE,
Check the sensor.
520321 0 2C.00 520321/0 Input signal from accelerator No limitation. Check the cable harness - -
pedal, signal voltage too high. between machine and
(D7930).
pedal, signal voltage too low. between machine and
(D7930).
520321 3 2C.03 520321/3 Input signal from accelerator Engine speed is limited Check the cable harness - -
pedal, short circuit to voltage. to idle. No gear changing between machine and
possible. Control unit transmission
(D7930).
No limitation.
520321 4 2C.04 520321/4 Input signal from accelerator Engine speed is limited Check the cable harness - -
pedal, open circuit or short to idle. No gear changing between machine and
circuit to ground. possible. Control unit transmission
(D7930).
VDU01.01GB
520321 9 2C.09 520321/9 Message error for accelerator Engine speed is limited Check the cable harness D7930/B1 - 2.8 Control
pedal on CAN bus drivetrain. to idle. No gear changing between machine and D7971/1:31 System 10/XX
D:97
possible. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
D:98

components
520321 15 2C.0F 520321/15 Input signal from accelerator No limitation. Check the cable harness - -
pedal, value error. between machine and
(D7930).
pedal, above normal level. between machine and
(D7930).
pedal, below normal level. between machine and

(D7930).
520288 9 2D.09 520288/9 Message error for gear No limitation. Check the cable harness D7930/B1 - 2.8 Control
selection on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520288 19 2D.13 520288/19 Message error for gear No limitation. Check the cable harness D7930/B1 - 2.8 Control
selection on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520313 0 2E.0F 520313/15 Exceeded torque during Transmission Exceeded torque during - -
inching. disengaged. inching.
520315 0 2F.00 520315/0 Max. rotation speed No limitation. Rotation speed exceeded. - -
exceeded, output shaft.
520315 16 2F.10 520315/16 Close to max. rotation speed, No limitation. Rotation speed exceeded. - -
output shaft.
520208 0 32.00 520208/0 Sensor oil temperature sump No limitation. Check the sensor. D7930/A22 - 2.8 Control
(B7660), temperature too B7660/1 System 23/XX
high. Check other error codes for DIAGNOSE,
(B7660), temperature too low. B7660/1 System 23/XX
Check other error codes for DIAGNOSE,

components
520208 3 32.03 520208/3 Sensor oil temperature sump No limitation. Check the cable harness D7930/A22 - 2.8 Control
(B7660), short circuit to between Control unit, B7660/1 System 23/XX
voltage. transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
(B7660), open circuit or short between Control unit, B7660/1 System 23/XX
circuit to ground. transmission (7930) and DIAGNOSE,

Check the sensor.
the sensor.
520209 0 33.00 520209/0 Sensor, oil temperature No limitation. Check the sensor. D7930/B32 - 2.8 Control
torque converter (B7661), B7661/1 System 23/XX
temperature too high. Check other error codes for DIAGNOSE,
520209 1 33.01 520209/1 Sensor, oil temperature No limitation. Check the sensor. D7930/B32 - 2.8 Control
torque converter (B7661), B7661/1 System 23/XX
temperature too low. Check other error codes for DIAGNOSE,
520209 3 33.03 520209/3 Sensor, oil temperature No limitation. Check the cable harness D7930/B32 - 2.8 Control
torque converter (B7661), between Control unit, B7661/1 System 23/XX
short circuit to voltage. transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
VDU01.01GB
D:99
VDU01.01GB
D:100

components
520209 4 33.04 520209/4 Sensor oil temperature torque No limitation. Check the cable harness D7930/B32 - 2.8 Control
converter (B7661), open between Control unit, B7661/1 System 23/XX
circuit or short circuit to transmission (7930) and DIAGNOSE,
ground. the sensor page 8:33
Check the sensor.
the sensor.
520210 0 34.00 520210/0 Analogue input signal C0, No limitation. Check the cable harness - -
value error. between machine and

(D7930).
(D7930).
electrical problem. between machine and
(D7930).
(D7930).
520210 15 34.0F 520210/15 Analogue input signal C0, No limitation. Check the cable harness - -
(D7930).
(D7930).
(D7930).

components
(D7930).
(D7930).

(D7930).
(D7930).
(D7930).
(D7930).
(D7930).
(D7930).
VDU01.01GB

(D7930).
D:101
VDU01.01GB
D:102

components
(D7930).
(D7930).

(D7930).
(D7930).
(D7930).
(D7930).
(D7930).
(D7930).
(D7930).

components
(D7930).
(D7930).

(D7930).
(D7930).
(D7930).
520218 0 3C.00 520218/0 Sensor, drum rpm (B7520), No limitation. Check the transmission with D7930/A3 - 2.8 Control
rotation speed too high. regard to slipping clutches. B7520/1 System 10/XX
DIAGNOSE,
page 8:31
DIAGNOSE,
page 8:31
rotation speed too low. regard to slipping clutches. B7520/1 System 10/XX
DIAGNOSE,
page 8:31
VDU01.01GB
DIAGNOSE,
page 8:31
D:103
VDU01.01GB
D:104

components
520218 5 3C.05 520218/5 Sensor rpm drum (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control
short circuit to voltage between Control unit, B7520/1 System 10/XX
transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
520218 5 3C.05 520218/5 Sensor rpm drum (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control


Check the sensor.
the sensor.
520218 6 3C.06 520218/6 Sensor, drum rpm (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control
open circuit or short circuit to between Control unit, B7520/1 System 10/XX
ground. transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
520218 6 3C.06 520218/6 Sensor, drum rpm (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control
Check the sensor.
the sensor.
520219 0 3D.00 520219/0 Sensor rpm output shaft No limitation. Check the transmission with D7930/A6 - 2.8 Control
(B7580), rotation speed too regard to slipping clutches. B7580/1 System 10/XX
high. DIAGNOSE,
page 8:31

components
high. DIAGNOSE,
page 8:31
low. DIAGNOSE,
page 8:31
low. DIAGNOSE,

page 8:31
520219 5 3D.05 520219/5 Sensor rpm output shaft, No limitation. Check the cable harness D7930/A6 - 2.8 Control
voltage transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
Check the sensor.
the sensor.
Check the sensor.
VDU01.01GB
the sensor.
D:105
VDU01.01GB
D:106

components
Check the sensor.
the sensor.
520220 0 3E.00 520220/0 Sensor engine speed No limitation. Check the transmission with D7930/B27 - 2.8 Control
(B7530), rotation speed regard to slipping clutches. B7530/1 System 10/XX
too high. DIAGNOSE,

page 8:31
520220 1 3E.01 520220/1 Sensor engine speed No limitation. Check the transmission with D7930/B27 - 2.8 Control
(B7530), rotation speed regard to slipping clutches. B7530/1 System 10/XX
too low. DIAGNOSE,
page 8:31
520220 5 3E.05 520220/5 Sensor engine speed No limitation. Check the cable harness D7930/B27 - 2.8 Control
Check the sensor.
the sensor.
520220 6 3E.06 520220/6 Sensor engine speed No limitation. Check the cable harness D7930/B27 - 2.8 Control
(B7530), open circuit or between Control unit, B7530/1 System 10/XX
short circuit to ground. transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
520221 0 3F.00 520221/0 Sensor rpm turbine (B7510), No limitation. Check the transmission with D7930/B29 - 2.8 Control
DIAGNOSE,
page 8:31

components
DIAGNOSE,
page 8:31
DIAGNOSE,
page 8:31
DIAGNOSE,

page 8:31
520221 5 3F.05 520221/5 Sensor rpm turbine (B7510), No limitation. Check the cable harness D7930/B29 - 2.8 Control
Check the sensor.
the sensor.
Check the sensor.
the sensor.
Check the sensor.
VDU01.01GB
the sensor.
D:107
VDU01.01GB
D:108

components
Check the sensor.
the sensor.
520316 0 41.00 520316/0 Sensor engine speed Transmission locked Check the sensor. D7930/B27 - 2.8 Control
(B7530), rotation speed to gear 1 and 2 B7530/1 System 10/XX
too high. (Limp-home). DIAGNOSE,

page 8:31
520316 1 41.01 520316/1 Sensor engine speed Transmission locked Check the cable harness D7930/B27 - 2.8 Control
(B7530), rotation speed to gear 1 and 2 between Control unit, B7530/1 System 10/XX
too low. (Limp-home). transmission (7930) and DIAGNOSE,
Check the sensor.
(B7530), short circuit to to gear 1 and 2 between Control unit, B7530/1 System 10/XX
voltage (Limp-home). transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
(B7530), open circuit or to gear 1 and 2 between Control unit, B7530/1 System 10/XX
short circuit to ground. (Limp-home). transmission (7930) and DIAGNOSE,
Check the sensor.
the sensor.
520316 9 41.09 520316/9 Message error for engine Transmission locked Check the cable harness D7930/B1 - 2.8 Control
speed on CAN bus drivetrain. to gear 1 and 2 between machine and D7971/1:31 System 10/XX
(Limp-home). Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32

components
520316 19 41.13 520316/19 Message error for engine Transmission locked Check the cable harness D7930/B1 - 2.8 Control
speed on CAN bus drivetrain. to gear 1 and 2 between machine and D7971/1:31 System 10/XX
(Limp-home). Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520317 0 42.00 520317/0 Sensor rpm turbine (B7510), No limitation. Check the transmission with D7930/B29 - 2.8 Control
DIAGNOSE,
page 8:31
520317 1 42.01 520317/1 Sensor rpm turbine (B7510), No limitation. Check the transmission with D7930/B29 - 2.8 Control

DIAGNOSE,
page 8:31
520317 5 42.05 520317/5 Sensor rpm turbine (B7510), No limitation. Check the cable harness D7930/B29 - 2.8 Control
Check the sensor.
the sensor.
520317 6 42.06 520317/6 Sensor rpm turbine (B7510), No limitation. Check the cable harness D7930/B29 - 2.8 Control
Check the sensor.
the sensor.
520317 9 42.09 520317/9 Message error for rotation No limitation. Check the cable harness D7930/B1 - 2.8 Control
speed turbine on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
speed turbine on CAN bus between machine and D7971/1:31 System 10/XX
D:109
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
D:110

components
520318 0 43.00 520318/0 Sensor, drum rpm (B7520), No limitation. Check the transmission with D7930/A3 - 2.8 Control
DIAGNOSE,
page 8:31
DIAGNOSE,
page 8:31
520318 5 43.05 520318/5 Sensor rpm drum (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control


Check the sensor.
the sensor.
520318 6 43.06 520318/6 Sensor, drum rpm (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control
Check the sensor.
the sensor.
speed drum on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
speed drum on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520319 0 44.00 520319/0 Sensor rpm output shaft No limitation. Check the transmission with D7930/A6 - 2.8 Control
high. DIAGNOSE,
page 8:31

components
520319 1 44.01 520319/1 Sensor rpm output shaft No limitation. Check the transmission with D7930/A6 - 2.8 Control
low. DIAGNOSE,
page 8:31
520319 5 44.05 520319/5 Sensor rpm output shaft, No limitation. Check the cable harness D7930/A6 - 2.8 Control
Check the sensor.

the sensor.
520319 6 44.06 520319/6 Sensor rpm output shaft, No limitation. Check the cable harness D7930/A6 - 2.8 Control
Check the sensor.
the sensor.
speed output shaft on CAN between machine and D7971/1:31 System 10/XX
bus drivetrain. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
speed output shaft on CAN between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520312 7 45.07 520312/7 Sensor signals for rotation No limitation. Check the lock-up pressure. - -
speed indicate that the
transmission is not in lock-up, Check Servo valve lock-up
but Servo valve lock-up (Y6038).
(Y6038) is activated.
VDU01.01GB
D:111
VDU01.01GB
D:112

components
520224 3 46.03 520224/3 Servo valve drive forward Transmission in Check the cable harness D7930/B22 - 2.8 Control
(Y6300), short circuit to locked neutral position between Control unit, Y6300/1 System 21/XX
voltage (high voltage). (Shutdown). transmission (7930) and DIAGNOSE,
the servo valve. page 8:33
Check the servo valve. 2.8 Control
System 24/XX


System 24/XX
520224 4 46.04 520224/4 Servo valve drive forward Transmission locked Check the cable harness D7930/B22 - 2.8 Control
(Y6300), short circuit to to gear 1 and 2 between Control unit, Y6300/1 System 21/XX
ground (low voltage). (Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX
System 24/XX

components
(Y6300), open circuit (low to gear 1 and 2 between Control unit, Y6300/1 System 21/XX
current). (Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX

System 24/XX
ground (high current). (Shutdown). transmission (7930) and DIAGNOSE,
System 24/XX
System 24/XX
VDU01.01GB
D:113
VDU01.01GB
D:114

components
(Y6300), frequency error to gear 1 and 2 between Control unit, Y6300/1 System 21/XX
PWM control. (Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX


System 24/XX
520225 3 47.03 520225/3 Servo valve gear 1/3 (Y6067), Transmission in Check the cable harness D7930/B18 - 2.8 Control
short circuit to voltage (high locked neutral position between Control unit, Y6067/1 System 21/XX
voltage). (Shutdown). transmission (7930) and DIAGNOSE,
System 24/XX
System 24/XX

components
short circuit to ground (low locked neutral position between Control unit, Y6067/1 System 21/XX
System 24/XX

System 24/XX
open circuit (low current). locked neutral position between Control unit, Y6067/1 System 21/XX
(Shutdown). transmission (7930) and DIAGNOSE,
System 24/XX
System 24/XX
VDU01.01GB
D:115
VDU01.01GB
D:116

components
short circuit to ground (high locked neutral position between Control unit, Y6067/1 System 21/XX
current). (Shutdown). transmission (7930) and DIAGNOSE,
System 24/XX


System 24/XX
520225 8 47.08 520225/8 Servo valve gear 1/3 (Y6067), Transmission locked Check the cable harness D7930/B18 - 2.8 Control
frequency error PWM control. to gear 1 and 2 between Control unit, Y6067/1 System 21/XX
(Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX
System 24/XX

components
System 24/XX

System 24/XX
System 24/XX
System 24/XX
VDU01.01GB
D:117
VDU01.01GB
D:118

components
System 24/XX


System 24/XX
System 24/XX
System 24/XX

components
System 24/XX

System 24/XX
520227 3 49.03 520227/3 Servo valve drive backward Transmission in Check the cable harness D7930/A1 - 2.8 Control
System 24/XX
System 24/XX
VDU01.01GB
D:119
VDU01.01GB
D:120

components
ground (low voltage). (Shutdown). transmission (7930) and DIAGNOSE,
System 24/XX
ground (low voltage). (Shutdown). transmission (7930) and DIAGNOSE,


System 24/XX
(Y6310), open circuit (low locked neutral position between Control unit, Y6310/1 System 21/XX
System 24/XX
(Y6310), open circuit (low locked neutral position between Control unit, Y6310/1 System 21/XX
System 24/XX

components
System 24/XX

System 24/XX
520227 8 49.08 520227/8 Servo valve drive backward Transmission locked Check the cable harness D7930/A1 - 2.8 Control
System 24/XX
520227 8 49.08 520227/8 Servo valve drive backward Transmission locked Check the cable harness D7930/A1 - 2.8 Control
System 24/XX
VDU01.01GB
D:121
VDU01.01GB
D:122

components
520228 3 4A.03 520228/3 Servo valve lock-up (Y6038), Transmission in Check the cable harness D7930/B21 - 2.8 Control
System 24/XX


System 24/XX
520228 4 4A.04 520228/4 Servo valve lock-up (Y6038), Transmission locked Check the cable harness D7930/B21 - 2.8 Control
short circuit to ground (low to gear 1 and 2 between Control unit, Y6038/1 System 21/XX
voltage). (Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX
System 24/XX

components
open circuit (low current). to gear 1 and 2 between Control unit, Y6038/1 System 21/XX
System 24/XX
open circuit (low current). to gear 1 and 2 between Control unit, Y6038/1 System 21/XX

System 24/XX
System 24/XX
System 24/XX
VDU01.01GB
D:123
VDU01.01GB
D:124

components
System 24/XX


System 24/XX
520229 4 4B.04 520229/4 Common output for control of Transmission in Check the cable harness D7930/A5 2.8 Control
servo valves, short circuit to locked neutral position between Control unit, - Y6038/2, System 21/XX
ground. (Shutdown). transmission (7930) and Y6067/2, DIAGNOSE,
the servo valves. Y6069/2, page 8:33
Y6300/2,
Check the servo valves. Y6310/2 2.8 Control
System 24/XX
the servo valves. page 8:34
520229 11 4B.0B 520229/11 Common output for control of Transmission in Check the cable harness D7930/A5 2.8 Control
servo valves, unknown error. locked neutral position between Control unit, - Y6038/2, System 21/XX
(Shutdown). transmission (7930) and Y6067/2, DIAGNOSE,
Y6300/2,
System 24/XX

components
520229 31 4B.1F 520229/31 Common output for control of Transmission in Check the cable harness D7930/A5 2.8 Control
servo valves, unknown error. locked neutral position between Control unit, - Y6038/2, System 21/XX
(Shutdown). transmission (7930) and Y6067/2, DIAGNOSE,
Y6300/2,
System 24/XX
520230 3 4C.03 520230/3 Analogue output 5, short Transmission in Check the cable harness at - -
circuit to voltage (high locked neutral position Control unit, transmission
voltage). (Shutdown). (7930).

520230 4 4C.04 520230/4 Analogue output 5, short Transmission locked Check the cable harness at - -
circuit to ground (low voltage). to gear 1 and 2 Control unit, transmission
(Limp-home). (7930).
520230 4 4C.04 520230/4 Analogue output 5, short Transmission locked Check the cable harness at - -
520230 5 4C.05 520230/5 Analogue output 5, open Transmission locked Check the cable harness at - -
circuit (low current). to gear 1 and 2 Control unit, transmission
520230 5 4C.05 520230/5 Analogue output 5, open Transmission locked Check the cable harness at - -
circuit to ground (high locked neutral position Control unit, transmission
current). (Shutdown). (7930).
520230 8 4C.08 520294/8 Analogue output 5, frequency Transmission locked Check the cable harness at - -
VDU01.01GB
error PWM control. to gear 1 and 2 Control unit, transmission

D:125
VDU01.01GB
D:126

components
520230 8 4C.08 520294/8 Analogue output 5, frequency Transmission locked Check the cable harness at - -
520294 3 4D.03 520294/3 Analogue output 6, short Transmission in Check the cable harness at - -
520294 4 4D.04 520294/4 Analogue output 6, short Transmission locked Check the cable harness at - -
circuit to ground (low voltage). to gear 1 and 2

Control unit, transmission
520294 5 4D.05 520294/5 Analogue output 6, open Transmission locked Check the cable harness at - -
520294 8 4D.08 520294/8 Analogue output 6, frequency Transmission locked Check the cable harness at - -

components

520231 3 50.03 520231/3 Solenoid valve gear selection Transmission locked Check the cable harness D7930/B19 - 2.8 Control
1/3 (Y6075), short circuit to to gear 1 and 2 between Control unit, Y6075/1 System 20/XX
voltage (high voltage). (Limp-home). transmission (7930) and DIAGNOSE,
the solenoid valve. page 8:32
Check the solenoid valve.
VDU01.01GB

the solenoid valve.
D:127
VDU01.01GB
D:128

components
the solenoid valve.


the solenoid valve.
the solenoid valve.
1/3 (Y6075), open circuit (low to gear 1 and 2 between Control unit, Y6075/1 System 20/XX
the solenoid valve.

components
the solenoid valve.

the solenoid valve.
the solenoid valve.
the solenoid valve.
VDU01.01GB
D:129
VDU01.01GB
D:130

components
the solenoid valve.


the solenoid valve.
the solenoid valve.
520233 3 52.03 520233/3 Digital output 2 (high side), No limitation. Check the cable harness at - -
short circuit to voltage (high Control unit, transmission
voltage). (7930).
short circuit to ground (low Control unit, transmission
voltage). (7930).
open circuit (low current). Control unit, transmission
(7930).
voltage). (7930).

components
voltage). (7930).
(7930).
520235 3 54.03 520235/3 Common output for control of Transmission locked Check the cable harness D7930/A5 2.8 Control
servo valves, short circuit to to gear 1 and 2 between Control unit, - Y6038/2, System 21/XX
voltage (high voltage). (Limp-home). transmission (7930) and Y6067/2, DIAGNOSE,
Y6300/2,

System 24/XX
voltage (high voltage). (Limp-home). transmission (7930) and Y6067/2, DIAGNOSE,
Y6300/2,
System 24/XX
ground (low voltage). (Limp-home). transmission (7930) and Y6067/2, DIAGNOSE,
Y6300/2,
System 24/XX
ground (low voltage). (Limp-home). transmission (7930) and Y6067/2, DIAGNOSE,
VDU01.01GB
Y6300/2,
D:131
System 24/XX
VDU01.01GB
D:132

components
520235 5 54.05 520235/5 Common output for control Transmission locked Check the cable harness D7930/A5 2.8 Control
of servo valves, open circuit to gear 1 and 2 between Control unit, - Y6038/2, System 21/XX
(low current). (Limp-home). transmission (7930) and Y6067/2, DIAGNOSE,
Y6300/2,
System 24/XX
520235 5 54.05 520235/5 Common output for control Transmission locked Check the cable harness D7930/A5 2.8 Control
of servo valves, open circuit to gear 1 and 2 between Control unit, - Y6038/2, System 21/XX
(low current). (Limp-home). transmission (7930) and Y6067/2, DIAGNOSE,


Y6300/2,
System 24/XX
solenoid valves, short circuit to gear 1 and 2 between Control unit, - Y6096/2, System 20/XX
to voltage (high voltage). (Limp-home). transmission (7930) and Y6075/2 DIAGNOSE,
the solenoid valves. page 8:32
the solenoid valves.
to voltage (high voltage). (Limp-home). transmission (7930) and Y6075/2 DIAGNOSE,

components
to ground (low voltage). (Limp-home). transmission (7930) and Y6075/2 DIAGNOSE,
Check the solenoid valves.
to ground (low voltage). (Limp-home). transmission (7930) and Y6075/2 DIAGNOSE,

solenoid valves, open circuit to gear 1 and 2 between Control unit, - Y6096/2, System 20/XX
(low current). (Limp-home). transmission (7930) and Y6075/2 DIAGNOSE,
solenoid valves, open circuit to gear 1 and 2 between Control unit, - Y6096/2, System 20/XX
(low current). (Limp-home). transmission (7930) and Y6075/2 DIAGNOSE,
VDU01.01GB
D:133
VDU01.01GB
D:134

components
520237 3 56.03 520237/3 Servo valve lock-up (Y6038), Transmission locked Check the cable harness D7930/A14 - 2.8 Control
short circuit to voltage (high to gear 1 and 2 between Control unit, Y6038/2 System 21/XX
System 24/XX
short circuit to voltage (high to gear 1 and 2 between Control unit, Y6038/2 System 21/XX


System 24/XX
System 24/XX
System 24/XX

components
520237 5 56.05 520237/5 Servo valve lock-up (Y6038), No limitation. Check the cable harness D7930/A14 - 2.8 Control
open circuit (low current). between Control unit, Y6038/2 System 21/XX
Transmission locked transmission (7930) and DIAGNOSE,
to gear 1 and 2 the servo valve. page 8:33
(Limp-home).
System 24/XX
520237 5 56.05 520237/5 Servo valve lock-up (Y6038), No limitation. Check the cable harness D7930/A14 - 2.8 Control
open circuit (low current). between Control unit, Y6038/2 System 21/XX
Transmission locked transmission (7930) and DIAGNOSE,

to gear 1 and 2 the servo valve. page 8:33
(Limp-home).
System 24/XX
520238 3 57.03 520238/3 Digital output 3 (low side), No limitation. Check the cable harness at - -
voltage). (7930).
voltage). (7930).
(7930).
520353 31 5A.1F 520353/31 Software error, Control unit No limitation. Stop the machine, switch - -
transmission (D7930). off the engine. Wait for 2
minutes, then switch off the
battery voltage. Wait for 1
minute, then switch on the
battery voltage and start the
machine.
If the fault persists, reprogram
Control unit, transmission
VDU01.01GB
(D7930).
D:135
520322 0 70.00 520322/0 Analogue input signal No limitation. Check the cable harness at - -
hydraulic controls, input Control unit, transmission
signal too high. (7930).
VDU01.01GB
D:136

components
hydraulic controls, input Control unit, transmission
signal too low. (7930).
hydraulic controls, short Control unit, transmission
circuit to voltage. (7930).
hydraulic controls, short Control unit, transmission
circuit to ground. (7930).
520322 9 70.09 520322/9 Message error for hydraulic No limitation. Check the cable harness D7930/B1 - 2.8 Control

controls on CAN bus between machine and D7971/1:31 System 10/XX

(D7930). D7930/B2 - page 8:31
D7971/1:32
520322 15 70.0F 520322/15 Analogue input signal No limitation. Check the cable harness at - -
hydraulic controls, high Control unit, transmission
signal. (7930).
hydraulic controls, low signal. Control unit, transmission
(7930).
520322 19 70.13 520322/19 Message error for hydraulic No limitation. Check the cable harness D7930/B1 - 2.8 Control
controls on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520323 0 71.00 520323/0 Analogue input signal brake No limitation. Check the cable harness at - -
pedal, input signal too high. Control unit, transmission
(7930).
pedal, input signal too low. Control unit, transmission
(7930).
pedal, short circuit to voltage. Control unit, transmission
(7930).
pedal, short circuit to ground. Control unit, transmission
(7930).

components
520323 9 71.09 520323/9 Message error for brake No limitation. Check the cable harness D7930/B1 - 2.8 Control
pedal on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520323 15 71.0F 520323/15 Analogue input signal brake No limitation. Check the cable harness at - -
pedal, high signal. Control unit, transmission
(7930).
pedal, low signal. Control unit, transmission
(7930).

520323 19 71.13 520323/19 Message error for brake No limitation. Check the cable harness D7930/B1 - 2.8 Control
pedal on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
(B7660), temperature too B7660/1 System 23/XX
high. Check other error codes for DIAGNOSE,
Check the transmission oil
cooler.
cooler's thermostat.
Check the error codes on
other sensors.
(B7660), temperature too low. B7660/1 System 23/XX
cooler's thermostat.
Check the error codes on
VDU01.01GB
other sensors.
D:137
VDU01.01GB
D:138

components
voltage. transmission (D7930) and the DIAGNOSE,
sensor. page 8:33
Check the sensor.
the sensor.
ground. transmission (D7930) and the DIAGNOSE,

sensor. page 8:33

Check the sensor.
the sensor.
520326 0 73.00 520326/0 Sensor oil filter, signal too No limitation. Check the cable harness - -
high. between Control unit,
transmission (D7930) and the
sensor.
Check the sensor.
the sensor.
520326 1 73.01 520326/1 Sensor oil filter, signal too low No limitation. Check the cable harness - -
between Control unit,
sensor.
Check the sensor.
the sensor.

components
520326 3 73.03 520326/3 Sensor, oil filter, short circuit No limitation. Check the cable harness D7930/A22 - -
to ground. between Control unit, B7660/1
sensor. -
Check the sensor.

the sensor.
520326 4 73.04 520326/4 Sensor, oil filter, short circuit No limitation. Check the cable harness - -
to ground. between Control unit,

sensor.
Check the sensor.
the sensor.
DIAGNOSE,
page 8:31
DIAGNOSE,
page 8:31
520327 3 74.03 520327/3 Sensor rpm drum (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control
Check the sensor.
the sensor.
VDU01.01GB
D:139
VDU01.01GB
D:140

components
520327 4 74.04 520327/4 Sensor, drum rpm (B7520), No limitation. Check the cable harness D7930/A3 - 2.8 Control
Check the sensor.
the sensor.
520372 5 76.05 520372/5 Output for signal ground, Transmission in Check the cable harness D7930/B28 -
open circuit. locked neutral position between Control unit,
(Shutdown). transmission (7930) and

sensors.
Check sensors.
sensors.
520370 0 77.00 520370/0 Output for reference voltage Transmission in Check the cable harness D7930/B10 2.8 Control
to sensors, short circuit to locked neutral position between Control unit, System 20/XX
voltage. (Shutdown). transmission (7930) and DIAGNOSE,
sensors. page 8:32
Check sensors.
sensors.
520370 1 77.01 520370/1 Output for reference voltage Transmission in Check the cable harness D7930/B10 2.8 Control
to sensors, short circuit to locked neutral position between Control unit, System 20/XX
sensors. page 8:32
Check sensors.
sensors.
520371 0 78.00 520371/0 Internal voltage feed, Control Transmission in Check the cable harness - -
unit, transmission (D7930), locked neutral position to Control unit transmission
too high. (Shutdown). (D7930).
Check Control unit,

components
520371 1 78.01 520371/1 Internal voltage feed, Control Transmission in Check the cable harness - -
unit, transmission (D7930), locked neutral position to Control unit transmission
too low. (Shutdown). (D7930).
Check Control unit,
520330 9 79.09 520330/9 Message error for declutch Transmission in Check the cable harness D7930/B1 - 2.8 Control
on CAN bus drivetrain. locked neutral position between machine and D7971/1:31 System 10/XX
(Shutdown). Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520330 19 79.13 520330/19 Message error for declutch No limitation. Check the cable harness D7930/B1 - 2.8 Control

on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520331 9 7A.09 520331/9 Message error for automatic No limitation. Check the cable harness D7930/B1 - 2.8 Control
shifting on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520331 19 7A.13 520331/19 Message error for automatic No limitation. Check the cable harness D7930/B1 - 2.8 Control
shifting on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520333 9 7C.09 520333/9 Message error for parking No limitation. Check the cable harness D7930/B1 - 2.8 Control
brake on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520333 19 7C.13 520333/19 Message error for parking No limitation. Check the cable harness D7930/B1 - 2.8 Control
brake on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520334 9 7D.09 520334/9 Message error for direction No limitation. Check the cable harness D7930/B1 - 2.8 Control
VDU01.01GB
of driver's seat on CAN bus between machine and D7971/1:31 System 10/XX
D:141
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
D:142

components
520334 19 7D.13 520334/19 Message error for direction No limitation. Check the cable harness D7930/B1 - 2.8 Control
of driver's seat on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520335 9 7E.09 520335/9 Message error for speed No limitation. Check the cable harness D7930/B1 - 2.8 Control
limitation on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520335 19 7E.13 520335/19 Message error for speed No limitation. Check the cable harness D7930/B1 - 2.8 Control
limitation on CAN bus between machine and D7971/1:31 System 10/XX


(D7930). D7930/B2 - page 8:31
D7971/1:32
520336 9 7F.09 520336/9 Message error for extra No limitation. Check the cable harness D7930/B1 - 2.8 Control
speed signal on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520336 19 7F.13 520336/19 Message error for extra No limitation. Check the cable harness D7930/B1 - 2.8 Control
speed signal on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520337 9 80.09 520337/9 Message error for start No limitation. Check the cable harness D7930/B1 - 2.8 Control
gear 1/gear 2 on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520337 19 80.13 520337/19 Message error for start No limitation. Check the cable harness D7930/B1 - 2.8 Control
gear 1/gear 2 on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520338 9 81.09 520338/9 Message error for operator No limitation. Check the cable harness D7930/B1 - 2.8 Control
in driver's seat on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32

components
520338 19 81.13 520338/19 Message error for operator No limitation. Check the cable harness D7930/B1 - 2.8 Control
in driver's seat on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520359 9 82.09 520359/9 Message error for neutral No limitation. Check the cable harness D7930/B1 - 2.8 Control
position on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520359 19 82.13 520359/19 Message error for neutral No limitation. Check the cable harness D7930/B1 - 2.8 Control
position on CAN bus between machine and D7971/1:31 System 10/XX

(D7930). D7930/B2 - page 8:31
D7971/1:32
520360 9 83.09 520360/9 Message error for idle on No limitation. Check the cable harness D7930/B1 - 2.8 Control
CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520360 19 83.13 520360/19 Message error for idle on No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520343 9 86.09 520343/9 Message error for lock-up on No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520343 19 86.13 520343/19 Message error for lock-up on No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520349 2 8C.02 520349/2 Incorrect input signal for Transmission in Check the cable harness D7930/B1 - 2.8 Control
declutch. Transmission locked neutral position between machine and D7971/1:31 System 10/XX
VDU01.01GB
in locked neutral position (Shutdown). Control unit transmission DIAGNOSE,
D:143
(Shutdown). (D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
D:144

components
520349 9 8C.09 520349/9 Message error for declutch No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520349 19 8C.13 520349/19 Message error for declutch No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520350 9 8D.09 520350/9 Message error for Eco Drive No limitation. Check the cable harness D7930/B1 - 2.8 Control
Mode on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX


(D7930). D7930/B2 - page 8:31
D7971/1:32
520350 19 8D.13 520350/19 Message error for Eco Drive No limitation. Check the cable harness D7930/B1 - 2.8 Control
Mode on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520351 9 8E.09 520351/9 Message error for speed on No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520351 19 8E.13 520351/19 Message error for speed on No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520354 9 8F.09 520354/9 Message error for loaded No limitation. Check the cable harness D7930/B1 - 2.8 Control
mode on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520354 19 8F.13 520354/19 Message error for loaded No limitation. Check the cable harness D7930/B1 - 2.8 Control
mode on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32

components
520355 9 90.09 520355/9 Message error for kickdown No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32
520355 19 90.13 520355/19 Message error for kickdown No limitation. Check the cable harness D7930/B1 - 2.8 Control
(D7930). D7930/B2 - page 8:31
D7971/1:32

(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
520358 9 93.09 520358/9 Message error for prevent No limitation. Check the cable harness D7930/B1 - 2.8 Control
upshift on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520358 19 93.13 520358/19 Message error for prevent No limitation. Check the cable harness D7930/B1 - 2.8 Control
upshift on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
520240 3 94.03 520240/3 Function error drive forward, Transmission in Check the cable harness - 2.8 Control
output short-circuited to locked neutral position between Control unit, System 21/XX
System 24/XX
VDU01.01GB

D:145
VDU01.01GB
D:146

components
520240 4 94.04 520240/4 Function error drive forward, Transmission locked Check the cable harness - 2.8 Control
output short-circuited to to gear 1 and 2 between Control unit, System 21/XX
System 24/XX
open circuit on output (low to gear 1 and 2 between Control unit, System 21/XX


System 24/XX
520240 6 94.06 520240/6 Function error drive forward, Transmission in Check the cable harness - 2.8 Control
output short-circuited to locked neutral position between Control unit, System 21/XX
System 24/XX
frequency error for PWM to gear 1 and 2 between Control unit, System 21/XX
control on output. (Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX
520241 3 95.03 520241/3 Function error high gear, Transmission in Check the cable harness at - -
output short-circuited to locked neutral position Control unit, transmission
voltage (high voltage). (Shutdown). (7930).
520241 4 95.04 520241/4 Function error high gear, Transmission locked Check the cable harness at - -
output short-circuited to to gear 1 and 2 Control unit, transmission
ground (low voltage). (Limp-home). (D7930).

components
open circuit on output (low to gear 1 and 2 Control unit, transmission
current). (Limp-home). (7930).
520241 6 95.06 520241/6 Function error high gear, Transmission in Check the cable harness at - -
output short-circuited to locked neutral position Control unit, transmission
ground (high current). (Shutdown). (7930).
frequency error for PWM to gear 1 and 2 Control unit, transmission
control on output. (Limp-home). (7930).
520242 3 96.03 520242/3 Function error drive Transmission in Check the cable harness - 2.8 Control
backward, output locked neutral position between Control unit, System 21/XX

short-circuited to voltage (Shutdown). transmission (7930) and DIAGNOSE,
(high voltage). the servo valve. page 8:33
System 24/XX
520242 4 96.04 520242/4 Function error drive Transmission locked Check the cable harness - 2.8 Control
backward, output to gear 1 and 2 between Control unit, System 21/XX
short-circuited to ground (Limp-home). transmission (7930) and DIAGNOSE,
(low voltage). the servo valve. page 8:33
System 24/XX
backward, open circuit to gear 1 and 2 between Control unit, System 21/XX
on output (low current). (Limp-home). transmission (7930) and DIAGNOSE,
System 24/XX
VDU01.01GB
D:147
VDU01.01GB
D:148

components
520242 6 96.06 520242/6 Function error drive Transmission in Check the cable harness - 2.8 Control
backward, output locked neutral position between Control unit, System 21/XX
short-circuited to ground (Shutdown). transmission (7930) and DIAGNOSE,
(high current). the servo valve. page 8:33
System 24/XX
backward, frequency error for to gear 1 and 2 between Control unit, System 21/XX
PWM control on output. (Limp-home). transmission (7930) and DIAGNOSE,


System 24/XX
520244 3 98.03 520244/3 Function error gear 1, output Transmission in Check the cable harness - 2.8 Control
short-circuited to voltage locked neutral position between Control unit, System 21/XX
(high voltage). (Shutdown). transmission (7930) and DIAGNOSE,
System 24/XX
520244 4 98.04 520244/4 Function error gear 1, output Transmission locked Check the cable harness - 2.8 Control
short-circuited to ground (low to gear 1 and 2 between Control unit, System 21/XX
System 24/XX

components
520244 5 98.05 520244/5 Function error gear 1, open Transmission locked Check the cable harness - 2.8 Control
circuit on output (low current). to gear 1 and 2 between Control unit, System 21/XX
System 24/XX
short-circuited to ground locked neutral position between Control unit, System 21/XX
(high current). (Shutdown). transmission (7930) and DIAGNOSE,

System 24/XX
520244 8 98.08 520244/8 Function error gear 1, Transmission locked Check the cable harness - 2.8 Control
System 24/XX
System 24/XX
VDU01.01GB
D:149
VDU01.01GB
D:150

components
520245 4 99.04 520245/4 Function error gear 2, output Transmission locked Check the cable harness - 2.8 Control
System 24/XX
520245 5 99.05 520245/5 Function error gear 2, open Transmission locked Check the cable harness - 2.8 Control


System 24/XX
System 24/XX
520245 8 99.08 520245/8 Function error gear 2, Transmission locked Check the cable harness - 2.8 Control
System 24/XX

components
520246 3 9A.03 520246/3 Function error gear 3, output Transmission in Check the cable harness - 2.8 Control
System 24/XX
520246 4 9A.04 520246/4 Function error gear 3, output Transmission locked Check the cable harness - 2.8 Control

System 24/XX
520246 5 9A.05 520246/5 Function error gear 3, open Transmission locked Check the cable harness - 2.8 Control
System 24/XX
520246 6 9A.06 520246/6 Function error gear 3, output Transmission in Check the cable harness - 2.8 Control
System 24/XX
VDU01.01GB
D:151
VDU01.01GB
D:152

components
520246 8 9A.08 520246/8 Function error gear 3, Transmission locked Check the cable harness - 2.8 Control
System 24/XX
520247 3 9B.03 520247/3 Function error gear 4, output Transmission in Check the cable harness - 2.8 Control


System 24/XX
520247 4 9B.04 520247/4 Function error gear 4, output Transmission locked Check the cable harness - 2.8 Control
System 24/XX
520247 5 9B.05 520247/5 Function error gear 4, open Transmission locked Check the cable harness - 2.8 Control
System 24/XX

components
520247 6 9B.06 520247/6 Function error gear 4, output Transmission in Check the cable harness - 2.8 Control
System 24/XX
520247 8 9B.08 520247/8 Function error gear 4, Transmission locked Check the cable harness - 2.8 Control

System 24/XX
520248 3 9C.03 520248/3 Function error lock-up, output Transmission in Check the cable harness - 2.8 Control
System 24/XX
520248 4 9C.04 520248/4 Function error lock-up, output Transmission locked Check the cable harness - 2.8 Control
System 24/XX
VDU01.01GB
D:153
VDU01.01GB
D:154

components
520248 5 9C.05 520248/5 Function error lock-up, open Transmission locked Check the cable harness - 2.8 Control
System 24/XX
520248 6 9C.06 520248/6 Function error lock-up, output Transmission in Check the cable harness - 2.8 Control


System 24/XX
520248 8 9C.08 520248/8 Function error lock-up, Transmission locked Check the cable harness - 2.8 Control
System 24/XX
520252 3 A0.03 520252/3 Output signal to warning No limitation. Check the cable harness at - -
lamp, short circuit to voltage. Control unit, transmission
(7930).
lamp, short circuit to ground. Control unit, transmission
(7930).
lamp, open circuit. Control unit, transmission
(7930).
520252 9 A0.09 520252/9 Message error for warning No limitation. Check the cable harness D7930/B1 - 2.8 Control
lamp on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32

components
lamp, short circuit to voltage. Control unit, transmission
(7930).
lamp, short circuit to ground. Control unit, transmission
(7930).
lamp, open circuit. Control unit, transmission
(7930).
520253 9 A1.09 520253/9 Message error for warning No limitation. Check the cable harness D7930/B1 - 2.8 Control
lamp on CAN bus drivetrain. between machine and D7971/1:31 System 10/XX

(D7930). D7930/B2 - page 8:31
D7971/1:32
520255 0 A3.00 520255/0 Output signal for selection of No limitation. Check the cable harness at - -
gear range high/low, signal Control unit, transmission
too high. (7930).
520255 1 A3.01 520255/1 Output signal for selection of No limitation. Check the cable harness at - -
gear range high/low, signal Control unit, transmission
too low. (7930).
520255 3 A3.03 520255/3 Output signal for selection No limitation. Check the cable harness at - -
of gear range high/low, short Control unit, transmission
circuit to voltage. (7930).
of gear range high/low, short Control unit, transmission
circuit to ground. (7930).
of gear range high/low, open Control unit, transmission
circuit. (7930).
520255 9 A3.09 520255/9 Message error for selection of No limitation. Check the cable harness D7930/B1 - 2.8 Control
gear range high/low on CAN between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
520256 3 A4.03 520256/3 Output signal to No limitation. Check the cable harness at - -
D:155
speed-dependent function, Control unit, transmission
short circuit to voltage. (7930).
VDU01.01GB
D:156

components
short circuit to ground. (7930).
open circuit. (7930).
520256 9 A4.09 520256/9 Message error for No limitation. Check the cable harness D7930/B1 - 2.8 Control
speed-dependent function on between machine and D7971/1:31 System 10/XX
CAN bus drive-train. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32

520257 3 A5.03 520257/3 Output signal for control of No limitation. Check the cable harness at - -
parking brake, short circuit to Control unit, transmission
voltage. (7930).
ground. (7930).
parking brake, open circuit. Control unit, transmission
(7930).
520257 9 A5.09 520257/9 Message error for Output No limitation. Check the cable harness D7930/B1 - 2.8 Control
signal for control of parking between machine and D7971/1:31 System 10/XX
brake on CAN bus drive-train. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520258 3 A6.03 520258/3 Output signal to indicator light No limitation. Check the cable harness at - -
voltage. (7930).
ground. (7930).
parking brake, open circuit. Control unit, transmission
(7930).

components
520258 9 A6.09 520258/9 Message error for indicator No limitation. Check the cable harness D7930/B1 - 2.8 Control
light parking brake on CAN between machine and D7971/1:31 System 10/XX
bus drive-train. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520259 3 A7.03 520259/3 Servo valve lock-up (Y6038), Transmission locked Check the cable harness D7930/B32 - 2.8 Control
short circuit to voltage. to gear 1 and 2 between Control unit, Y6038/1 System 21/XX
(Limp-home). transmission (D7930) and the DIAGNOSE,
servo valve. D7930/A14 - page 8:33
Y6038/2
System 24/XX

the servo valve page 8:34
short circuit to ground. to gear 1 and 2 between Control unit, Y6038/1 System 21/XX
Y6038/2
System 24/XX
open circuit. to gear 1 and 2 between Control unit, Y6038/1 System 21/XX
Y6038/2
System 24/XX
520259 9 A7.09 520259/9 Message error on CAN bus No limitation. Check the cable harness D7930/B1 - 2.8 Control
drivetrain. between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32
- -
VDU01.01GB
520263 3 AB.03 520263/3 Output signal to warning lamp No limitation. Check the cable harness at
speed warning, short circuit Control unit, transmission
D:157
to voltage. (7930).
VDU01.01GB
D:158

components
520263 4 AB.04 520263/4 Output signal to warning lamp No limitation. Check the cable harness at - -
speed warning, short circuit Control unit, transmission
to ground. (7930).
520263 5 AB.05 520263/5 Output signal to warning lamp No limitation. Check the cable harness at - -
speed warning, open circuit. Control unit, transmission
(7930).
520263 9 AB.09 520263/9 Message error for speed No limitation. Check the cable harness D7930/B1 - 2.8 Control
warning on CAN bus between machine and D7971/1:31 System 10/XX
(D7930). D7930/B2 - page 8:31
D7971/1:32

520264 3 AC.03 520264/3 Servo valve drive forward Transmission in Check the cable harness D7930/B22 - 2.8 Control
System 24/XX
520264 4 AC.04 520264/4 Servo valve drive forward Transmission locked Check the cable harness D7930/B22 - 2.8 Control
System 24/XX
520264 5 AC.05 520264/5 Servo valve drive forward Transmission locked Check the cable harness D7930/B22 - 2.8 Control
System 24/XX
520265 3 AD.03 520265/3 Output signal to drive forward Transmission locked Check the cable harness at - -
high, short circuit to voltage. to gear 1 and 2 Control unit, transmission

components
high, short circuit to ground. to gear 1 and 2 Control unit, transmission
high, open circuit. to gear 1 and 2 Control unit, transmission
520266 3 AE.03 520266/3 Servo valve drive backward Transmission locked Check the cable harness D7930/A1 - 2.8 Control

System 24/XX
System 24/XX
System 24/XX
520268 3 B0.03 520268/3 Solenoid valve gear selection Transmission locked Check the cable harness D7930/B19 - 2.8 Control
1/3 (Y6075) for selection of to gear 1 and 2 between Control unit, Y6075/1 System 20/XX
gear 1, short circuit to voltage (Limp-home). transmission (7930) and DIAGNOSE,
(high voltage). the solenoid valve. page 8:32
VDU01.01GB
D:159
the solenoid valve.
VDU01.01GB
D:160

components
gear 1, short circuit to ground (Limp-home). transmission (7930) and DIAGNOSE,
(low voltage). the solenoid valve. page 8:32
the solenoid valve.
1/3 (Y6075) for selection to gear 1 and 2 between Control unit, Y6075/1 System 20/XX
of gear 1, open circuit (low (Limp-home). transmission (7930) and DIAGNOSE,

current). the solenoid valve. page 8:32

the solenoid valve.
the solenoid valve.
the solenoid valve.

components
the solenoid valve.

the solenoid valve.
the solenoid valve.
the solenoid valve.
VDU01.01GB
D:161
VDU01.01GB
D:162

components
the solenoid valve.


the solenoid valve.
the solenoid valve.
520272 3 B4.03 520272/3 Output to clutch for low gear, Transmission locked Check the cable harness at - -
short circuit to voltage (high to gear 1 and 2 Control unit, transmission
voltage). (Limp-home). (7930).
short circuit to ground (low to gear 1 and 2 Control unit, transmission
open circuit (low current). to gear 1 and 2 Control unit, transmission
short circuit to ground (high to gear 1 and 2 Control unit, transmission

components
frequency error PWM control to gear 1 and 2 Control unit, transmission
520273 3 B5.03 520273/3 Output to clutch for high gear, Transmission locked Check the cable harness at - -
short circuit to voltage (high to gear 1 and 2 Control unit, transmission
short circuit to ground (low to gear 1 and 2 Control unit, transmission
open circuit (low current). to gear 1 and 2 Control unit, transmission

short circuit to ground (high to gear 1 and 2 Control unit, transmission
frequency error PWM control to gear 1 and 2 Control unit, transmission
520276 3 B8.03 520276/3 Output signal to reverse No limitation. Check the cable harness at - -
alarm, short circuit to voltage. Control unit, transmission
(7930).
alarm, short circuit to ground. Control unit, transmission
(7930).
alarm, open circuit. Control unit, transmission
(7930).
520276 9 B8.09 520276/9 Message error for indicator No limitation. Check the cable harness D7930/B1 - 2.8 Control
light parking brake on CAN between machine and D7971/1:31 System 10/XX
bus drive-train. Control unit transmission DIAGNOSE,
(D7930). D7930/B2 - page 8:31
D7971/1:32
520385 9 C1.09 520385/9 Communication error CAN No limitation. Check the cable harness D7930/B1 - 2.8 Control
VDU01.01GB
bus drivetrain. between machine and D7971/1:31 System 10/XX

D:163
(D7930). D7930/B2 - page 8:31
D7971/1:32
VDU01.01GB
D:164

components
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32


(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
(D7930). D7930/B2 - page 8:31
D7971/1:32
520417 15 E0.0F 520417/15 Machine's speed is too high No limitation. Inform the operator, to adapt - -
to enable downshift. driving behaviour.
520418 15 E1.0F 520418/15 Machine speed is too high No limitation. Inform the operator, to adapt - -
to enable change of travel driving behaviour.
direction.
520419 15 E2.0F 520419/15 Engine rpm is too high to No limitation. Inform the operator, to adapt - -
enable change of travel driving behaviour.
direction or select same
travel direction again.
520420 14 E3.0E 520420/14 Machine's speed limitation is No limitation. Inform the operator, to adapt - -
activated. driving behaviour.
520420 15 E3.0F 520420/15 Machine's speed limitation No limitation. Inform the operator, to adapt - -
is activated regardless of if driving behaviour.
speed is above the limit value.

components
520420 16 E3.10 520420/16 Machine's speed is higher No limitation. Inform the operator, to adapt - -
than the upper limit value. driving behaviour.
520416 13 E5.0D 520416/13 Time for calibration reached. No limitation. Calibrate the transmission, - -
see Maintenance manual
section 2.
520416 15 E5.0F 520416/15 Time for calibration reached. No limitation. Calibrate the transmission, - -
see Maintenance manual
section 2.
520422 14 E6.0E 520422/14 The operator is not sitting in No limitation. Inform the operator, to adapt - -
the operator's seat and the driving behaviour.
gear selector is not in neutral

and/or the parking brake is
not activated.
520423 15 E7.0F 520423/15 Turbine rotation speed Transmission control unit Inform the operator, to adapt - -
exceeds limit value. forces engine to idle. driving behaviour.
520432 F0.XX 520432/XX Configuration error. One error Transmission in Note time and contact - -
code per message. locked neutral position Cargotec support.
(Shutdown).
(Shutdown).
(Shutdown).
520435 F3.XX 520435/XX Memory error, Transmission Transmission in If the error is created - -
control unit. One error code locked neutral position in connection with
per message. (Shutdown). programming. Stop the
machine, switch off the
engine. Wait for 2 minutes,
then switch off the battery
voltage. Wait for 1 minute,
then switch on the battery
voltage and start the machine.
If the error persists, contact
VDU01.01GB
Cargotec support.
D:165
VDU01.01GB
D:166

components
520436 F4.XX 520436/XX Memory error, Transmission Transmission in If the error is created - -
control unit. One error code locked neutral position in connection with
per message. (Shutdown). programming. Stop the
Cargotec support.

520437 F5.XX 520437/XX Configuration error. One error Transmission in If the error is created - -
code per message. locked neutral position in connection with
(Shutdown). programming. Stop the
Cargotec support.
Cargotec support.

components
Cargotec support.

Cargotec support.
Cargotec support.
VDU01.01GB
D:167
VDU01.01GB
D:168

components
520442 FA.XX 520442/XX Configuration error. One error Transmission in If the error is created - -
Cargotec support.

520443 FB.XX 520443/XX Configuration error. One error Transmission in If the error is created - -
Cargotec support.
520444 FC.XX 520444/XX Configuration error. One error Transmission in If the error is created - -
Cargotec support.

components
520445 FD.XX 520445/XX Configuration error. One error Transmission in If the error is created - -
Cargotec support.

520446 FE.XX 520446/XX Configuration error. One error Transmission in If the error is created - -
Cargotec support.
520447 FF.XX 520447/XX Configuration error. One error Transmission in If the error is created - -
Cargotec support.
VDU01.01GB
D:169
:170 D Error codes – Machine
D.8 Machine
Error codes machine
The error codes for the machine are sorted in numerical order. The
table contains the following information:
• Type - Specifies type of component, see Component type (B),
page D:7.
page D:8.
• Node - Specifies which control unit set the error code, see below.
• Location - Specifies code for component location if there are
several with the same component number, see Component
location (DD), page D:8.
• Description - Gives a description of the error code.
• Limitation - Gives any limitation which may exist on the machine
for the current error code.
• Reference - Specifies which section of the workshop manual it is
that contains information relating to the error code.
Table Node, explanation
Node Control unit

1 KCU (D7901)
2 KFU (D7971)
3 KFU-2 (D7972)
6 KAU-2 (D7912)
7 KAU (D7911)
11 KPU (D7902)
12 KID (D7950)
200 Drive regulator
201 Pump regulator steering and load handling
202 Pump regulator brake system and A/C
compressor

Table Error codes machine
Type SPN FMI Node Location Description Limitation Action Connections Diagnostic Reference
and menu
components
H 1037 6 11 2 Indicator light Levelling Light not working. Check the cable harness H1037 Control
lock (H1037) in switch between control unit control lever (EGO),
on control lever. lever. D7902/C4:2 description,
page 7:8
S 1310 7 11 Travel direction Selection of gear Check cabling between S1310 2.1 Controls Travel
selector (S1310), or activation of the control unit and the & Instr 1/XX direction
logical error parking brake not component with diagnostic DIAGNOSE, selector and
working. menu. page 8:28 parking brake,
description,
Check the travel direction page 2:9
selector.
H 1753 6 1 2 Indicator light wide Indicator light not Check cabling between H1753-2
twistlocks (WTP), outer working. the control unit and the

position (H1753-2), component with diagnostic D7901/C2:34
short circuit to ground. menu.
Check the travel direction
selector.
H 1753 6 7 1 Indicator light wide Indicator light not Check cabling between H1753-1
twistlocks (WTP), outer working. the control unit and the
position (H1753-1), component with diagnostic D7911/C1:20
Check the travel direction
selector.
B 2070 3 2 Differential lock contact Differential lock not Check cabling between B2070
(B2070), position signal working. the control unit and the
component with diagnostic D7971/C1:5
menu.
B 2190 2 1 Sensor cab filter Poor air flow to the Replace the cab filter. B2190 9.4 Climate Fresh air filter,
B2190, pressure drop cab. System 6/XX description,
over cab filter too high. Check the sensor. D7901/C1:15 DIAGNOSE, page 9:25
page 8:61
VDU01.01GB
D:171
VDU01.01GB
D:172
Table Error codes machine (continued)
and menu
components
B 2460 2 1 Pressure switch Cooling function Check the drive belt for B2460 9.4 Climate Pressure
(B2460) for low or high for air conditioning the compressor for air System 6/XX switch,
pressure in refrigerant unit not working. conditioning. D7901/C1:1 DIAGNOSE, description,
circuit. page 8:61 page 9:35
Check that compressor for
air conditioning is activated.
Check cabling between
the control unit and the
component with diagnostic
menu.
Pressure test the air
conditioning unit.
D Error codes – Machine

K 3150 6 1 Relay ignition (K3150), Starter motor not Check cabling between K3150 11.7 I/O Ignition
short circuit to ground. working. the control unit and the D7901 KCU voltage (15),
component with diagnostic D7901/C2:11 1-48/XX description,
menu. DIAGNOSE, page 11:17
page 8:91
K 3312 6 2 Driving forwards relay Driving forwards Check the cable harness D7971/C1:22 11.1 Controls
(K3312), signal status not working. between control unit and & Instr 3/XX
page 8:77
page 8:77
page 8:77
K 3320 6 2 Reversing relay Reversing not Check the cable harness D7971/C1:23 11.1 Controls
(K3320), signal status working. between control unit and & Instr 4/XX
page 8:77
and menu
components
page 8:77
page 8:77
K 3600 6 2 Starter relay engine Engine does not Check the cable harness K3600/86 1.11 Start & Engine option
(K3600) short circuit to start. between control unit and Stop 1/XX Cummins
ground. component. D7971/C1:43 DIAGNOSE, QSB6.7,

page 8:26 function
Only engine option Check the component. description,
Cummins. page 1:20
E 4000 5 2 10 Low beam left (E4000), Low beam left not Check the lamp. E4000-LE 9.6 Lighting Headlights,
open circuit. working. Sys 3/XX description,
Check cabling between D7971/C2:1 DIAGNOSE, page 9:57
the control unit and the page 8:68
menu.
E 4000 5 3 210 Low beam left rear Low beam left rear Check the lamp. E4000-LR Headlights,
(E4000), open circuit. not working. description,
Check cabling between D7972/C2:1 page 9:57
At turnable the control unit and the
operator's station. component with diagnostic
menu.
E 4000 6 2 10 Low beam left (E4000) Low beam left not Check cabling between E4000-LE 9.6 Lighting Headlights,
short circuit to ground. working. the control unit and the Sys 3/XX description,
component with diagnostic D7971/C2:1 DIAGNOSE, page 9:57
menu. page 8:68
E 4000 6 3 210 Low beam left rear Low beam left rear Check cabling between E4000-LR Headlights,
(E4000), short circuit to not working. the control unit and the description,
ground. component with diagnostic D7972/C2:1 page 9:57
At turnable menu.
operator's station.
VDU01.01GB
D:173
VDU01.01GB
D:174
and menu
components
E 4000 5 2 20 Low beam right Low beam right not Check the lamp. E4000-RI 9.6 Lighting Headlights,
(E4000), open circuit. working. Sys 3/XX description,
Check cabling between D7971C2:3 DIAGNOSE, page 9:57
menu.
E 4000 5 3 220 Low beam right rear Low beam right Check the lamp. E4000-RR Headlights,
(E4000), open circuit. rear not working. description,
menu.
E 4000 6 2 20 Low beam right Low beam right not Check cabling between E4000-RI 9.6 Lighting Headlights,

(E4000), short circuit to working. the control unit and the Sys 3/XX description,
ground. component with diagnostic D7971C2:3 DIAGNOSE, page 9:57
menu. page 8:68
E 4000 6 3 220 Low beam right rear Low beam right Check cabling between E4000-RR Headlights,
(E4000), short circuit to rear not working. the control unit and the description,
At turnable menu.
operator's station.
E 4020 5 2 10 High beam left (E4020), High beam left not Check the lamp. E4020-LE Headlights,
open circuit. working. description,
menu.
E 4020 5 3 210 High beam left rear High beam left rear Check the lamp. E4020-LR Headlights,
menu.
E 4020 6 2 10 High beam left (E4020), High beam left not Check cabling between E4020-LE Headlights,
short circuit to ground. working. the control unit and the description,
component with diagnostic D7971/C2:2 page 9:57
menu.
and menu
components
E 4020 6 3 210 High beam left rear High beam left rear Check cabling between E4020-LR Headlights,
At turnable menu.
operator's station.
E 4020 5 2 20 High beam right High beam right Check the lamp. E4020-RI Headlights,
menu.
E 4020 5 3 220 High beam right rear High beam right Check the lamp. E4020-RR Headlights,
(E4020), open circuit. rear not working. description,

menu.
E 4020 6 2 20 High beam right High beam right Check cabling between E4020-RI Headlights,
menu.
E 4041 5 2 1 Extra working Extra working Check the lamp. E4041 9.6 Lighting Mast working
lights frame left lights frame left Sys 17/XX lights,
(E4041-LE-A) not working. Check cabling between D7971/C2:5 DIAGNOSE, description,
(E4041-LE-B), open the control unit and the page 8:71 page 9:60
circuit. component with diagnostic
menu.
E 4041 6 2 1 Extra working Extra working Check the lamp. E4041 9.6 Lighting Mast working
lights frame left lights frame left Sys 17/XX lights,
(E4041-LE-A) not working. Check cabling between D7971/C2:5 DIAGNOSE, description,
(E4041-LE-B), short the control unit and the page 8:71 page 9:60
circuit to ground. component with diagnostic
menu.
E 4041 5 2 2 Extra working Extra working Check the lamp. E4041 9.6 Lighting Extra working
lights frame right lights frame right Sys 17/XX lights frame,
(E4041-RI-A) not working. Check cabling between D7971/C2:6 DIAGNOSE, description,
(E4041-RI B), open the control unit and the page 8:71 page 9:61
VDU01.01GB
circuit. component with diagnostic

menu.
D:175
VDU01.01GB
D:176
and menu
components
E 4041 6 2 2 Extra working Extra working Check the lamp. E4041 9.6 Lighting Extra working
lights frame right lights frame right Sys 17/XX lights frame,
(E4041-RI-A) not working. Check cabling between D7971/C2:6 DIAGNOSE, description,
(E4041-RI-B), short the control unit and the page 8:71 page 9:61
circuit to ground. component with diagnostic
menu.
E 4042 5 1 10 Working lights cab Working lights left Check the lamp. E4042-LE 9.6 Lighting Working
left (E4042-LE), open not working. Sys 11/XX lights, cab,
circuit. Check cabling between D7901/C2:22 DIAGNOSE, description,
the control unit and the page 8:70 page 9:60
menu.
E 4042 6 1 10 Working lights cab Working lights left Check cabling between E4042-LE 9.6 Lighting Working

left (E4042-LE), short not working. the control unit and the Sys 11/XX lights, cab,
circuit to ground. component with diagnostic D7901/C2:22 DIAGNOSE, description,
menu. page 8:70 page 9:60
E 4042 5 1 20 Working lights cab Working lights right Check the lamp. E4042-RI 9.6 Lighting Working
right (E4042-RI) open not working. Sys 11/XX lights, cab,
circuit. Check cabling between D7901/C2:23 DIAGNOSE, description,
menu.
E 4042 6 1 20 Working lights cab Working lights right Check cabling between E4042-RI 9.6 Lighting Working
right (E4042-RI), short not working. the control unit and the Sys 11/XX lights, cab,
E 4042 5 1 1 Extra work lights left Extra work lighting Check the lamp. E4042-1 Working
(E4042-1), open circuit. left not working. lights, cab,
Check cabling between D7901/C2:18 description,
menu.
E 4042 6 1 1 Extra work lights left Extra work lighting Check the lamp. E4042-1 Working
(E4042-1), short circuit left not working. lights, cab,
to ground. Check cabling between D7901/C2:18 description,
menu.
and menu
components
E 4042 5 1 2 Extra work lights right Extra work lighting Check the lamp. E4042-2 Working
(E4042-2), open circuit. right not working. lights, cab,
Check cabling between D7901/C2:36 description,
menu.
E 4042 6 1 2 Extra work lights right Extra work lighting Check the lamp. E4042-2
(E4042-2), short circuit right not working.
to ground. Check cabling between D7901/C2:36
menu.
E 4043 5 2 10 Work lights mast left Working lights Check the lamp. E4043-LE 9.6 Lighting Mast working

(E4043-LE), open mast left not Sys 14/XX lights,
circuit. working. Check cabling between D7971/C2:36 DIAGNOSE, description,
menu.
E 4043 6 2 10 Work lights mast left Working lights Check the lamp. E4043-LE 9.6 Lighting Mast working
(E4043-LE), short mast left not Sys 14/XX lights,
circuit to ground. working. Check cabling between D7971/C2:36 DIAGNOSE, description,
menu.
E 4043 5 2 20 Working lights mast Working lights Check the lamp. E4043-RI 9.6 Lighting Mast working
right (E4043-RI) mast right not Sys 14/XX lights,
working. Check cabling between D7971/C2:36 DIAGNOSE, description,
menu.
E 4043 6 2 20 Working lights mast Working lights Check the lamp. E4043-RI 9.6 Lighting Mast working
right (E4043-RI) mast right not Sys 14/XX lights,
working. Check cabling between D7971/C2:36 DIAGNOSE, description,
menu.
E 4044 5 7 10 Working lights Working lights Check the lamp. E4044-LE-A 9.6 Lighting Working lights,
VDU01.01GB
attachment left attachment left not Sys 21/XX attachment,

(E4044-LE-A), open working. Check cabling between D7911/C2:5 DIAGNOSE, description,
D:177
circuit. the control unit and the page 8:72 page 9:61
menu.
VDU01.01GB
D:178
and menu
components
E 4044 6 7 10 Working lights Working lights Check cabling between E4044-LE-A 9.6 Lighting Working lights,
attachment left attachment left not the control unit and the Sys 21/XX attachment,
(E4044-LE-A), short working. component with diagnostic D7911/C2:5 DIAGNOSE, description,
circuit to ground. menu. page 8:72 page 9:61
E 4044 5 7 110 Working lights Working lights Check the lamp. E4044-LE-B 9.6 Lighting Working lights,
attachment left attachment left not Sys 22/XX attachment,
(E4044-LE-B), open working. Check cabling between D7911/C2:3 DIAGNOSE, description,
menu.
E 4044 6 7 110 Working lights Working lights Check cabling between E4044-LE-B 9.6 Lighting Working lights,
attachment left attachment left not the control unit and the Sys 22/XX attachment,
D7911/C2:3

(E4044-LE-B), short working. component with diagnostic DIAGNOSE, description,
E 4044 5 7 20 Working lights Working lights Check the lamp. E4044-RI-A 9.6 Lighting Working lights,
attachment right attachment right Sys 21/XX attachment,
(E4044-RI-A), open not working. Check cabling between D7911/C2:6 DIAGNOSE, description,
menu.
E 4044 6 7 20 Working lights Working lights Check cabling between E4044-RI-A 9.6 Lighting Working lights,
attachment right attachment right the control unit and the Sys 21/XX attachment,
(E4044-RI-A), short not working. component with diagnostic D7911/C2:6 DIAGNOSE, description,
E 4044 5 7 120 Working lights Working lights Check the lamp. E4044-RI-B 9.6 Lighting Working lights,
attachment right attachment right Sys 22/XX attachment,
(E4044-RI-B), open not working. Check cabling between D7911/C2:4 DIAGNOSE, description,
menu.
E 4044 6 7 120 Working lights Working lights Check cabling between E4044-RI-B 9.6 Lighting Working lights,
attachment right attachment right the control unit and the Sys 22/XX attachment,
(E4044-RI-B), short not working. component with diagnostic D7911/C2:4 DIAGNOSE, description,
E 4045 5 6 110 Work lights lift legs Work lights lift legs Check the lamp. E4045-LF Working lights,
attachment left front attachment left attachment,
(E4045-LF), open front not working. Check cabling between D7912/C2:3 description,
circuit. the control unit and the page 9:61
menu.
and menu
components
E 4045 6 6 110 Work lights attachment Work lights lift legs Check cabling between E4045-LF Working lights,
lift legs left front attachment left the control unit and the attachment,
(E4045-LF), short front not working. component with diagnostic D7912/C2:3 description,
circuit to ground. menu. page 9:61
E 4045 5 6 120 Work lights lift legs Work lights lift legs Check the lamp. E4045-RF Working lights,
attachment right front attachment right attachment,
(E4045-RF), open front not working. Check cabling between D7912/C2:4 description,
menu.
E 4045 6 6 120 Work lights attachment Work lights lift legs Check cabling between E4045-RF Working lights,
lift legs right front attachment right the control unit and the attachment,
D7912/C2:4

(E4045-RF), short front not working. component with diagnostic description,
E 4045 5 6 210 Work lights lift legs Work lights lift legs Check the lamp. E4045-LR Working lights,
attachment left rear attachment left attachment,
(E4045-LR), open rear not working. Check cabling between D7912/C2:5 description,
menu.
E 4045 6 6 210 Work lights attachment Work lights lift legs Check cabling between E4045-LR Working lights,
lift legs left rear attachment left the control unit and the attachment,
(E4045-LR), short rear not working. component with diagnostic D7912/C2:5 description,
E 4045 5 6 220 Work lights lift legs Work lights lift legs Check the lamp. E4045-RR Working lights,
attachment right rear attachment right attachment,
(E4045-RR), open rear not working. Check cabling between D7912/C2:6 description,
menu.
E 4045 6 6 220 Work lights attachment Work lights lift legs Check cabling between E4045-RR Working lights,
lift legs right rear attachment right the control unit and the attachment,
(E4045-RR), short rear not working. component with diagnostic D7912/C2:6 description,
E 4050 5 1 10 Work lights backwards Working lights Check the lamp. E4050-LE 9.6 Lighting
left (E4050-LE), open backward left not Sys 10/XX
VDU01.01GB
circuit. working. Check cabling between D7901/C2:20 DIAGNOSE,

D:179
page 8:70
menu.
VDU01.01GB
D:180
and menu
components
E 4050 6 1 10 Work lights backwards Working lights Check the lamp. E4050-LE 9.6 Lighting
left (E4050-LE), short backward left not Sys 10/XX
circuit to ground. working. Check cabling between D7901/C2:20 DIAGNOSE,
menu.
E 4050 5 1 20 Work lights backwards Working lights Check the lamp. E4050-RI 9.6 Lighting
right (E4050-RI) open backward right not Sys 10/XX
circuit. working. Check cabling between D7901/C2:21 DIAGNOSE,
menu.
E 4050 6 1 20 Work lights backwards Working lights Check the lamp. E4050-RI 9.6 Lighting

right (E4050-RI), short backward right not Sys 10/XX
circuit to ground. working. Check cabling between D7901/C2:21 DIAGNOSE,
menu.
E 4050 6 2 Working lights steering Working lights Check the lamp. E4050
(E4050), short circuit to steering not
ground. working. Check cabling between D7971/C1:45
menu.
H 4110 6 2 Brake lights (H4110-RI) Brake lights not Check cabling between H4110 9.6 Lighting Brake lights,
and (H4110-LE), short working. the control unit and the Sys 5/XX description,
circuit to ground. component with diagnostic D7971/C1:13 DIAGNOSE, page 9:58
menu. page 8:68
Check the lamp.
H 4110 6 3 100 Brake lights front Brake lights front Check cabling between H4110 Brake lights,
(H4110-LF) and not working. the control unit and the description,
(H4110-RF), short component with diagnostic D7972/C1:20 page 9:58
circuit to ground. At revolving menu.
driver's seat.
Check the lamp.
H 4120 6 2 1 Tail lights (H4120-LE) Tail lights not Check cabling between H4120 9.6 Lighting Tail lights,
and (H4120-RI), short working. the control unit and the Sys 4/XX description,
circuit to ground. component with diagnostic D7971/C1:19 DIAGNOSE, page 9:58
menu. page 8:68
Check the lamp.
and menu
components
H 4120 6 3 100 Tail lights front Tail light front not Check cabling between H4120 Tail lights,
(H4120-LF) and working. the control unit and the description,
(H4120-RF), short component with diagnostic D7972/C1:19 page 9:58
circuit to ground. At revolving menu.
driver's seat.
Check the lamp.
H 4160 6 2 Position lights Running lights not Check cabling between H4160-LF 9.6 Lighting Running
(H4160-LF, working. the control unit and the Sys 9/XX lights,
H4160-RF, H4160-LR, component with diagnostic H4160-RF DIAGNOSE, description,
H4160-RR), short menu. page 8:69 page 9:57
circuit to ground. H4160-LR
Check the lamp.
H4160-RR

D7971/C1:16
H 4220 6 2 10 Direction indicators Left direction Check cabling between H4220-FL 9.6 Lighting Direction
left (H4220-FL) and indicator not the control unit and the Sys 7/XX indicators,
(H4220-RL), short working. component with diagnostic H4220-RL DIAGNOSE, description,
D7971/C1:20
Check the lamp.
H 4220 6 2 20 Direction indicators Right direction Check cabling between H4220-FR 9.6 Lighting Direction
right (H4220-FR) and indicator not the control unit and the Sys 8/XX indicators,
(H4220-RR), short working. component with diagnostic H4220-RR DIAGNOSE, description,
D7971/C1:26
Check the lamp.
H 4281 6 2 Revolving beacon on Revolving beacon Check the lamp. H4281 9.7 Signalling Revolving
counterweight (H4281), on counterweight Sys 3/XX beacon,
short circuit to ground. not working. Check the bulb holder. D7971/C1:45 DIAGNOSE, description,
page 8:73 page 9:59
menu.
H 4282 6 1 Revolving beacon Revolving beacon Check the lamp. H4282 9.7 Signalling Revolving
(H4282), short circuit not working. Sys 2/XX beacon,
to ground. Check the bulb holder. D7901/C2:13 DIAGNOSE, description,
VDU01.01GB
page 8:73 page 9:59

D:181
menu.
VDU01.01GB
D:182
and menu
components
H 4284 6 7 Revolving beacon Revolving beacon, Check cabling between H4284 9.7 Signalling Revolving
attachment (H4284), attachment, not the control unit and the Sys 4/XX beacon,
short circuit to ground. working. component with diagnostic D7911/C1:45 DIAGNOSE, description,
Check the bulb holder.
E 4340 6 1 Interior lighting Interior lighting in Check cabling between E4340 9.6 Lighting Interior
(E4340), short circuit to cab not working. the control unit and the Sys 19/XX lighting,
ground. component with diagnostic D7901/C2:30 DIAGNOSE, description,
Check the lamp.
H 5001 6 7 30 Indicator light Indicator light not Check cabling between H5001

overheight-legs up working. the control unit and the
(H5001) (on inner component with diagnostic D7911/C1:20
boom), short circuit to menu.
ground.
Check the lamp.
H 5004 6 7 Indicator light scale Indicator light not Check cabling between H5004
position load receipt working. the control unit and the
(H5004) (on inner component with diagnostic D7911/C1:19
boom), short circuit to menu.
ground.
Check the lamp.
H 5620 6 1 2 Indicator light unlocked Indicator light not Check cabling between H5620-2 7.9 Load Twistlocks,
twistlocks (H5620-2) working. the control unit and the Carrier 13/XX description,
(on roof panel in cab), component with diagnostic D7901/C2:1 DIAGNOSE, page 7:67
short circuit to ground. menu. page 8:49
Check the light panel.
H 5620 6 7 1 Indicator light unlocked Indicator light not Check cabling between H5620 7.9 Load Twistlocks,
twistlocks (H5620) (on working. the control unit and the Carrier 9/XX description,
inner boom), short component with diagnostic D7911/C1:12 DIAGNOSE, page 7:67
Check the lamp.
H 5630 6 1 2 Indicator light locked Indicator light not Check cabling between H5630-2 7.9 Load Twistlocks,
twistlocks (H5630-2) working. the control unit and the Carrier 12/XX description,
(on roof panel in cab), component with diagnostic D7901/C2:2 DIAGNOSE, page 7:67
and menu
components
H 5630 6 7 1 Indicator light locked Indicator light not Check cabling between H5620 7.9 Load Twistlocks,
twistlocks (H5630) (on working. the control unit and the Carrier 8/XX description,
inner boom), short component with diagnostic D7911/C1:13 DIAGNOSE, page 7:67
Check the lamp.
H 5640 6 1 2 Indicator light contact Indicator light not Check cabling between H5640-2 7.9 Load Twistlocks,
(H5640-2) (on roof working. the control unit and the Carrier 14/XX description,
panel in cab), short component with diagnostic D7901/C2:3 DIAGNOSE, page 7:67
H 5640 6 7 1 Indicator light contact Indicator light not Check cabling between H5640-1 7.9 Load Twistlocks,

(H5640-1), short circuit working. the control unit and the Carrier 8/XX description,
to ground. component with diagnostic D7911/C1:16 DIAGNOSE, page 7:67
menu. page 8:47
Check the lamp.
H 5640 6 7 30 Indicator light contact Indicator light not Check cabling between H5640-1
(H5640-1), short circuit working. the control unit and the
to ground. component with diagnostic D7911/C1:16
menu.
Check the lamp.
H 5640 6 7 40 Indicator light contact Indicator light not Check cabling between H5640-2
(H5640-2), short circuit working. the control unit and the
to ground. component with diagnostic D7911/C1:20
menu.
Check the lamp.
H 5720 6 7 Indicator light height Indicator light not Check cabling between H5720
restriction (H5720), working. the control unit and the
short circuit to ground. component with diagnostic D7911/C1:20
menu.
H 5740 6 1 Indicator light support Indicator light not Check cabling between H5740 11.7 I/O
VDU01.01GB
jacks down (H5740) working. the control unit and the D7901 KCU
(on roof panel in cab), component with diagnostic D7901/C2:4 1-48/XX
D:183
short circuit to ground. menu. DIAGNOSE,
page 8:91
VDU01.01GB
D:184
and menu
components
H 5760 6 6 110 Indicator light contact Indicator light not Check cabling between H5760-LF
lifting leg left front working. the control unit and the
(H5760-LF), short component with diagnostic D7912/C1:12
circuit to ground. menu.
H 5760 6 6 120 Indicator light contact Indicator light not Check cabling between H5760-RF
lifting leg right front working. the control unit and the
(H5760-RF), short component with diagnostic D7912/C1:13
H 5760 6 6 210 Indicator light contact Indicator light not Check cabling between H5760-LR

lifting leg left rear working. the control unit and the
(H5760-LR), short component with diagnostic D7912/C1:16
H 5760 6 6 220 Indicator light contact Indicator light not Check cabling between H5760-RR
lifting leg right rear working. the control unit and the
(H5760-RR), short component with diagnostic D7912/C1:19
H 5780 6 6 100 Indicator light lifting Indicator light not Check cabling between H5780-FR
legs clamping position working. the control unit and the
front (5780-FR), short component with diagnostic D7912/C1:42
H 5780 6 6 200 Indicator light Indicator light not Check cabling between H5780-RE
clamping position rear working. the control unit and the
(5780-RE), short circuit component with diagnostic D7912/C1:46
to ground. menu.
H 5800 6 6 30 Indicator light contact Indicator light not Check cabling between H5800-UP
lifting legs front up working. the control unit and the
(5800-UP), short circuit component with diagnostic D7912/C1:20
to ground. menu.
and menu
components
H 5800 6 6 40 Indicator light contact Indicator light not Check cabling between H5800-UP
lifting legs front down working. the control unit and the
(5800-LO), short circuit component with diagnostic D7912/C1:26
to ground. menu.
H 5991 6 1 Fasten seat belt Indicator light not Check cabling between H5991 9.3 Seat 1/XX Seat, general,
indicator light (H5991), working. the control unit and the DIAGNOSE, page 9:16
short circuit to ground. component with diagnostic D7901/C2:7 page 8:58
menu.
H 5992 6 1 Mini-wheel/joystick Indicator light not Check cabling between H5992

control, indicator light working. the control unit and the
(on/off) (H5992), short component with diagnostic D7901/C2:33
H 5993 6 11 3 Indicator light tilt lock Indicator light not Check the cable harness H5993 11.8 I/O Control
(H5993) in the switch working. between control unit control D7902 KPU lever (EGO),
on the control lever, lever. D7902/C4:3 1–41/XX description,
short circuit to ground DIAGNOSE, page 7:8
Check the control lever. page 8:91
Y 6002 5 2 Servo valve load signal The attachment Check cabling between Y6002
attachment (Y6002), functions work, but the control unit and the
open circuit. are working under component with diagnostic D7971/C1:38
full pressure all the menu.
time.
Y 6003 5 2 Solenoid valve Attachment Check cabling between Y6003 10.4 Pumps Solenoid
engagement of functions not the control unit and the 1/XX valve,
hydraulics top lift working or are component with diagnostic D7971/C1:15 DIAGNOSE, engagement
(Y6003), open circuit. very slow. menu. page 8:76 of hydraulics
for top lift,
Check the component. page 10:20
Y 6003 6 2 Solenoid valve Attachment Check cabling between Y6003 10.4 Pumps Solenoid
engagement of functions not the control unit and the 1/XX valve,
VDU01.01GB
hydraulics top lift working or are component with diagnostic D7971/C1:15 DIAGNOSE, engagement
D:185
(Y6003), short circuit to very slow. menu. page 8:76 of hydraulics
ground. for top lift,
VDU01.01GB
D:186
and menu
components
Y 6004 5 2 Solenoid valve, lower Lower not working Check cabling between Y6004 7.2 Lifting Lifting/lower-
(Y6004), open circuit. the control unit and the Lowering 2/XX ing, function
component with diagnostic D7971/C1:28 DIAGNOSE, description,
Y 6004 6 2 Solenoid valve lower Lower not working Check cabling between Y6004 7.2 Lifting Lifting/lower-
(Y6004), short circuit to the control unit and the Lowering 2/XX ing, function
Y 6004 5 2 2 Solenoid valve, lower 2 Lower not working Check cabling between Y6004-2 Lifting/lower-

(Y6004-2), open circuit. the control unit and the C1p41 D7971 ing, function
component with diagnostic description,
menu. page 7:16
Y 6004 6 2 2 Solenoid valve lower 2 Lower not working Check cabling between Y6004-2 Lifting/lower-
(Y6004-2), short circuit the control unit and the C1p41 D7971 ing, function
to ground. component with diagnostic description,
menu. page 7:16
Y 6005 5 2 Solenoid valve, lift Lift not working. Check cabling between Y6005 7.2 Lifting Lifting/lower-
(Y6005), open circuit the control unit and the Lowering 1/XX ing, function
component with diagnostic D7971/C1:27 DIAGNOSE, description,
Y 6005 6 2 Solenoid valve lift Lift not working. Check cabling between Y6005 7.2 Lifting Lifting/lower-
(Y6005), short circuit to the control unit and the Lowering 1/XX ing, function
Y 6005 5 2 2 Solenoid valve, lift 2 Lift not working. Check cabling between Y6005-2 Lifting/lower-
(Y6005-2), open circuit the control unit and the C1p40 D7971 ing, function
component with diagnostic description,
menu. page 7:16
and menu
components
Y 6005 6 2 2 Solenoid valve lift 2 Lift not working. Check cabling between Y6005-2 Lifting/lower-
(Y6005-2), short circuit the control unit and the C1p40 D7971 ing, function
to ground. component with diagnostic description,
menu. page 7:16
Y 6006 5 2 Solenoid valve, boom Boom out not Check cabling between Y6006
out (Y6006), open working. the control unit and the
circuit. component with diagnostic D7971/C1:33
menu.
Y 6006 6 2 Solenoid valve boom Boom out not Check cabling between Y6006

out (Y6006), short working. the control unit and the
circuit to ground. component with diagnostic D7971/C1:33
menu.
Y 6007 5 2 Solenoid valve, boom Boom in not Check cabling between Y6007
in (Y6007), open circuit. working. the control unit and the
menu.
Y 6007 6 2 Solenoid valve boom in Boom in not Check cabling between Y6007
(Y6007), short circuit to working. the control unit and the
ground. component with diagnostic D7971/C1:29
menu.
Y 6008 5 2 Solenoid valve rotation Rotation clockwise Check cabling between Y6008
clockwise (Y6008), not working. the control unit and the
open circuit component with diagnostic D7971/C1:38
menu.
VDU01.01GB

D:187
menu.
VDU01.01GB
D:188
and menu
components
menu.
menu.
Y 6009 5 2 Solenoid valve rotation Rotation Check cabling between Y6009

anticlockwise (Y6009), anticlockwise not the control unit and the
open circuit working. component with diagnostic D7971/C1:39
menu.
short circuit to ground. working. component with diagnostic D7971/C1:39
menu.
menu.
menu.
Y 6010 5 2 Solenoid valve, tilt out Tilt out not working Check cabling between Y6010 7.7 Tilt 2/XX Tilt, function
(Y6010), open circuit the control unit and the DIAGNOSE, description,
component with diagnostic D7971/C1:33 page 8:46 page 7:62
menu.
and menu
components
Y 6010 6 2 Solenoid valve tilt out Tilt out not working Check cabling between Y6010 7.7 Tilt 2/XX Tilt, function
(Y6010), short circuit to the control unit and the DIAGNOSE, description,
ground. component with diagnostic D7971/C1:33 page 8:46 page 7:62
menu.
Y 6010 5 7 Solenoid valve, tilt out Tilt out not working Check cabling between Y6010
(Y6010), open circuit the control unit and the
menu.
Y 6010 6 7 Solenoid valve tilt out Tilt out not working Check cabling between Y6010

(Y6010), short circuit to the control unit and the
menu.
Y 6011 5 2 Solenoid valve, tilt in Tilt in not working Check cabling between Y6011 7.7 Tilt 1/XX Tilt, function
(Y6011), open circuit. the control unit and the DIAGNOSE, description,
component with diagnostic D7971/C1:29 page 8:46 page 7:62
menu.
Y 6011 6 2 Solenoid valve tilt in Tilt in not working Check cabling between Y6011 7.7 Tilt 1/XX Tilt, function
(Y6011), short circuit to the control unit and the DIAGNOSE, description,
ground. component with diagnostic D7971/C1:29 page 8:46 page 7:62
menu.
Y 6011 5 7 Solenoid valve, tilt in Tilt in not working Check cabling between Y6011
(Y6011), open circuit. the control unit and the
menu.
Y 6011 6 7 Solenoid valve tilt in Tilt in not working Check cabling between Y6011
VDU01.01GB
(Y6010), short circuit to the control unit and the

D:189
menu.
VDU01.01GB
D:190
and menu
components
Y 6012 5 7 1 Solenoid valve tilt lock Tilt damping not Check cabling between Y6012-1
1 (Y6012-1), open working, tilt locked. the control unit and the
Machine speed menu.
limited to 5 km/h.
1 (Y6012-1), short working, tilt locked. the control unit and the
Machine speed menu.
limited to 5 km/h.

2 (Y6012-2), open working, tilt locked. the control unit and the
Machine speed menu.
limited to 5 km/h.
2 (Y6012-2), short working, tilt locked. the control unit and the
Machine speed menu.
limited to 5 km/h.
Y 6014 5 2 Solenoid valve, Differential lock not Check cabling between Y6014
differential lock working the control unit and the
(Y6014), open circuit. component with diagnostic D7971/C1:15
menu.
Y 6014 6 2 Solenoid valve, Differential lock not Check cabling between Y6014
differential lock working the control unit and the
(Y6014), short circuit to component with diagnostic D7971/C1:15
ground. menu.
Y 6016 5 2 Solenoid valve Hydraulic cab Check cabling between Y6016
cab movement out movement only the control unit and the
(forward/up) (Y6016), moves in one component with diagnostic D7971/C1:41
open circuit. direction. menu.
and menu
components
cab movement out movement only the control unit and the
(forward/up) (Y6016), moves in one component with diagnostic D7971/C1:41
short circuit to ground. direction. menu.
Y 6016 5 3 Solenoid valve cab Hydraulic cab Check cabling between Y6016
movement up (Y6016), movement only the control unit and the
open circuit. moves in one component with diagnostic D7972/C1:35
direction. menu.
Y 6016 6 3 Solenoid valve cab Hydraulic cab Check cabling between Y6016

movement up (Y6016), movement only the control unit and the
short circuit to ground. moves in one component with diagnostic D7972/C1:35
direction. menu.
cab movement in movement only the control unit and the
(back/lower) (Y6017), moves in one component with diagnostic D7971/C1:40
open circuit. direction. menu.
cab movement in movement only the control unit and the
(back/lower) (Y6017), moves in one component with diagnostic D7971/C1:40
short circuit to ground. direction. menu.
Y 6017 5 3 Solenoid valve cab Hydraulic cab Check cabling between Y6017 -
movement lower movement only the control unit and the
(Y6017), open circuit. moves in one component with diagnostic D7972/C1:34
direction. menu.
Y 6017 6 3 Solenoid valve cab Hydraulic cab Check cabling between Y6017 -
VDU01.01GB
movement lower movement only the control unit and the

(Y6017), short circuit to moves in one component with diagnostic D7972/C1:34
D:191
ground. direction. menu.
VDU01.01GB
D:192
and menu
components
Y 6018 5 2 Solenoid valve, Spreading out not Check cabling between Y6018 Spreading,
spreading out (Y6018), working the control unit and the function
open circuit component with diagnostic D7971/c1:37 description,
menu. page 7:52
Y 6018 6 2 Solenoid valve Spreading out not Check cabling between Y6018 Spreading,
spreading out (Y6018), working the control unit and the function
short circuit to ground. component with diagnostic D7971/c1:37 description,
menu. page 7:52
Y 6018 5 2 10 Solenoid valve, Spreading out left Check cabling between Y6018-LE Spreading,

spreading out left fork not working the control unit and the function
fork (Y6018-LE), open component with diagnostic D7971/c1:37 description,
circuit. menu. page 7:52
Y 6018 6 2 10 Solenoid valve, Spreading out left Check cabling between Y6018-LE Spreading,
spreading out left fork not working the control unit and the function
fork (Y6018-LE), short component with diagnostic D7971/c1:37 description,
Y 6018 5 2 20 Solenoid valve, Spreading out right Check cabling between Y6018-RI Spreading,
spreading out right fork not working the control unit and the function
fork (Y6018-RI), open component with diagnostic D7917/C1:41 description,
Y 6018 6 2 20 Solenoid valve, Spreading out right Check cabling between Y6018-RI Spreading,
spreading out right fork not working the control unit and the function
fork (Y6018-RI), short component with diagnostic D7917/C1:41 description,
Y 6018 5 7 Solenoid valve, Spreading not Check cabling between Y6018
spreading out (Y6018), working. the control unit and the
menu.
and menu
components
Y 6018 6 7 Solenoid valve Spreading not Check cabling between Y6018
spreading out (Y6018), working. the control unit and the
menu.
Y 6018 5 7 10 Solenoid valve, Spreading left side Check cabling between Y6018-LE 7.5 Spreading Spreading,
spreading out left not working. the control unit and the 12/XX function
(Y6018-LE), open component with diagnostic D7911/C1:29 DIAGNOSE, description,
circuit. menu. page 8:44 page 7:52
Y 6018 6 7 10 Solenoid valve Spreading left side Check cabling between Y6018-LE 7.5 Spreading Spreading,

spreading out left not working. the control unit and the 12/XX function
(Y6018-LE), short component with diagnostic D7911/C1:29 DIAGNOSE, description,
Y 6018 5 7 20 Solenoid valve, Spreading right Check cabling between Y6018-RI 7.5 Spreading Spreading,
spreading out right side not working. the control unit and the 14/XX function
(Y6018-RI), open component with diagnostic D7911/C1:34 DIAGNOSE, description,
circuit menu. page 8:45 page 7:52
Y 6018 6 7 20 Solenoid valve Spreading right Check cabling between Y6018-RI 7.5 Spreading Spreading,
spreading out right side not working. the control unit and the 14/XX function
(Y6018-RI), short component with diagnostic D7911/C1:34 DIAGNOSE, description,
Y 6019 5 2 Solenoid valve, Spreading in not Check cabling between Y6019 Spreading,
spreading in (Y6019), working the control unit and the function
open circuit. component with diagnostic D7971/C1:36 description,
menu. page 7:52
Y 6019 6 2 Solenoid valve Spreading in not Check cabling between Y6019 Spreading,
VDU01.01GB
spreading in (Y6019), working the control unit and the function

short circuit to ground. component with diagnostic D7971/C1:36 description,
D:193
menu. page 7:52
VDU01.01GB
D:194
and menu
components
Y 6019 5 2 10 Solenoid valve, Spreading in left Check cabling between Y6019-LE Spreading,
spreading in left fork fork not working the control unit and the function
(Y6019-LE), open component with diagnostic D7971/C1:36 description,
Y 6019 6 2 10 Solenoid valve, Spreading in left Check cabling between Y6019-LE Spreading,
spreading in left fork fork not working the control unit and the function
(Y6019-LE), short component with diagnostic D7971/C1:36 description,
Y 6019 5 2 20 Solenoid valve, Spreading in right Check cabling between Y6019-RI Spreading,

spreading in right fork not working the control unit and the function
fork (Y6019-RI), open component with diagnostic D7971/C1:40 description,
Y 6019 6 2 20 Solenoid valve, Spreading in right Check cabling between Y6019-RI Spreading,
spreading in right fork not working the control unit and the function
fork (Y6019-RI), short component with diagnostic D7971/C1:40 description,
Y 6019 5 7 Solenoid valve, Spreading not Check cabling between Y6019
spreading in (Y6019), working. the control unit and the
open circuit. component with diagnostic D7911/C1:33
menu.
Y 6019 6 7 Solenoid valve Spreading not Check cabling between Y6019
spreading in (Y6019), working. the control unit and the
menu.
spreading in left not working. the control unit and the 13/XX function
(Y6019-LE), open component with diagnostic D7911/C1:33 DIAGNOSE, description,
and menu
components
spreading in left not working. the control unit and the 13/XX function
(Y6019-LE), short component with diagnostic D7911/C1:33 DIAGNOSE, description,
spreading in right side not working. the control unit and the 15/XX function
(Y6019-RI), open component with diagnostic D7911/C1:35 DIAGNOSE, description,

spreading in right side not working. the control unit and the 15/XX function
(Y6019-RI), short component with diagnostic D7911/C1:35 DIAGNOSE, description,
Y 6020 5 2 Solenoid valve, side Side shift left not Check cabling between Y6020 Side shift,
shift left (Y6020), open working the control unit and the function
circuit component with diagnostic D7971/C1:34 description,
menu. page 7:48
Y 6020 6 2 Solenoid valve side Side shift left not Check cabling between Y6020 Side shift,
shift left (Y6020), short working the control unit and the function
circuit to ground. component with diagnostic D7971/C1:34 description,
menu. page 7:48
Y 6020 5 7 Solenoid valve, side Side shift left not Check cabling between Y6020 7.4 Side Side shift,
shift left (Y6020), open working the control unit and the Shift 4/XX function
circuit component with diagnostic D7911/C1:38 DIAGNOSE, description,
Y 6020 6 7 Solenoid valve side Side shift left not Check cabling between Y6020 7.4 Side Side shift,
VDU01.01GB
shift left (Y6020), short working the control unit and the Shift 4/XX function
D:195
VDU01.01GB
D:196
and menu
components
Y 6021 5 2 Solenoid valve, side Side shift right not Check cabling between Y6021 Side shift,
shift right (Y6021), working the control unit and the function
open circuit. component with diagnostic D7971/C1:35 description,
menu. page 7:48
Y 6021 6 2 Solenoid valve side Side shift right not Check cabling between Y6021 Side shift,
shift right (Y6021), working the control unit and the function
short circuit to ground. component with diagnostic D7971/C1:35 description,
menu. page 7:48
Y 6021 5 7 Solenoid valve, side Side shift right not Check cabling between Y6021 7.4 Side Side shift,

shift right (Y6021), working the control unit and the Shift 3/XX function
open circuit. component with diagnostic D7911/C1:39 DIAGNOSE, description,
Y 6021 6 7 Solenoid valve side Side shift right not Check cabling between Y6021 7.4 Side Side shift,
shift right (Y6021), working the control unit and the Shift 3/XX function
short circuit to ground. component with diagnostic D7911/C1:39 DIAGNOSE, description,
Y 6022 5 2 Solenoid valve, extra Extra hydraulic Check cabling between Y6022
hydraulic function out function out not the control unit and the
(Y6022), open circuit. working component with diagnostic D7971/C1:41
menu.
Y 6022 6 2 Solenoid valve Extra hydraulic Check cabling between Y6022
hydraulic function out function out not the control unit and the
(Y6022), short circuit to working component with diagnostic D7971/C1:41
ground. menu.
Y 6022 5 7 Solenoid valve Open container Check cabling between Y6022 See separate
open container door door not working the control unit and the supplement.
menu.
and menu
components
Y 6022 6 7 Solenoid valve Open container Check cabling between Y6022 See separate
hydraulic function out door not working the control unit and the supplement.
ground. menu.
Y 6023 5 2 Solenoid valve, extra Extra hydraulic Check cabling between Y6023
hydraulic function in function in not the control unit and the
(Y6023), open circuit. working component with diagnostic D7971/C1:40
menu.
Y 6023 6 2 Solenoid valve, Extra hydraulic Check cabling between Y6023

hydraulic function in function in not the control unit and the
(Y6023), short circuit to working component with diagnostic D7971/C1:40
ground. menu.
Y 6023 5 7 Solenoid valve Close container Check cabling between Y6023 See separate
close container door door not working the control unit and the supplement.
menu.
Y 6023 6 7 Solenoid valve Close container Check cabling between Y6023 See separate
close container door door not working the control unit and the supplement.
ground. menu.
Y 6034 5 7 1 Solenoid valve levelling Levelling locked, Check cabling between Y6034-1
lock 1 (Y6034-1), open levelling not the control unit and the
circuit. working. component with diagnostic D7911/C1:21
menu.
VDU01.01GB
lock 1 (Y6034-1), short levelling not the control unit and the
circuit to ground. working. component with diagnostic D7911/C1:21
D:197
menu.
VDU01.01GB
D:198
and menu
components
lock 2 (Y6034-2), open levelling not the control unit and the
menu.
lock 2 (Y6034-2), short levelling not the control unit and the
menu.
Y 6035 5 2 Solenoid valve, Levelling right Check cabling between Y6035 C1p38

levelling right up/anticlockwise the control unit and the D7971
up/anticlockwise not working. component with diagnostic
(Y6035), open circuit. menu.
Y 6035 6 2 Solenoid valve, Levelling right Check cabling between Y6035 C1p38
levelling right up/anticlockwise the control unit and the D7971
up/anticlockwise not working. component with diagnostic
(Y6035), short circuit to menu.
ground.
Y 6035 5 7 Solenoid valve levelling Levelling not Check cabling between Y6035
anticlockwise (Y6035), working. the control unit and the
menu.
anticlockwise (Y6035), working. the control unit and the
menu.
Y 6036 5 2 Solenoid valve, Levelling left Check cabling between Y6036 C1p39
levelling left up/clockwise not the control unit and the D7971
up/clockwise (Y6036), working. component with diagnostic
open circuit. menu.
and menu
components
Y 6036 6 2 Solenoid valve, Levelling left Check cabling between Y6036 C1p39
levelling left up/clockwise not the control unit and the D7971
up/clockwise (Y6036), working. component with diagnostic
clockwise (Y6036), working. the control unit and the
menu.

clockwise (Y6036), working. the control unit and the
menu.
Y 6039 5 7 Solenoid valve, lock Twistlocks: Check cabling between Y6039 7.9 Load Twistlocks,
twistlocks (Y6039), Twistlocks not the control unit and the Carrier 7/XX function
open circuit. working. component with diagnostic D7911/C1:15 DIAGNOSE, description,
Lift hooks: Lock
lugs not working. Check the component.
Y 6039 6 7 Solenoid valve lock Twistlocks: Check cabling between Y6039 7.9 Load Twistlocks,
Lift hooks: Lock
Y 6040 5 7 Solenoid valve, open Lift hooks: Lock Check cabling between Y6040 7.9 Load Twistlocks,
twistlocks (Y6040), lugs not working. the control unit and the Carrier 6/XX function
open circuit. component with diagnostic D7911/C1:14 DIAGNOSE, description,
Y 6040 6 7 Solenoid valve open Twistlocks: Check cabling between Y6040 7.9 Load Twistlocks,
VDU01.01GB
D:199
Lift hooks: Lock
VDU01.01GB
D:200
and menu
components
Y 6045 5 2 10 Solenoid valve blocking Lower not working. Check cabling between Y6045 7.2 Lifting
lower left (Y6045-LE), the control unit and the Lowering 8/XX
open circuit. component with diagnostic D7971/C1:36 DIAGNOSE,
menu. page 8:42
lower left (Y6045-LE), the control unit and the Lowering 8/XX
short circuit to ground. component with diagnostic D7971/C1:36 DIAGNOSE,
menu. page 8:42

lower right (Y6045-RI), the control unit and the Lowering 8/XX
open circuit. component with diagnostic D7971/C1:37 DIAGNOSE,
menu. page 8:42
lower right (Y6045-RI), the control unit and the Lowering 8/XX
short circuit to ground. component with diagnostic D7971/C1:37 DIAGNOSE,
menu. page 8:42
Y 6046 5 7 1 Solenoid valve WTP WTP not working. Check cabling between Y6046-1 See separate
(Y6046-1), twistlocks the control unit and the supplement.
out to WTP position, component with diagnostic A7993/C2:3
open circuit. menu.
out to WTP position, component with diagnostic A7993/C2:3
in to standard position, component with diagnostic A7993/C2:4
open circuit. menu.
and menu
components
in to standard position, component with diagnostic A7993/C2:4
open circuit. menu.
Y 6047 5 2 Solenoid valve cab Cab tilt not Check cabling between Y6047
tilt up (Y6047), open working. the control unit and the
menu.
Y 6047 6 2 Solenoid valve cab Cab tilt not Check cabling between Y6047

tilt up (Y6047), short working. the control unit and the
menu.
Y 6048 5 2 Solenoid valve cab tilt Cab tilt not Check cabling between Y6048
down (Y6048), open working. the control unit and the
menu.
Y 6048 6 2 Solenoid valve cab tilt Cab tilt not Check cabling between Y6048
down (Y6048), short working. the control unit and the
menu.
Y 6050 5 2 Solenoid valve blocking Boom in not Check cabling between Y6050
extension (Y6050), working. the control unit and the
menu.
Y 6050 6 2 Solenoid valve blocking Boom in not Check cabling between Y6050
VDU01.01GB
extension (Y6050), working. the control unit and the

D:201
menu.
VDU01.01GB
D:202
and menu
components
Y 6051 5 2 1 Solenoid valve Regeneration, Check cabling between Y6051-1
regeneration extension extension not the control unit and the
(Y6051-1), open circuit. working. component with diagnostic D7971/C1:34
menu.
Y 6051 6 2 1 Solenoid valve Regeneration, Check cabling between Y6051-1
regeneration extension extension not the control unit and the
(Y6051-1), short circuit working. component with diagnostic D7971/C1:34
to ground. menu.
Y 6051 5 2 10 Solenoid valve Regeneration, lift Check cabling between Y6051-LE

regeneration lift left not working. the control unit and the
(Y6051-LE), open component with diagnostic D7971/C1:11
circuit. menu.
Y 6051 6 2 10 Solenoid valve Regeneration, lift Check cabling between Y6051-LE
regeneration lift left not working. the control unit and the
(Y6051-LE), short component with diagnostic D7971/C1:11
Y 6051 5 2 20 Solenoid valve Regeneration, lift Check cabling between Y6051-RI
regeneration lift right not working. the control unit and the
(Y6051-RI), open component with diagnostic D7971/C1:01
circuit menu.
Y 6051 6 2 20 Solenoid valve Regeneration, lift Check cabling between Y6051-RI
regeneration lift right not working. the control unit and the
(Y6051-RI), short component with diagnostic D7971/C1:01
Y 6053 5 6 10 Solenoid valve Lowering of lift legs Check cabling between Y6053-LE
operating position not working. the control unit and the
left (Y6053-LE), open component with diagnostic D7912/C1:01
circuit. menu.
and menu
components
Y 6053 6 6 10 Solenoid valve Lowering of lift legs Check cabling between Y6053-LE
left (Y6053-LE), short component with diagnostic D7912/C1:01
Y 6053 5 6 20 Solenoid valve Lowering of lift legs Check cabling between Y6053-RI
right (Y6053-RI), open component with diagnostic D7912/C1:11
circuit. menu.
Y 6053 6 6 20 Solenoid valve Lowering of lift legs Check cabling between Y6053-RI

right (Y6053-RI), short component with diagnostic D7912/C1:11
Y 6054 5 2 Solenoid valve clamp Clamp close not Check cabling between Y6054
close (Y6054), open working. the control unit and the
menu.
Y 6054 6 2 Solenoid valve clamp Clamp close not Check cabling between Y6054
close (Y6054), short working. the control unit and the
menu.
Y 6054 5 2 10 Solenoid valve clamp Clamp close left Check cabling between Y6054-LE
close left (Y6054-LE), not working. the control unit and the
menu.
Y 6054 6 2 10 Solenoid valve clamp Clamp close left Check cabling between Y6054-LE
VDU01.01GB
D:203
menu.
VDU01.01GB
D:204
and menu
components
Y 6054 5 2 20 Solenoid valve clamp Clamp close right Check cabling between Y6054-RI
close right (Y6054-RI), not working. the control unit and the
menu.
menu.
Y 6054 5 3 10 Solenoid valve, clamp Clamp close not Check cabling between Y6054

close (Y6054), open working. the control unit and the
menu.
Y 6054 6 3 10 Solenoid valve clamp Clamp close not Check cabling between Y6054
close (Y6054), short working. the control unit and the
menu.
menu.
menu.
Y 6054 5 6 10 Solenoid valve clamp Lowering of lift legs Check cabling between Y6054-LE
menu.
and menu
components
menu.
Y 6054 5 6 20 Solenoid valve clamp Lowering of lift legs Check cabling between Y6054-RI
menu.

menu.
Y 6054 6 7 Solenoid valve clamp Lowering of lift legs Check cabling between Y6054 See separate
ELME (Y6054), short not working. the control unit and the supplement.
menu.
Y 6055 5 2 Solenoid valve clamp Clamp open not Check cabling between Y6055
open (Y6055), open working. the control unit and the
menu.
Y 6055 6 2 Solenoid valve clamp Clamp open not Check cabling between Y6055
open (Y6055), short working. the control unit and the
menu.
Y 6055 5 2 10 Solenoid valve clamp Clamp open left Check cabling between Y6055-LE
VDU01.01GB
open left (Y6055-LE), not working. the control unit and the
D:205
menu.
VDU01.01GB
D:206
and menu
components
Y 6055 6 2 10 Solenoid valve clamp Clamp open left Check cabling between Y6055-LE
menu.
Y 6055 5 2 20 Solenoid valve clamp Clamp open right Check cabling between Y6055-RI
open right (Y6055-RI), not working. the control unit and the
menu.

menu.
Y 6055 5 3 10 Solenoid valve clamp Clamp open not Check cabling between Y6055
open (Y6055), open working. the control unit and the
menu.
Y 6055 6 3 10 Solenoid valve clamp Clamp open not Check cabling between Y6055
open (Y6055), short working. the control unit and the
menu.
menu.
menu.
and menu
components
menu.
menu.

menu.
menu.
Y 6055 6 7 Solenoid valve detach Lowering of lift legs Check cabling between Y6055 See separate
ELME (Y6055) not working. the control unit and the supplement.
menu.
Y 6056 5 6 110 Solenoid valve front Lowering of lift legs Check cabling between Y6056-LF
knee in left (Y6056-LF), not working. the control unit and the
menu.
VDU01.01GB
knee in left (Y6056-LF), not working. the control unit and the
D:207
menu.
VDU01.01GB
D:208
and menu
components
Y 6056 5 6 120 Solenoid valve Lowering of lift legs Check cabling between Y6056-RF
front knee in right not working. the control unit and the
(Y6056-RF), open component with diagnostic D7912/C1:34
circuit. menu.
front knee in right not working. the control unit and the
(Y6056-RF), short component with diagnostic D7912/C1:34
Y 6056 5 6 210 Solenoid valve rear Lowering of lift legs Check cabling between Y6056-LR

knee in left (Y6056-LR), not working. the control unit and the
menu.
knee in left (Y6056-LR), not working. the control unit and the
menu.
Y 6056 5 6 220 Solenoid valve Lowering of lift legs Check cabling between Y6056-RR
rear knee in right not working. the control unit and the
(Y6056-RR), open component with diagnostic D7912/C1:47
circuit. menu.
rear knee in right not working. the control unit and the
(Y6056-RR), short component with diagnostic D7912/C1:47
Y 6057 5 6 110 Solenoid valve Lowering of lift legs Check cabling between Y6057-LF
front knee out left not working. the control unit and the
(Y6057-LF), open component with diagnostic D7912/C1:28
circuit. menu.
and menu
components
Y 6057 6 6 110 Solenoid valve Lowering of lift legs Check cabling between Y6057-LF
front knee out left not working. the control unit and the
(Y6057-LF), short component with diagnostic D7912/C1:28
front knee out right not working. the control unit and the
(Y6057-RF), open component with diagnostic D7912/C1:35
circuit. menu.

front knee out right not working. the control unit and the
(Y6057-RF), short component with diagnostic D7912/C1:35
Y 6057 5 6 210 Solenoid valve Lowering of lift legs Check cabling between Y6057-LR
rear knee out left not working. the control unit and the
(Y6057-LR), open component with diagnostic D7912/C1:39
circuit. menu.
Y 6057 6 6 210 Solenoid valve Lowering of lift legs Check cabling between Y6057-LR
rear knee out left not working. the control unit and the
(Y6057-LR), short component with diagnostic D7912/C1:39
rear knee out right not working. the control unit and the
circuit. menu.
VDU01.01GB
rear knee out right not working. the control unit and the
D:209
VDU01.01GB
D:210
and menu
components
leg up left (Y6058-LF), not working. the control unit and the
menu.
leg up left (Y6058-LF), not working. the control unit and the
menu.
Y 6058 5 6 120 Solenoid valve front leg Lowering of lift legs Check cabling between Y6058-RF

up right (Y6058-RF), not working. the control unit and the
menu.
up right (Y6058-RF), not working. the control unit and the
menu.
leg up left (Y6058-LR), not working. the control unit and the
menu.
leg up left (Y6058-LR), not working. the control unit and the
menu.
Y 6058 6 7 100 Solenoid valve front Lowering of lift legs Check cabling between Y6058-FR See separate
leg down ELME not working. the control unit and the supplement.
(Y6058-FR). component with diagnostic D7911/C2:31
menu.
and menu
components
Y 6058 6 7 200 Solenoid valve rear leg Lowering of lift legs Check cabling between Y6058-RE See separate
up ELME (Y6058-RE). not working. the control unit and the supplement.
menu.
Y 6058 5 7 220 Solenoid valve rear Lowering of lift legs Check cabling between Y6058-RR
lift leg up right not working. the control unit and the
circuit. menu.

lift leg up right not working. the control unit and the
Y 6059 5 6 110 Solenoid valve front leg Lowering of lift legs Check cabling between Y6059-LF
down left (Y6059-LF), not working. the control unit and the
menu.
Y 6059 6 6 110 Solenoid valve front leg Lowering of lift legs Check cabling between Y6059-LF
down left (Y6059-LF), not working. the control unit and the
menu.
down right (Y6059-RF), not working. the control unit and the
menu.
VDU01.01GB
down right (Y6059-RF), not working. the control unit and the
D:211
menu.
VDU01.01GB
D:212
and menu
components
Y 6059 5 6 210 Solenoid valve rear leg Lowering of lift legs Check cabling between Y6059-LR
down left (Y6059-LR), not working. the control unit and the
menu.
Y 6059 6 6 210 Solenoid valve rear leg Lowering of lift legs Check cabling between Y6059-LR
down left (Y6059-LR), not working. the control unit and the
menu.
Y 6059 6 7 100 Solenoid valve front Lowering of lift legs Check cabling between Y6059-FR See separate

(Y6059-FR). component with diagnostic D7911/C1:01
menu.
Y 6059 6 7 200 Solenoid valve rear Lowering of lift legs Check cabling between D7911/C1:11 See separate
(Y6059-RE). component with diagnostic
menu.
lift leg down right not working. the control unit and the
circuit. menu.
lift leg down right not working. the control unit and the
Y 6062 5 2 Solenoid valve No limitation. Check cabling between Y6062
disengage hydraulic the control unit and the
oil pump 2 (Y6062). component with diagnostic D7971/C1:14
menu.
and menu
components
Y 6062 6 2 Solenoid valve No limitation. Check cabling between Y6062
disengage hydraulic the control unit and the
oil pump 2 (Y6062). component with diagnostic D7971/C1:14
menu.
Y 6063 5 3 Solenoid valve support Lowering of Check cabling between Y6063
jacks up (Y6063), open support jacks not the control unit and the
menu.

jacks up (Y6063), short support jacks not the control unit and the
menu.
jacks down (Y6064), support jacks not the control unit and the
menu.
jacks down (Y6064), support jacks not the control unit and the
menu.
Y 6065 5 7 Solenoid valve Declutch of Check cabling between Y6065
declutch rotation brake rotation brake not the control unit and the
(Y6065), open circuit. working. component with diagnostic D7911/C1:1
menu.
Y 6065 6 7 Solenoid valve Declutch of Check cabling between Y6065
VDU01.01GB
declutch rotation brake rotation brake not the control unit and the
(Y6065), short circuit to working. component with diagnostic D7911/C1:1
D:213
ground. menu.
VDU01.01GB
D:214
and menu
components
Y 6070 5 7 Solenoid valve, Lowering of Check cabling between Y6070
overheight-legs up overheight-legs the control unit and the
(Y6070), open circuit. not working. component with diagnostic D7911/C1:17
menu.
overheight-legs up overheight-legs the control unit and the
(Y6070), short circuit to not working. component with diagnostic D7911/C1:17
ground. menu.

overheight-legs down overheight-legs the control unit and the
(Y6071), open circuit. not working. component with diagnostic D7911/C1:18
menu.
overheight-legs down overheight-legs the control unit and the
(Y6071), short circuit to not working. component with diagnostic D7911/C1:18
ground. menu.
Y 6072 5 3 1 Solenoid valve, No limitation. Check cabling between Y6072-1 See separate
clamping pressure the control unit and the supplement.
(Y6072-1), open circuit. component with diagnostic D7972/C1:27
menu.
(Y6072-1), short circuit component with diagnostic D7972/C1:27
to ground. menu.
(Y6072-2), open circuit. component with diagnostic D7972/C1:28
menu.
and menu
components
(Y6072-2), short circuit component with diagnostic D7972/C1:28
to ground. menu.
Y 6078 5 3 1 Solenoid valve, paper No limitation. Check cabling between Y6078-1 See separate
attachment, shutdown the control unit and the supplement.
upper clamping arm component with diagnostic D7972/C1:14
(Y6078-1), open circuit. menu.

(Y6078-1), short circuit menu.
to ground.
(Y6078-2), open circuit. menu.
(Y6078-2), short circuit menu.
to ground.
Y 6080 5 2 Solenoid valve, cab Cab movement Check cabling between Y6080
movement activation activation not the control unit and the
(Y6080), open circuit. working. component with diagnostic D7971/C2:31
menu.
Y 6080 6 2 Solenoid valve, cab Cab movement Check cabling between Y6080
VDU01.01GB
movement activation activation not the control unit and the

(Y6080), short circuit to working. component with diagnostic D7971/C2:31
D:215
ground. menu.
VDU01.01GB
D:216
and menu
components
Y 6085 5 2 Solenoid valve, split Hydraulic function Check cabling between Y6085
hydraulic function 1 1 cannot be split. the control unit and the
menu.
ground. menu.
Y 6085 5 7 Solenoid valve door Select door Check cabling between Y6085

opener (Y6085), open opening the control unit and the
circuit. (depending on component with diagnostic D7911/C2:38
container width) menu.
not working.
Y 6085 6 7 Solenoid valve select Select door Check cabling between Y6085
door opening (Y6085), opening the control unit and the
short circuit to ground. (depending on component with diagnostic D7911/C2:38
container width) menu.
not working.
menu.
ground. menu.
Y 6088 5 2 Solenoid valve, Deactivation of Check cabling between Y6088 Accumulator
shutdown accumulator accumulator not the control unit and the damping,
(Y6088), open circuit working. component with diagnostic D7971/C1:44 description,
menu. page 7:42
and menu
components
Y 6088 6 2 Solenoid valve, Deactivation of Check cabling between Y6088 Accumulator
shutdown accumulator accumulator not the control unit and the damping,
(Y6088), short circuit to working. component with diagnostic D7971/C1:44 description,
ground. menu. page 7:42
Y 6089 5 2 Solenoid valve activate Quick-lift not Check cabling between Y6089 Axial piston
extra hydraulic oil working. the control unit and the pump with
pump lift (Y6089), open component with diagnostic D7971/C1:1 variable
circuit. menu. displacement,
function
Check the component. description,
page 10:9

Y 6089 6 2 Solenoid valve activate Quick-lift not Check cabling between Y6089 Axial piston
extra hydraulic oil working. the control unit and the pump with
pump lift (Y6089), short component with diagnostic D7971/C1:1 variable
circuit to ground. menu. displacement,
function
Check the component. description,
page 10:9
Y 6091 5 2 Solenoid valve, fan Cooling fan not Check cabling between Y6091
speed, engine cooling working. the control unit and the
fan (Y6091), open component with diagnostic D7971/C1:47
circuit. menu.
Y 6091 6 2 Solenoid valve, fan Cooling fan not Check cabling between Y6091
speed, engine cooling working. the control unit and the
fan (Y6091), short component with diagnostic D7971/C1:47
Y 6092 5 2 Solenoid valve, fan Reversing of Check cabling between Y6092
speed direction, engine cooling fan not the control unit and the
cooling fan (Y6092), working. component with diagnostic D7971/C1:21
open circuit. menu.
VDU01.01GB
D:217
VDU01.01GB
D:218
and menu
components
Y 6092 6 2 Solenoid valve, fan Reversing of Check cabling between Y6092
speed direction, engine cooling fan not the control unit and the
cooling fan (Y6092), working. component with diagnostic D7971/C1:21
Y 6093 5 2 Solenoid valve pump Disengagement of Check cabling between Y6093
unloading boom in the hydraulic oil the control unit and the
(Y6093), open circuit. pump not working. component with diagnostic D7971/C1:14
menu.
Y 6093 6 2 Solenoid valve pump Disengagement of Check cabling between Y6093

unloading boom in the hydraulic oil the control unit and the
(Y6093), short circuit to pump not working. component with diagnostic D7971/C1:14
ground. menu.
Y 6094 5 2 Solenoid valve Disengagement of Check cabling between
disengage hydraulic the hydraulic oil the control unit and the
pump attachment pump not working. component with diagnostic
(Y6094), open circuit. menu.
Y 6094 6 2 Solenoid valve Disengagement of Check cabling between
disengage hydraulic the hydraulic oil the control unit and the
pump attachment pump not working. component with diagnostic
(Y6094), short circuit to menu.
ground.
Y 6095 5 2 Solenoid valve split - Check cabling between Y6095 11.9 I/O
function mast (Y6095), the control unit and the D7971 KFU
open circuit. component with diagnostic D7971/C1:40 1–75/XX
menu. DIAGNOSE,
page 8:91
Y 6095 6 2 Solenoid valve split - Check cabling between Y6095 11.9 I/O
function mast (Y6095), the control unit and the D7971 KFU
short circuit to ground. component with diagnostic D7971/C1:40 1–75/XX
menu. DIAGNOSE,
page 8:91
and menu
components
Y 6100 5 7 Solenoid valve Wide Wide body in not Check cabling between Y6100
body in (Y6100), open working. the control unit and the
menu.
body in (Y6100), short working. the control unit and the
menu.

body out (Y6101), open working. the control unit and the
menu.
body out (Y6101), short working. the control unit and the
menu.
Y 6104 6 7 Solenoid valve, beam Tilting of Check cabling between Y6104
lock locked (Y6104), attachment more the control unit and the
open circuit. than 10° not component with diagnostic D7911/C2:31
working. menu.
Y 6105 6 7 Solenoid valve, beam Tilting of Check cabling between Y6105
lock unlocked (Y6105), attachment more the control unit and the
short circuit to ground. than 10° not component with diagnostic D7911/C2:30
working. menu.
Y 6120 5 1 1 Damper motor, Recirculation Check cabling between Y6120 9.4 Climate Fresh air and
VDU01.01GB
recirculation air damper for the control unit and the System 11/XX recirculation
conditioning (Y6120), ventilation not component with diagnostic D7901/C2:28 DIAGNOSE, damper,
D:219
open circuit. working. menu. page 8:62 description,
page 9:25
VDU01.01GB
D:220
and menu
components
Y 6120 6 1 1 Damper motor Recirculation Check cabling between Y6120 9.4 Climate Fresh air and
conditioning unit ventilation not component with diagnostic D7901/C2:28 DIAGNOSE, damper,
(Y6120), short circuit to working. menu. page 8:62 description,
ground. page 9:25
conditioning (Y6120), ventilation not component with diagnostic D7901/C2:29 DIAGNOSE, damper,
open circuit. working. menu. page 8:62 description,
page 9:25

conditioning unit ventilation not component with diagnostic D7901/C2:29 DIAGNOSE, damper,
(Y6120), short circuit to working. menu. page 8:62 description,
ground. page 9:25
Y 6150 6 2 1 Voltage feed Joystick control Check cabling between Y6150/4 Control valve
to electronic or mini-wheel not the control unit and the steering,
steering module working. component with diagnostic D7971/C1:48 description,
(Y6150) for joystick menu. page 5:12
control/mini-wheel,
short circuit to ground. Check the component.
Y 6150 5 2 2 Electronic control Joystick control Check cabling between Y6150/1 Control valve
module (Y6150) or mini-wheel not the control unit and the steering,
for joystick working. component with diagnostic D7971/C1:50 description,
control/mini-wheel, menu. page 5:12
open circuit.
Y 6150 6 2 2 Electronic steering Joystick control Check cabling between Y6150/1 Control valve
module (Y6150) or mini-wheel not the control unit and the steering,
for joystick working. component with diagnostic D7971/C1:50 description,
control/mini-wheel, menu. page 5:12
and menu
components
Y 6150 2 2 3 Electronic control Joystick control Check the steering valve. Y6150/2 Control valve
module (Y6150) or mini-wheel not steering,
for joystick working. Check control valve D7971/C2:23 description,
control/mini-wheel, steering. page 5:12
oversteer.
This error code may be the control unit and the
generated if the valve component with diagnostic
slide is pressurised menu.
in the wrong way, for
example by turning the
steering wheel when
joystick control or mini
wheel is activated.

Y 6150 31 2 Control unit control Standard steering Check the CAN wiring Y6150 Control valve
valve feedback seat function works with between control unit D7971 steering,
position and Control limited capacity and Y6150 and power D7971 /C1:48 description,
unit mini-wheel or and mini-wheel supply from D7971 /C1:48. page 5:12
joystick control (Y6150) or joystick control
are missing. inoperative.
Y 6360 5 3 100 Directional control No limitation. Check cabling between Y6360–FR
valve steering the control unit and the
(Y6360–FR), forward, component with diagnostic D7972/C1:21
open circuit. At menu.
revolving driver's seat.
Y 6360 6 3 100 Directional control No limitation. Check cabling between Y6360–FR
(Y6360–FR), forward, component with diagnostic D7972/C1:21
At revolving driver's
seat. Check the component.
Y 6360 5 3 200 Directional control No limitation. Check cabling between Y6360–RI

(Y6360–RI), backward, component with diagnostic D7972/C1:22
open circuit. At menu.
revolving driver's seat.
VDU01.01GB
D:221
VDU01.01GB
D:222
and menu
components
Y 6360 6 3 200 Directional control No limitation. Check cabling between Y6360–RI
(Y6360–RI), backward, component with diagnostic D7972/C1:22
At revolving driver's
seat. Check the component.
Y 6420 2 2 Solenoid valve parking Parking brake Check cabling between Y6420 4.5 Park Brake Solenoid valve
brake (Y6420), cannot be the control unit and the Sys 4/XX parking brake,
incorrect data. released. component with diagnostic D7971/C1:17 DIAGNOSE, description,

brake (Y6420), open cannot be the control unit and the Sys 4/XX parking brake,
circuit. released. component with diagnostic D7971/C1:17 DIAGNOSE, description,
brake (Y6420), short cannot be the control unit and the Sys 4/XX parking brake,
circuit to ground. released. component with diagnostic D7971/C1:17 DIAGNOSE, description,
Y 6450 5 2 Magnetic clutch, Air conditioning not Check cabling between Y6450 9.4 Climate Compressor
cooling compressor working. the control unit and the System 13/XX air
(Y6450), open circuit. component with diagnostic D7971/C2:34 DIAGNOSE, conditioning,
menu. page 8:62 description,
page 9:30
Y 6450 6 2 Magnetic clutch, Air conditioning not Check cabling between Y6450 9.4 Climate Compressor
cooling compressor working. the control unit and the System 13/XX air
(Y6450), short circuit to component with diagnostic D7971/C2:34 DIAGNOSE, conditioning,
ground. menu. page 8:62 description,
page 9:30
and menu
components
K 6501 6 1 10 Windscreen wiper left, Left wiper front not Check cabling between K6501-LE 9.5 Wiper Wiper
relay (K6501-LE), short working the control unit and the & Washer motor front,
circuit to ground component with diagnostic D7901/C2:8 Sys 8/XX description,
page 8:65
K 6501 6 1 20 Windscreen wiper right, Right wiper front Check cabling between K6501-RI 9.5 Wiper
relay (K6501-RI), short not working the control unit and the & Washer
circuit to ground component with diagnostic D7901/C2:9 Sys 9/XX
menu. DIAGNOSE,
page 8:66
M 6501 7 1 10 Left wiper windscreen, Right wiper front Check cabling between M6501-LE 9.5 Wiper Wiper

position signal not working the control unit and the & Washer motor front,
(M6501-LE) component with diagnostic D7901/C1:10 Sys 8/XX description,
page 8:65
M 6501 7 1 20 Right wiper Right wiper front Check cabling between M6501-RI 9.5 Wiper
windscreen, position not working the control unit and the & Washer
signal (M6501-RI) component with diagnostic D7901/C1:11 Sys 9/XX
menu. DIAGNOSE,
page 8:66
M 6502 5 1 Wiper rear window Rear window wiper Check cabling between M6502/2 9.5 Wiper Wiper
(M6502), open circuit. not working. the control unit and the & Washer motor rear,
component with diagnostic D7901/C2:17 Sys 5/XX description,
page 8:64
M 6502 6 1 Wiper rear window Rear window wiper Check cabling between M6502/2 9.5 Wiper Wiper
(M6502), short circuit not working. the control unit and the & Washer motor rear,
to ground. component with diagnostic D7901/C2:17 Sys 5/XX description,
page 8:64
M 6502 7 1 Wiper rear window, Rear window wiper Check cabling between M6502/3 9.5 Wiper Wiper
VDU01.01GB
position signal not working. the control unit and the & Washer motor rear,
(M6502), the wiper component with diagnostic D7901/C1:12 Sys 5/XX description,
D:223
does not move. menu. DIAGNOSE, page 9:52
page 8:64
Check the motor.
VDU01.01GB
D:224
and menu
components
M 6503 5 1 Roof window wiper Wiper roof not Check cabling between M6503/2 9.5 Wiper Wiper
(M6503), open circuit. working. the control unit and the & Washer motor roof,
component with diagnostic D7901/C2:19 Sys 12/XX description,
page 8:67
M 6503 6 1 Wiper roof window Wiper roof not Check cabling between M6503/2 9.5 Wiper Wiper
(M6503), short circuit working. the control unit and the & Washer motor roof,
to ground. component with diagnostic D7901/C2:19 Sys 12/XX description,
page 8:67
M 6503 7 1 Roof window wiper, Wiper roof not Check cabling between M6503/3 9.5 Wiper Wiper

position signal working. the control unit and the & Washer motor roof,
(M6503). component with diagnostic D7901/C1:13 Sys 12/XX description,
page 8:67
M 6511 6 1 Relay windscreen Front windscreen Check cabling between K6511 9.5 Wiper Washer motor
washing (K6511), short washer not the control unit and the & Washer and reservoir,
circuit to ground. working. component with diagnostic D7901/C2:10 Sys 10/XX description,
page 8:66
M 6512 5 1 Motor, washing rear Rear window Check cabling between M6512 9.5 Wiper Washer motor
window (M6512), open washer not the control unit and the & Washer and reservoir,
circuit. working. component with diagnostic D7901/C2:16 Sys 6/XX description,
page 8:65
M 6512 6 1 Motor, washing rear Rear window Check cabling between M6512 9.5 Wiper Washer motor
window (M6512), short washer not the control unit and the & Washer and reservoir,
circuit to ground. working. component with diagnostic D7901/C2:16 Sys 6/XX description,
page 8:65
M 6513 5 1 Motor, washer fluid, Roof window Check cabling between M6513 9.5 Wiper Washer motor
roof window (M6513), washer not the control unit and the & Washer and reservoir,
open circuit. working. component with diagnostic D7901/C2:15 Sys 13/XX description,
page 8:67
and menu
components
M 6513 6 1 Motor, washer fluid, Roof window Check cabling between M6513 9.5 Wiper Washer motor
roof window (M6513), washer not the control unit and the & Washer and reservoir,
short circuit to ground. working. component with diagnostic D7901/C2:15 Sys 13/XX description,
page 8:67
M 6570 5 1 Cab fan (M6570), open Cab fan not Check cabling between M6570 9.4 Climate Cab fan,
circuit. working. the control unit and the System 9/XX description,
menu. page 8:62
M 6570 6 1 Cab fan (M6570), short Cab fan not Check cabling between M6570 9.4 Climate Cab fan,

circuit to ground. working. the control unit and the System 9/XX description,
menu. page 8:62
M 6570 7 1 10 Cooling fan Cooling fan Check cabling between M6590-LE
transmission left transmission not the control unit and the
(M6590-LE), no signal working. component with diagnostic A7991/C1:6
on activation. (Fan not menu.
working.)
M 6570 7 1 20 Cooling fan Cooling fan Check cabling between M6590
transmission right transmission not the control unit and the
(M6590-RI), no signal working. component with diagnostic A7991/C1:7
on activation. (Fan not menu.
working.)
M 6580 6 2 Magnetic clutch, The engine's Check cabling between M6580 1.7 Cooling Engine,
cooling fan engine cooling fan the control unit and the system 4/XX general, page
(M6580), short circuit operates at full component with diagnostic D7971/C1:47 DIAGNOSE, 1:3
to ground. power. menu. page 8:23
Check the component. 1.7 Cooling
system 5/XX
DIAGNOSE,
VDU01.01GB
page 8:23
D:225
VDU01.01GB
D:226
and menu
components
M 6580 7 2 Magnetic clutch, No limitation. Check the component. M6580 1.7 Cooling Engine,
cooling fan engine Possible system 4/XX general, page
(M6580), drive speed subsequent faults Check cabling between D7971/C2:20 DIAGNOSE, 1:3
too low. with increased the control unit and the page 8:23
temperatures. component with diagnostic
menu. 1.7 Cooling
system 5/XX
DIAGNOSE,
page 8:23
M 6590 6 2 Cooling fan intercooler Cooling fan Check cabling between M6590 1.7 Cooling Engine,
(H6590), short circuit intercooler not the control unit and the system 6/XX general, page
to ground. working. component with diagnostic D7971/C1:34 DIAGNOSE, 1:3
menu. page 8:23

system 7/XX
DIAGNOSE,
page 8:23
M 6590 7 2 10 Cooling fan intercooler Cooling fan Check cabling between M6590-LE 1.7 Cooling Engine,
left (M6590-LE), no intercooler not the control unit and the system 6/XX general, page
signal on activation. working. component with diagnostic D7971/C2:9 DIAGNOSE, 1:3
(Fan not working.) menu. page 8:23
system 7/XX
DIAGNOSE,
page 8:23
M 6590 7 2 20 Cooling fan intercooler Cooling fan Check cabling between M6590-RI 1.7 Cooling Engine,
right (M6590-RI), no intercooler not the control unit and the system 6/XX general, page
signal on activation. working. component with diagnostic D7971/C2:21 DIAGNOSE, 1:3
(Fan not working.) menu. page 8:23
system 7/XX
DIAGNOSE,
page 8:23
M 6670 5 1 Circulation pump, Pause heater not Check cabling between M6670
pause heater (M6670), working. the control unit and the
menu.
and menu
components
M 6670 6 1 Circulation pump Pause heater not Check cabling between M6670
pause heater (M6670), working. the control unit and the
menu.
M 6680 5 2 Cooling fan (M6680) Cooling of Check cabling between M6680
(hydraulic system), hydraulic oil not the control unit and the
open circuit. working. component with diagnostic D7971/C2:35
menu.
M 6680 6 2 Cooling fan (M6680) Cooling of Check cabling between M6680

(hydraulic system), hydraulic oil not the control unit and the
menu.
Y 6720 3 1 Air distribution valve Air distribution in Check cabling between Y6720/9 9.4 Climate Air distributor,
(Y6720) position signal, cab cannot be the control unit and the System 8/XX description,
high signal voltage. adjusted. component with diagnostic D7901/C1:28 DIAGNOSE, page 9:40
menu. page 8:61
Y 6720 4 1 Air distribution valve Air distribution in Check cabling between Y6720/9 9.4 Climate Air distributor,
(Y6720) position signal, cab cannot be the control unit and the System 8/XX description,
low signal voltage. adjusted. component with diagnostic D7901/C1:28 DIAGNOSE, page 9:40
menu. page 8:61
Y 6720 5 1 1 Air distribution valve Air distribution in Check cabling between Y6720/6 9.4 Climate Air distributor,
(Y6720), open circuit. cab cannot be the control unit and the System 16/XX description,
adjusted. component with diagnostic D7901/C2:24 DIAGNOSE, page 9:40
menu. page 8:63
VDU01.01GB
(Y6720), short circuit to cab cannot be the control unit and the System 16/XX description,
ground. adjusted. component with diagnostic D7901/C2:24 DIAGNOSE, page 9:40
D:227
menu. page 8:63
VDU01.01GB
D:228
and menu
components
(Y6720), open circuit. cab cannot be the control unit and the System 17/XX description,
adjusted. component with diagnostic D7901/C2:25 DIAGNOSE, page 9:40
menu. page 8:63
(Y6720), short circuit to cab cannot be the control unit and the System 17/XX description,
ground. adjusted. component with diagnostic D7901/C2:25 DIAGNOSE, page 9:40
menu. page 8:63
Y 6730 3 1 Heating valve (Y6730) Cab heat cannot Check cabling between Y6730/9 9.4 Climate Water valve,

position signal, high be adjusted. the control unit and the System 7/XX description,
signal voltage. component with diagnostic D7901/C1:29 DIAGNOSE, page 9:29
menu. page 8:61
Y 6730 4 1 Heating valve (Y6730) Cab heat cannot Check cabling between Y6730/9 9.4 Climate Water valve,
position signal, low be adjusted. the control unit and the System 7/XX description,
signal voltage. component with diagnostic D7901/C1:29 DIAGNOSE, page 9:29
menu. page 8:61
Y 6730 5 1 1 Heating valve (Y6730), Cab heat cannot Check cabling between Y6730/6 9.4 Climate Water valve,
open circuit. be adjusted. the control unit and the System 15/XX description,
menu. page 8:63
short circuit to ground. be adjusted. the control unit and the System 15/XX description,
menu. page 8:63
open circuit. be adjusted. the control unit and the System 14/XX description,
menu. page 8:63
and menu
components
short circuit to ground. be adjusted. the control unit and the System 14/XX description,
menu. page 8:63
M 6740 5 2 Cooling fan (M6740) Cooling of brake Check cabling between M6740
(brake system), open system not the control unit and the
menu.
If the temperature
becomes too high Check the component.
then machine

speed is limited,
and wear on the
brakes increases.
M 6740 6 2 Cooling fan (M6740) Cooling of brake Check cabling between M6740
(brake system), short system not the control unit and the
menu.
If the temperature
becomes too high Check the component.
then machine
speed is limited,
and wear on the
brakes increases.
M 6750 5 3 20 Motor seat turning Rotation of driver's Check cabling between M6750
(M6750), turning seat not working. the control unit and the
backwards, open component with diagnostic D7972/C2:35
circuit. menu.
backwards, short component with diagnostic D7972/C2:35
VDU01.01GB
D:229
VDU01.01GB
D:230
and menu
components
forwards, open circuit. component with diagnostic D7972/C2:37
menu.
forwards, short circuit component with diagnostic D7972/C2:37
to ground. menu.
Y 6760 5 1 Solenoid valve, The driver's seat Check cabling between Y6760

turnable driver's seat cannot be rotated. the control unit and the
menu.
Y 6760 6 1 Solenoid valve, The driver's seat Check cabling between Y6760
turnable driver's seat cannot be rotated. the control unit and the
ground. menu.
Y 6760 5 3 20 Solenoid valve, brake The operator's Check cabling between Y6760-RI
turnable driver's seat station cannot be the control unit and the
(Y6760-RI), open turned. component with diagnostic D7972/C1:23
circuit. menu.
Y 6760 6 3 20 Solenoid valve, brake The operator's Check cabling between Y6760-RI
(Y6760-RI), short turned. component with diagnostic D7972/C1:23
Y 6760 5 3 10 Solenoid valve, brake The operator's Check cabling between Y6760-LE
(Y6760-LE), open turned. component with diagnostic D7972/C1:24
circuit. menu.
and menu
components
Y 6760 6 3 10 Solenoid valve, brake The operator's Check cabling between Y6760-LE
(Y6760-LE), short turned. component with diagnostic D7972/C1:24
Y 6820 5 2 Solenoid valve, Extension out not Check cabling between Y6820
extension out (Y6820), working. the control unit and the
menu.
Y 6820 6 2 Solenoid valve Extension out not Check cabling between Y6820

extension out (Y6820), working. the control unit and the
menu.
Y 6821 5 2 Solenoid valve, Extension in not Check cabling between Y6821
extension in (Y6821), working. the control unit and the
menu.
Y 6821 6 2 Solenoid valve Extension in not Check cabling between Y6821
extension in (Y6821), working. the control unit and the
menu.
R 6900 3 11 1 Accelerator pedal Engine speed Check cabling between R6900/5 1.1 Controls Accelerator
(R6900) signal A, high limited to idling the control unit and the & Instr 1/XX pedal
voltage signal. speed. component with diagnostic D7902/C8:6 DIAGNOSE, description,
VDU01.01GB
(R6900) signal A, low limited to idling the control unit and the & Instr 1/XX pedal
D:231
VDU01.01GB
D:232
and menu
components
R 6900 13 11 1 Accelerator pedal Engine speed Calibrate the accelerator R6900/5 1.1 Controls Accelerator
(R6900) signal A, limited to idling pedal & Instr 1/XX pedal
incorrectly calibrated. speed. D7902/C8:6 DIAGNOSE, description,
page 8:21 page 1:31
(R6900) signal B, high limited to idling the control unit and the & Instr 1/XX pedal
(R6900) signal B, low limited to idling the control unit and the & Instr 1/XX pedal
D7902/C8:5

voltage signal. speed. component with diagnostic DIAGNOSE, description,
R 6900 13 11 2 Accelerator pedal Engine speed Calibrate the accelerator R6900/2 1.1 Controls Accelerator
(R6900) signal B, limited to idling pedal & Instr 1/XX pedal
incorrectly calibrated. speed. D7902/C8:5 DIAGNOSE, description,
page 8:21 page 1:31
R 6900 3 11 3 Accelerator pedal 2 Engine speed Check cabling between R6900/5 Accelerator
(R6900) signal A, high limited to idling the control unit and the pedal
voltage signal. speed. component with diagnostic D7902/C8:8 description,
menu. page 1:31
(R6900) signal A, low limited to idling the control unit and the pedal
menu. page 1:31
R 6900 13 11 3 Accelerator pedal 2 Engine speed Calibrate the accelerator R6900/5 Accelerator
(R6900) signal A, limited to idling pedal pedal
incorrectly calibrated. speed. D7902/C8:8 description,
page 1:31
and menu
components
(R6900) signal B, high limited to idling the control unit and the pedal
menu. page 1:31
(R6900) signal B, low limited to idling the control unit and the pedal
menu. page 1:31
R 6900 13 11 4 Accelerator pedal 2 Engine speed Calibrate the accelerator R6900/2 Accelerator

(R6900) signal B, limited to idling pedal pedal
incorrectly calibrated. speed. D7902/C8:7 description,
page 1:31
R 6900 2 11 40 Travel direction Neutral position. Check cabling between R6900 2.1 Controls Accelerator
selector in accelerator the control unit and the & Instr 4/XX pedal
pedal forward/reverse component with diagnostic DIAGNOSE, description,
(R6900), logic error. menu. page 8:29 page 1:31
M 6930 5 2 1 Pump central Central lubrication Check cabling between M6930 9.14 Central Central
lubrication, frame not working. the control unit and the Lubr 2/XX lubrication,
(M6930), open circuit. component with diagnostic D7971/C1:46 DIAGNOSE, description,
lubrication, frame not working. the control unit and the Lubr 2/XX lubrication,
(M6930), short circuit component with diagnostic D7971/C1:46 DIAGNOSE, description,
to ground. menu. page 8:75 page 9:90
lubrication attachment not working. the control unit and the Lubr 3/XX lubrication,
(M6930), open circuit. component with diagnostic D7911/C1:46 DIAGNOSE, description,
VDU01.01GB
D:233
VDU01.01GB
D:234
and menu
components
lubrication attachment not working. the control unit and the Lubr 3/XX lubrication,
(M6930), short circuit component with diagnostic D7911/C1:46 DIAGNOSE, description,
to ground. menu. page 8:75 page 9:90
B 6941 3 11 Motor, right-hand Movement of Check cabling between B6941/9 9.1 Controls
dashboard panel dashboard panel the control unit and the & Instr 5/XX
forward/backward not working. component with diagnostic D7902/C2:3 DIAGNOSE,
position signal, high menu. page 8:57
signal voltage.

position signal, low menu. page 8:57
signal voltage.
B 6941 7 11 Motor, right-hand Movement of Check that nothing is B6941/9 9.1 Controls
dashboard panel dashboard panel blocking the movement of & Instr 5/XX
forward/backward not working. the dashboard panel. D7902/C2:3 DIAGNOSE,
position signal, page 8:57
mechanical fault. Check the motor.
M 6941 5 11 1 Motor right Movement of Check cabling between M6941/5 9.1 Controls
forwards/backwards not working. component with diagnostic D7902/C2:7 DIAGNOSE,
(M6941), open circuit menu. page 8:57
M 6941 6 11 1 Motor, right-hand Movement of Check cabling between M6941/5 9.1 Controls
(M6941), short circuit menu. page 8:57
to ground.
M 6941 5 11 2 Motor right Movement of Check cabling between M6941/6 9.1 Controls
forwards/backwards not working. component with diagnostic D7902/C2:8 DIAGNOSE,
(M6941), open circuit menu. page 8:57
and menu
components
(M6941), short circuit menu. page 8:57
to ground.
up/down position not working. component with diagnostic D7902/C2:4 DIAGNOSE,
signal, high signal menu. page 8:58
voltage.

up/down position not working. component with diagnostic D7902/C2:4 DIAGNOSE,
signal, low signal menu. page 8:58
voltage.
B 6942 7 11 Motor, right-hand Movement of Check that nothing is B6942/9 9.1 Controls
dashboard panel dashboard panel blocking the movement of & Instr 7/XX
up/down position not working. the dashboard panel. D7902/C2:4 DIAGNOSE,
signal, mechanical page 8:58
fault. Check the motor.
M 6942 6 11 1 Motor right dashboard Movement of Check cabling between M6942/5 9.1 Controls
panel up/down dashboard panel the control unit and the & Instr 7/XX
(M6942), open circuit. not working. component with diagnostic D7902/C2:9 DIAGNOSE,
menu. page 8:58
up/down (M6942), not working. component with diagnostic D7902/C2:9 DIAGNOSE,
M 6942 5 11 2 Motor right dashboard Movement of Check cabling between M6942/5 9.1 Controls
panel up/down dashboard panel the control unit and the & Instr 7/XX
VDU01.01GB
(M6942), open circuit. not working. component with diagnostic D7902/C2:9 DIAGNOSE,
D:235
menu. page 8:58
VDU01.01GB
D:236
and menu
components
up/down (M6942), not working. component with diagnostic D7902/C2:9 DIAGNOSE,
B 6943 3 11 Motor, steering panel Movement of Check cabling between B6943/9
up/down position steering panel not the control unit and the
signal, high signal working. component with diagnostic D7902/C1:9
voltage. menu.
B 6943 4 11 Motor, steering panel Movement of Check cabling between B6943/9

up/down position steering panel not the control unit and the
signal, low signal working. component with diagnostic D7902/C1:9
voltage. menu.
B 6943 7 11 Motor, steering panel Movement of Check that nothing is B6943/9
up/down position steering panel not blocking the movement of
signal, mechanical working. the dashboard panel. D7902/C1:9
problem.
Check the motor.
M 6943 5 11 1 Motor steering panel Movement of Check cabling between M6943/5
up/down (M6943), steering panel not the control unit and the
menu.
M 6943 6 11 1 Motor, steering panel Movement of Check cabling between M6943/5
menu.
M 6943 5 11 2 Motor steering panel Movement of Check cabling between M6943/6
menu.
and menu
components
M 6943 6 11 2 Motor, steering panel Movement of Check cabling between M6943/6
menu.
P 7080 14 1 Operating times do No limitation Connect the Kalmar Service D7901
not correspond to tool and Repair or contact
3 reference Control unit Cargotec support. D7902
KFU (D7971).
6 D7911
7 D7912

11 D7950
12 D7971
D7972
B 7202 2 7 Logic error sensor No load handling Check the sensors. B7202-FL 7.9 Load Side lift
contact B7202-XX, a functions are Carrier 115/XX attachment,
sensor has been active working. Check cabling between D7911/C2:17 DIAGNOSE, general, page
for longer than 120 the control unit and the page 8:50 7:70
seconds. component with diagnostic B7202-FR
menu. 7.9 Load
D7911/C2:16 Carrier 116/XX
B7202-RL DIAGNOSE,
page 8:50
D7911/C2:14
B7202-RR
D7911/C2:13
B 7205 3 7 10 Sensor twistlocks left No load handling Check cabling between B7204-LE 7.9 Load Side lift
(B7205-LE), signal functions are the control unit and the Carrier 115/XX attachment,
voltage too high. working. component with diagnostic D7911/C2:23 DIAGNOSE, general, page
menu. page 8:50 7:70
Check the component
VDU01.01GB
D:237
VDU01.01GB
D:238
and menu
components
(B7205-LE), signal functions are the control unit and the Carrier 115/XX attachment,
voltage too low. working. component with diagnostic D7911/C2:23 DIAGNOSE, general, page
Check the component
(B7205-LE), calibration functions are the control unit and the Carrier 115/XX attachment,
error. working. component with diagnostic D7911/C2:23 DIAGNOSE, general, page
Check the component
B 7205 3 7 20 Sensor twistlocks right No load handling Check cabling between B7204-RI 7.9 Load Side lift

(B7205-RI), signal functions are the control unit and the Carrier 116/XX attachment,
Check the component
(B7205-RI), signal functions are the control unit and the Carrier 116/XX attachment,
Check the component
(B7205-RI), calibration functions are the control unit and the Carrier 116/XX attachment,
Check the component
B 7205 3 7 110 Sensor twistlocks left No load handling Check cabling between B7204–LF Side lift
(B7205-LF), signal functions are the control unit and the attachment,
voltage too high. working. component with diagnostic D7911/C2:19 general, page
menu. 7:70
Check the component
(B7205-LF), signal functions are the control unit and the attachment,
voltage too low. working. component with diagnostic D7911/C2:19 general, page
menu. 7:70
Check the component
and menu
components
(B7205-LF), calibration functions are the control unit and the attachment,
error. working. component with diagnostic D7911/C2:19 general, page
menu. 7:70
Check the component
B 7205 3 7 120 Sensor twistlocks right No load handling Check cabling between B7204–RF Side lift
(B7205-RF), signal functions are the control unit and the attachment,
voltage too high. working. component with diagnostic D7911/C2:18 general, page
menu. 7:70
Check the component

(B7205-RF), signal functions are the control unit and the attachment,
voltage too low. working. component with diagnostic D7911/C2:18 general, page
menu. 7:70
Check the component
(B7205-RF), calibration functions are the control unit and the attachment,
error. working. component with diagnostic D7911/C2:18 general, page
menu. 7:70
Check the component
B 7205 3 7 210 Sensor twistlocks left No load handling Check cabling between B7204–LR 7.9 Load Side lift
(B7205-LR), signal functions are the control unit and the Carrier 115/XX attachment,
Check the component
(B7205-LR), signal functions are the control unit and the Carrier 115/XX attachment,
Check the component
VDU01.01GB
(B7205-LR), calibration functions are the control unit and the Carrier 115/XX attachment,
D:239
Check the component
VDU01.01GB
D:240
and menu
components
B 7205 3 7 220 Sensor twistlocks right No load handling Check cabling between B7204-RR 7.9 Load Side lift
(B7205-RR), signal functions are the control unit and the Carrier 116/XX attachment,
Check the component
B 7205 4 7 220 Sensor twistlocks right No load handling Check cabling between B7204-RR 7.9 Load Side lift
(B7205-RR), signal functions are the control unit and the Carrier 116/XX attachment,
Check the component
B 7205 13 7 220 Sensor twistlocks No load handling Check cabling between B7204-RR 7.9 Load Side lift

right (B7205-RR), functions are the control unit and the Carrier 116/XX attachment,
calibration error. working. component with diagnostic D7911/C2:21 DIAGNOSE, general, page
Check the component
B 7205 7 7 10 Logic error Sensor No load handling Check that the sensors are B7204-LE Side lift
twistlocks left functions are free of dirt. attachment,
(B7204-LE and working. D7911/C2:19 general, page
(B7205-LE), both Check sensor positions, 7:70
sensors active see . B7205-LE
simultaneously. D7911/C2:23
Check indicator plates and
twistlocks mechanism.
menu.
and menu
components
B 7205 7 7 20 Logic error Sensor No load handling Check that the sensors are B7204-RI Side lift
twistlocks right functions are free of dirt. attachment,
(B7204-RI and working. D7911/C2:18 general, page
B7205-RI), both Check sensor positions, 7:70
sensors active see . B7205-RI
simultaneously. D7911/C2:21
Check indicator plates and
twistlocks mechanism.
menu.

B 7216 2 7 Sensor fan position No limitation. Check that the sensor's B7216-LE 7.9 Load Lifting/lower-
lifting head (B7216-LE, indicator pin has not Carrier 92/XX ing, function
B7216-RI). Machine can start become stuck. D7911/C1:49 DIAGNOSE, description,
to damp the speed page 8:49 page 7:16
on lowering. Check the cable harness B7216-RI
between the control unit
and the sensor using the D7911/C1:46
diagnostic menu.
Check the sensor.
B 7226 3 2 1 Sensor, hydraulic Load sensor and Check the cable harness B7226-1 8.2 Monitoring Overload
pressure lift cylinder overload system between the control unit 3/XX system,
(B7226-1), high signal not working. Lift and the sensor using the D7971/C2:10 DIAGNOSE, description,
voltage. and tilt blocked. diagnostic menu. page 8:52 page 8:6
Check the sensor.
(B7226-1), low signal not working. Lift and the sensor using the D7971/C2:10 DIAGNOSE, description,
Check the sensor.
B 7226 13 2 1 Sensor hydraulic Load sensor and Check the cable harness B7226-1 8.2 Monitoring Overload
(B7226-1), calibration not working. Lift and the sensor using the D7971/C2:10 DIAGNOSE, description,
error. and tilt blocked. diagnostic menu. page 8:52 page 8:6
VDU01.01GB
D:241
Check the sensor.
VDU01.01GB
D:242
and menu
components
pressure lift cylinder, overload system between the control unit 17/XX system,
piston side, right not working. Lift and the sensor using the D7971/C2:13 DIAGNOSE, description,
(B7226-2), high signal and extension diagnostic menu. page 8:54 page 8:6
voltage. blocked.
Check the sensor. 8.2 Monitoring
18/XX
DIAGNOSE,
page 8:54
piston side, right not working. Lift and the sensor using the D7971/C2:13 DIAGNOSE, description,
(B7226-2), low signal and extension diagnostic menu. page 8:54 page 8:6

voltage. blocked.
18/XX
DIAGNOSE,
page 8:54
pressure tilt cylinder overload system between the control unit 17/XX system,
(B7226-3), high signal not working. Lift and the sensor using the D7971/C2:11 DIAGNOSE, description,
18/XX
DIAGNOSE,
page 8:54
pressure tilt cylinder overload system between the control unit 17/XX system,
(B7226-3), low signal not working. Lift and the sensor using the D7971/C2:11 DIAGNOSE, description,
18/XX
DIAGNOSE,
page 8:54
and menu
components
rod side, right not working. Lift and the sensor using the D7971/C2:14 DIAGNOSE, description,
(B7226-4), high signal and extension diagnostic menu. page 8:54 page 8:6
voltage. blocked.
18/XX
DIAGNOSE,
page 8:54
rod side, right not working. Lift and the sensor using the D7971/C2:14 DIAGNOSE, description,
(B7226-4), low signal and extension diagnostic menu. page 8:54 page 8:6

voltage. blocked.
18/XX
DIAGNOSE,
page 8:54
B 7228 3 2 Height sensor, lift Can give speed Check the cable harness B7228 Lifting/lower-
(B7228), high voltage. limitations between the control unit ing, descrip-
depending on the and the sensor using the D7971/C2:18 tion, page 7:15
configuration. diagnostic menu.
Check the sensor.
B 7228 4 2 Height sensor, lift Can give speed Check the cable harness B7228 Lifting/lower-
(B7228), low voltage. limitations between the control unit ing, descrip-
depending on the and the sensor using the D7971/C2:18 tion, page 7:15
Check the sensor.
B 7228 3 7 Height sensor, lift Can give speed Check the cable harness B7228 7.2 Lifting Lifting/lower-
(B7228), high voltage. limitations between the control unit Lowering ing, descrip-
depending on the and the sensor using the D7911/C2:24 11/XX tion, page 7:15
configuration. diagnostic menu. DIAGNOSE,
page 8:42
Check the sensor.
B 7228 4 7 Height sensor, lift Can give speed Check the cable harness B7228 7.2 Lifting Lifting/lower-
VDU01.01GB
(B7228), low voltage. limitations between the control unit Lowering ing, descrip-
depending on the and the sensor using the D7911/C2:24 11/XX tion, page 7:15
D:243
configuration. diagnostic menu. DIAGNOSE,
page 8:42
Check the sensor.
VDU01.01GB
D:244
and menu
components
B 7229 3 2 Sensor tilt angle Can give speed Check the cable harness B7229 7.7 Tilt 3/XX Tilt,
(B7229), high signal limitations between the control unit DIAGNOSE, description,
voltage. depending on the and the sensor using the D7971/C2:15 page 8:46 page 7:62
Check the sensor.
(B7229), low signal limitations between the control unit DIAGNOSE, description,
voltage. depending on the and the sensor using the D7971/C2:15 page 8:46 page 7:62
Check the sensor.

(B7229), calibration limitations between the control unit DIAGNOSE, description,
error. depending on the and the sensor using the D7971/C2:15 page 8:46 page 7:62
Check the sensor.
B 7230 3 7 Sensor damping Damping in vicinity Check the cable harness B7230 7.9 Load Lifting/lower-
attachment (B7230), of the container not between the control unit Carrier 78/XX ing, descrip-
high signal voltage. working and the sensor using the D7911/C2:12 DIAGNOSE, tion, page 7:15
diagnostic menu. page 8:49
Check the sensor.
B 7230 4 7 Sensor damping Damping in vicinity Check the cable harness B7230 7.9 Load Lifting/lower-
attachment (B7230), of the container not between the control unit Carrier 78/XX ing, descrip-
low signal voltage. working and the sensor using the D7911/C2:12 DIAGNOSE, tion, page 7:15
diagnostic menu. page 8:49
Check the sensor.
B 7235 3 2 10 Sensor power cell left When connected Check the cable harness B7235-LE 8.2.11 Load
(B7235-LE), high signal to OLS with between the control unit sensor, page
voltage. control, error and the sensor using the D7971/C2:10 8:11
codes give speed diagnostic menu.
limitations and
lift and tilt in are Check the sensor.
stopped.
and menu
components
(B7235-LE), low signal to OLS with between the control unit sensor, page
limitations and
stopped.
(B7235-LE), calibration to OLS with between the control unit sensor, page
error. control, error and the sensor using the D7971/C2:10 8:11
limitations and

stopped.
B 7235 3 2 20 Sensor power cell right When connected Check the cable harness B7235-RI 8.2.11 Load
(B7235-RI), high signal to OLS with between the control unit sensor, page
limitations and
stopped.
(B7235-RI), low signal to OLS with between the control unit sensor, page
limitations and
stopped.
(B7235-RI), calibration to OLS with between the control unit sensor, page
error. control, error and the sensor using the D7971/C2:13 8:11
limitations and
stopped.
B 7235 3 7 110 Sensor attachment TDB Check the cable harness B7235–LF
load, left front between the control unit
VDU01.01GB
(B7235-LF), high signal and the sensor using the A7992/C1:10
D:245
voltage. diagnostic menu.
Check the sensor.
VDU01.01GB
D:246
and menu
components
B 7235 4 7 110 Sensor attachment TDB Check the cable harness B7235–LF
load, left front between the control unit
(B7235-LF), low signal and the sensor using the A7992/C1:10
Check the sensor.
B 7235 3 7 120 Sensor attachment TDB Check the cable harness B7235–RF
load, right front between the control unit
(B7235-RF), high and the sensor using the A7992/C1:11
signal voltage. diagnostic menu.
Check the sensor.
B 7235 4 7 120 Sensor attachment TDB Check the cable harness B7235–RF

load, right front between the control unit
(B7235-RF), low signal and the sensor using the A7992/C1:11
Check the sensor.
B 7235 3 7 210 Sensor attachment TDB Check the cable harness B7235–LR
load, left rear between the control unit
(B7235-LR), high and the sensor using the A7992/C1:12
Check the sensor.
B 7235 4 7 210 Sensor attachment TDB Check the cable harness B7235–LR
load, left rear between the control unit
(B7235-LR), low signal and the sensor using the A7992/C1:12
Check the sensor.
B 7235 3 7 220 Sensor attachment TDB Check the cable harness B7235-RR
load, right rear between the control unit
(B7235-RR), high and the sensor using the A7992/C2:1
Check the sensor.
B 7235 4 7 220 Sensor attachment TDB Check the cable harness B7235-RR
load, right rear between the control unit
(B7235-RR), low signal and the sensor using the A7992/C2:1
Check the sensor.
and menu
components
B 7236 3 2 Sensor power cell tilt When connected Check the cable harness B7236 8.2.11 Load
(B7236), high signal to OLS with between the control unit sensor, page
voltage control, error and the sensor using the D7971/C2:11 8:11
limitations and
stopped.
B 7236 4 2 Sensor power cell tilt When connected Check the cable harness B7236 8.2.11 Load
(B7236), low signal to OLS with between the control unit sensor, page
voltage control, error and the sensor using the D7971/C2:11 8:11
limitations and

stopped.
B 7237 2 7 Logic error Sensor No load handling Check that the sensor's B7237-LE 8.2.11 Load
upper container functions are indicator pin has not sensor, page
(B7237-LE / B7237-RI), working. become stuck. D7971/C2:7 8:11
a sensor has been
active for longer than Check the cable harness B7237-RI
120 seconds. between the control unit
diagnostic menu.
Check the sensor.
B 7238 3 2 Tilt cylinder pressure When connected Check the cable harness B7238 8.2.11 Load
sensor (B7238) to OLS with between the control unit sensor, page
control, error and the sensor using the D7971/C2:11 8:11
limitations and
stopped.
B 7238 4 2 Tilt cylinder pressure When connected Check the cable harness B7238 8.2.11 Load
sensor (B7238) to OLS with between the control unit sensor, page
control, error and the sensor using the D7971/C2:11 8:11
limitations and
stopped.
VDU01.01GB
D:247
VDU01.01GB
D:248
and menu
components
B 7241 3 2 Sensor tilt angle Load sensor and Check the cable harness B7241
(B7241), high signal overload system between the control unit
voltage. not working. and the sensor using the D7971/C2:15
diagnostic menu.
Check the sensor.
B 7241 4 2 Sensor tilt angle Load sensor and Check the cable harness B7241
(B7241), low signal overload system between the control unit
voltage. not working. and the sensor using the D7971/C2:15
diagnostic menu.
Check the sensor.
B 7241 7 2 Sensor, tilt angle Load sensor and Check the cable harness B7241

(B7241), logic error. overload system between the control unit
not working. and the sensor using the D7971/C2:15
diagnostic menu.
Check the sensor.
B 7242 7 2 Sensor central Central lubrication Check the cable harness B7242 9.14 Central Sensor,
lubrication frame pump running with between the control unit Lubr 1/XX central
(B7242), time error. fixed lubrication and the sensor using the D7971/C1:12 DIAGNOSE, lubrication,
cycle time. diagnostic menu. page 8:75 description,
page 9:92
Check the sensor.
B 7242 7 7 Sensor central Central lubrication Check the cable harness B7242 9.14 Central Sensor,
lubrication attachment pump running with between the control unit Lubr 3/XX central
(B7242), time error. fixed lubrication and the sensor using the D7911/C1:20 DIAGNOSE, lubrication,
cycle time. diagnostic menu. page 8:75 description,
page 9:92
Check the sensor.
B 7243 3 2 Sensor electronic Oil level indicator Check the cable harness B7243
dipstick engine oil not working. between the control unit
(B7243) and the sensor using the D7911/C1:20
diagnostic menu.
Check the sensor.
B 7243 4 2 Sensor electronic Oil level indicator Check the cable harness B7243
dipstick engine oil not working. between the control unit
(B7243) and the sensor using the D7911/C1:20
diagnostic menu.
Check the sensor.
and menu
components
B 7244 3 2 Electric transmission Limits Check the cable harness B7244 11.9 I/O
dipstick sensor (B7244) transmission between the control unit D7971 KFU
performance and the sensor using the D7971/C2:17 1–75/XX
diagnostic menu. DIAGNOSE,
page 8:91
Check the sensor.
B 7244 4 2 Electric transmission Limits Check the cable harness B7244 11.9 I/O
dipstick sensor (B7244) transmission between the control unit D7971 KFU
performance and the sensor using the D7971/C2:17 1–75/XX
diagnostic menu. DIAGNOSE,
page 8:91
Check the sensor.
B 7245 3 2 10 Steering feedback Steering turns off Check the cable harness B7245-LE

sensor (B7245-LE), automatically. between the control unit
channel 1. and the sensor using the D7971/C2:12
diagnostic menu.
Check the sensor.
B 7245 4 2 10 Steering feedback Steering turns off Check the cable harness B7245-LE
sensor (B7245-LE), automatically. between the control unit
channel 1. and the sensor using the D7971/C2:12
diagnostic menu.
Check the sensor.
B 7245 3 2 20 Sensor, feedback Steering turns off Check the cable harness B7245-RI
steering, channel 2. automatically. between the control unit
diagnostic menu.
Check the sensor.
B 7245 4 2 20 Sensor, feedback Steering turns off Check the cable harness B7245-RI
steering, channel 2. automatically. between the control unit
diagnostic menu.
Check the sensor.
B 7252 3 11 Sensor, ambient Searchlight and Make sure there are no B7252 8.1 Controls Cab overview,
VDU01.01GB
brightness (B7252), function light in objects or dirt in front of & Instr 1/XX page 9:5
high signal voltage. silicone panels the sensor in the driveline D7902/C6:20 DIAGNOSE,
D:249
can give incorrect panel. page 8:51
brightness.
VDU01.01GB
D:250
and menu
components
B 7252 4 11 Sensor, ambient Searchlight and Make sure there are no B7252 8.1 Controls Cab overview,
brightness (B7252), function light in objects or dirt in front of & Instr 1/XX page 9:5
low signal voltage. silicone panels the sensor in the driveline D7902/C6:20 DIAGNOSE,
can give incorrect panel. page 8:51
brightness.
B 7253 3 7 Sensor tilt or levelling Sensor tilt or Check the cable harness B7253
angle attachment levelling angle between the control unit
(B7253), high signal attachment not and the sensor using the D7911/C2:15
voltage. working. diagnostic menu.
Check the sensor.
B 7253 4 7 Sensor tilt or levelling Sensor tilt or Check the cable harness B7253

angle attachment levelling angle between the control unit
(B7253), low signal attachment not and the sensor using the D7911/C2:15
voltage. working. diagnostic menu.
Check the sensor.
B 7254 3 1 Sensor cab position Overload system Check the cable harness B7254
(B7254), high signal and load centre between the control unit
voltage. limitation assume and the sensor using the D7901/C1:32
the cab is in fully diagnostic menu.
slid-forward/raised
position and limit Check the sensor.
the functions
accordingly.
B 7254 4 1 Sensor cab position Overload system Check the cable harness B7254
(B7254), low signal and load centre between the control unit
voltage. limitation assume and the sensor using the D7901/C1:32
the cab is in fully diagnostic menu.
slid-forward/raised
position and limit Check the sensor.
the functions
accordingly.
B 7255 3 1 Sensor cab tilt position No limitation. Check the cable harness B7255
(B7255), high signal between the control unit
voltage. and the sensor using the D7901/C1:31
diagnostic menu.
Check the sensor.
and menu
components
B 7255 4 1 Sensor cab tilt position No limitation. Check the cable harness B7255
(B7255), low signal between the control unit
voltage. and the sensor using the D7901/C1:31
diagnostic menu.
Check the sensor.
B 7258 2 7 Logic error Sensor No load handling Check that the sensor's B7258-LE
locking wedge position functions are indicator pin has not
locked (B7258-LE / working. become stuck. D7911/C2:29
B7258-RI), a sensor
has been active Check the cable harness B7258-RI
for longer than 120 between the control unit
D7971/C2:28
seconds. and the sensor using the

diagnostic menu.
Check the sensor.
B 7570 3 2 Sensor fuel level Incorrect display of Check the cable harness B7570 1.2 Fuel Sensor,
(B7570), high signal fuel volume (empty between the control unit System 1/XX fuel level,
voltage. or full). and the sensor using the D7971/C2:24 DIAGNOSE, description,
diagnostic menu. page 8:21 page 1:35
Check the sensor.
B 7570 4 2 Sensor fuel level Incorrect display of Check the cable harness B7570 1.2 Fuel Sensor,
(B7570), low signal fuel volume (empty between the control unit System 1/XX fuel level,
voltage. or full). and the sensor using the D7971/C2:24 DIAGNOSE, description,
diagnostic menu. page 8:21 page 1:35
Check the sensor.
B 7572 3 2 Sensor exhaust back Incorrect display Check the cable harness B7572 1.3 Aux
pressure (B7572), high of exhaust back between the control unit Exhaust
signal voltage. pressure. and the sensor using the D7971/C2:9 Clean 1/XX
diagnostic menu. Diagnose,
page 8:22
Check the sensor.
B 7572 4 2 Sensor exhaust back Incorrect display Check the cable harness B7572 1.3 Aux
pressure (B7572), low of exhaust back between the control unit Exhaust
signal voltage. pressure. and the sensor using the D7971/C2:9 Clean 1/XX
diagnostic menu. Diagnose,
VDU01.01GB
page 8:22
Check the sensor.
D:251
VDU01.01GB
D:252
and menu
components
B 7572 15 2 Sensor exhaust back Value too high, Clean the filter. B7572 1.3 Aux
pressure (B7572), high exhaust back Exhaust
value, still approved. pressure. Least D7971/C2:9 Clean 1/XX
severe level. Diagnose,
page 8:22
B 7572 16 2 Sensor exhaust back Value too Clean the filter. B7572 1.3 Aux
pressure (B7572), high high, exhaust Exhaust
value, still approved. back pressure. D7971/C2:9 Clean 1/XX
Moderately serious Diagnose,
level. page 8:22
B 7600 0 2 0 Speed sensor (B7600). Reduction of Check the wiring between B7600
engine speed. control unit and sensor.

D7971/C2:21
Check the sensor.
B 7600 8 2 0 Speed sensor (B7600). Reduction of Check the wiring between B7600
engine speed. control unit and sensor.
D7971/C2:21
Check the sensor.
B 7680 3 3 1 Sensor, clamping No clamping Check the cable harness B7680-1 See separate
pressure single/left pressure control between the control unit supplement.
clamp (B7680-1), high for single/left and the sensor using the D7972/C2:15
signal voltage. clamp. diagnostic menu.
Check the sensor.
clamp (B7680-1), low for single/left and the sensor using the D7972/C2:15
Check the sensor.
clamp (B7680-2), high for single/left and the sensor using the D7972/C2:13
Check the sensor.
and menu
components
clamp (B7680-2), low for single/left and the sensor using the D7972/C2:13
Check the sensor.
pressure right clamp pressure control between the control unit supplement.
(B7680-3), high signal for right clamp. and the sensor using the D7972/C2:16
Check the sensor.

(B7680-3), low signal for right clamp. and the sensor using the D7972/C2:16
Check the sensor.
(B7680-4), high signal for right clamp. and the sensor using the D7972/C2:14
Check the sensor.
(B7680-4), low signal for right clamp. and the sensor using the D7972/C2:14
Check the sensor.
B 7680 3 7 10 Sensor function lifting Lift with lifting tool Check the cable harness B7680-LE See separate
tool tool changer left not working. between the control unit supplement.
(B7680-LE), high signal and the sensor using the D7911/C2:24
Check the sensor.
B 7680 4 7 10 Sensor function lifting Lift with lifting tool Check the cable harness B7680-LE See separate
VDU01.01GB
tool tool changer left not working. between the control unit supplement.
(B7680-LE), low signal and the sensor using the D7911/C2:24
D:253
Check the sensor.
VDU01.01GB
D:254
and menu
components
B 7680 3 7 20 Sensor function lift Lift with lifting tool Check the cable harness B7680-RI See separate
tool, tool changer right not working. between the control unit supplement.
(B7680-RI), high signal and the sensor using the D7911/C2:25
Check the sensor.
B 7680 4 7 20 Sensor function lift Lift with lifting tool Check the cable harness B7680-RI See separate
tool, tool changer right not working. between the control unit supplement.
(B7680-RI), low signal and the sensor using the D7911/C2:25
Check the sensor.
B 7681 3 2 Sensor brake pressure Brake lights and Check the cable harness B7681 4.3 Power Brake

(B7681), high signal declutch not between the control unit Assisted 3/XX pressure
voltage. working. and the sensor using the D7971/C2:7 DIAGNOSE, sensor,
diagnostic menu. page 8:34 description,
page 4:27
Check the sensor.
B 7681 4 2 Sensor brake pressure Brake lights and Check the cable harness B7681 4.3 Power Brake
(B7681), low signal declutch not between the control unit Assisted 3/XX pressure
voltage. working. and the sensor using the D7971/C2:7 DIAGNOSE, sensor,
diagnostic menu. page 8:34 description,
page 4:27
Check the sensor.
B 7682 3 2 Sensor parking brake Indicator light Check the cable harness B7682 4.5 Park Brake Sensor
(B7682), high signal parking brake and between the control unit Sys 3/XX parking brake
voltage. warning for low and the sensor using the D7971/C2:17 DIAGNOSE, pressure,
brake pressure not diagnostic menu. page 8:35 description,
switching off. Gear page 4:36
cannot be engaged Check the sensor.
because the
signal for released
parking brake is
not working.
and menu
components
(B7682), low signal parking brake and between the control unit Sys 3/XX parking brake
voltage. warning for low and the sensor using the D7971/C2:17 DIAGNOSE, pressure,
because the
signal for released
parking brake is
not working.
(B7682), value too parking brake and between the control unit Sys 3/XX parking brake
high. warning for low and the sensor using the D7971/C2:17 DIAGNOSE, pressure,

because the
signal for released
parking brake is
not working.
B 7683 3 2 Sensor accumulator Indicator light Check the cable harness B7683 4.3 Power Accumulator
pressure (B7683), high parking brake and between the control unit Assisted 4/XX pressure
signal voltage. warning for low and the sensor using the D7971/C2:8 DIAGNOSE, sensor,
because the
signal for released
parking brake is
not working.
B 7683 4 2 Sensor accumulator Indicator light Check the cable harness B7683 4.3 Power Accumulator
pressure (B7683), low parking brake and between the control unit Assisted 4/XX pressure
signal voltage. warning for low and the sensor using the D7971/C2:8 DIAGNOSE, sensor,
because the
signal for released
VDU01.01GB
parking brake is
not working.
D:255
VDU01.01GB
D:256
and menu
components
B 7686 3 2 Sensor boom length Load sensor and Check the cable harness B7686
(B7686), high signal overload system between the control unit
voltage. not working. Lift and the sensor using the D7971/C2:16
and extension diagnostic menu.
blocked.
Check the sensor.
Regeneration
extension and end
position damping
not working.
B 7686 4 2 Sensor boom length Load sensor and Check the cable harness B7686
(B7686), low signal overload system between the control unit
voltage. not working. Lift and the sensor using the D7971/C2:16

blocked.
Check the sensor.
Regeneration
extension and end
position damping
not working.
B 7686 7 2 Sensor, boom length Load sensor and Check the cable harness B7686
(B7686), mechanical overload system between the control unit
fault. not working. Lift and the sensor using the D7971/C2:16
blocked.
Check the sensor.
Regeneration
extension and end
position damping
not working.
B 7688 3 7 Sensor LS-pressure Attachment Check the cable harness B7688
attachment (B7688), functions work between the control unit
high signal voltage. but at full pressure. and the sensor using the D7911/C1:5
diagnostic menu.
Check the sensor.
B 7688 4 7 Sensor LS-pressure Attachment Check the cable harness B7688
attachment (B7688), functions work between the control unit
low signal voltage. but at full pressure. and the sensor using the D7911/C1:5
diagnostic menu.
Check the sensor.
and menu
components
B 7701 2 3 Revolving driver's Drive in neutral. Check the cable harness B7701
seat, incorrect or no between the control unit
feedback. and the sensor using the D7972/C1:12
diagnostic menu.
D7972/C1:13
Check the sensor.
B 7720 0 2 High temperature oil Machine speed is Check the function of the B7720
brake system. limited. cooling fan.
D7971/C2:29
Check that the radiator is
not clogged.
Check the oil level in the

brake system's tank.
B 7720 32 2 Sensor temperature oil Display of brake Check the cable harness B7720
brake system (B7720), oil temperature not between the control unit
high resistance or open working, warning and the sensor using the D7971/C2:29
circuit. for high brake oil diagnostic menu.
temperature not
working. Machine Check the sensor.
speed is limited.
B 7720 33 2 Sensor temperature oil Display of brake Check the cable harness B7720
brake system (B7720), oil temperature not between the control unit
low resistance or short working, warning and the sensor using the D7971/C2:29
circuit. for high brake oil diagnostic menu.
temperature not
working. Machine Check the sensor.
speed is limited.
B 7740 32 1 Sensor ambient Air conditioning not Check the cable harness B7740 9.4 Climate Ambient
temperature (B7740), working. between the control unit System 4/XX temperature
high resistance or open and the sensor using the D7901/C1:36 DIAGNOSE, sensor,
circuit. diagnostic menu. page 8:60 description,
page 9:44
Check the sensor. 9.4 Climate
System 5/XX
DIAGNOSE,
page 8:60
VDU01.01GB
D:257
VDU01.01GB
D:258
and menu
components
B 7740 33 1 Sensor ambient Air conditioning not Check the cable harness B7740 9.4 Climate Ambient
low resistance or short and the sensor using the D7901/C1:36 DIAGNOSE, sensor,
page 9:44
System 5/XX
DIAGNOSE,
page 8:60
B 7751 32 1 Sensor inside Air conditioning not Check the cable harness B7751 9.4 Climate Interior
high resistance or open and the sensor using the D7901/C1:33 DIAGNOSE, sensor,

page 9:43
System 5/XX
DIAGNOSE,
page 8:60
B 7751 33 1 Sensor inside Air conditioning not Check the cable harness B7751 9.4 Climate Interior
page 9:43
System 5/XX
DIAGNOSE,
page 8:60
B 7752 32 1 Sensor fan Air conditioning not Check cabling between B7751 9.4 Climate Fan
temperature (B7752), working. the control unit and the System 4/XX temperature
high resistance or open component with diagnostic D7901/C1:34 DIAGNOSE, sensor,
circuit. menu. page 8:60 description,
page 9:42
System 5/XX
DIAGNOSE,
page 8:60
and menu
components
B 7752 33 1 Sensor fan Air conditioning not Check the cable harness B7751 9.4 Climate Fan
page 9:42
System 5/XX
DIAGNOSE,
page 8:60
B 7753 32 1 Sensor temperature Air conditioning not Check the cable harness B7753 9.4 Climate Temperature
display (B7753), high working. between the control unit System 4/XX deicing
resistance or open and the sensor using the D7901/C1:35 DIAGNOSE, sensor,

page 9:37
System 5/XX
DIAGNOSE,
page 8:60
B 7753 33 1 Sensor temperature Air conditioning not Check the cable harness B7753 9.4 Climate Temperature
display (B7753), low working. between the control unit System 4/XX deicing
resistance or short and the sensor using the D7901/C1:35 DIAGNOSE, sensor,
page 9:37
System 5/XX
DIAGNOSE,
page 8:60
B 7755 1 2 Sensor ECC water Heater in cab not Fill with glycol-mixed water. B7755 See
level (B7755) in water working. Maintenance
heater air conditioning, D7971/C2:20 manual
water level low.
B 7760 32 2 Sensor temperature Speed limitation. Check the cable harness B7760 10.6 Oil Sensor,
hydraulic oil (B7760), between the control unit Temp/Clean hydraulic oil
high resistance or open and the sensor using the D7971/C2:25 1/XX temperature,
circuit. diagnostic menu. DIAGNOSE, description,
page 8:76 page 10:27
Check the sensor.
VDU01.01GB
D:259
VDU01.01GB
D:260
and menu
components
B 7760 33 2 Sensor temperature Speed limitation. Check the cable harness B7760 10.6 Oil Sensor,
hydraulic oil (B7760), between the control unit Temp/Clean hydraulic oil
low resistance or short and the sensor using the D7971/C2:25 1/XX temperature,
circuit. diagnostic menu. DIAGNOSE, description,
page 8:76 page 10:27
Check the sensor.
B 7770 3 3 Potentiometer turnable Drive in neutral. Check the cable harness B7770
operator's station between the control unit
(B7770), high signal and the sensor using the D7972/C2:07
Check the sensor.
B 7770 4 3 Potentiometer turnable Drive in neutral. Check the cable harness B7770

(B7770), low signal and the sensor using the D7972/C2:07
Check the sensor.
B 7770 2 3 Potentiometer, turnable Drive in neutral. Check the cable harness B7770
(B7770). and the sensor using the D7972/C2:07
diagnostic menu.
Check the sensor.
B 7770 3 7 Position sensor side No limitation but Check the cable harness B7770
shift (B7770), high skewed load between the control unit
signal voltage. system can and the sensor using the D7911/C2:02
interrupt lifting. diagnostic menu.
Check the sensor.
B 7770 4 7 Position sensor side No limitation but Check the cable harness B7770
shift (B7770), low skewed load between the control unit
signal voltage. system can and the sensor using the D7911/C2:02
interrupt lifting. diagnostic menu.
Check the sensor.
D 7801 31 2 20 Drive regulator Drive not working. Check that the drive D7801
right-hand drive motor regulator is switched on
missing (D7801). and communicates on the
CAN bus.
and menu
components
D 7802 31 2 10 Drive regulator Drive not working. Check that the drive D7802
left-hand drive motor regulator is switched on
missing (D7802). and communicates on the
CAN bus.
D 7811 31 2 Pump regulator load Load handling Check that the pump D7811
handling and steering and steering nor regulator is switched on
missing (D7811). working and communicates on the
CAN bus.
D 7812 31 2 Pump regulator brake Brake and AC not Check that the pump D7812
system and AC missing working regulator is switched on
(D7812). and communicates on the
CAN bus.

A 7870 2 2 Sensor fault, overload Load handling Check and rectify error - Overload
system. One of the functions are codes for position sensor system,
sensors connected to blocked. and pressure sensor. description,
the overload system page 8:6
has active error codes
VDU01.01GB
D:261
VDU01.01GB
D:262
and menu
components
D 7901 31 12 Cab control unit Functions in cab Check the cable harness to D7901/C1:3 11.6 Commu- 11.6.2
(D7901) missing. not working. the control unit. nication 1/XX, Redundant
D7901/C1:4 page 8:85 CAN bus,
Troubleshoot the CAN bus page 11:42
with the diagnostic menu. D7901/C1:6 11.6 Commu-
nication 2/XX,
D7901/C1:7 page 8:86
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
and menu
components
D 7902 31 12 KPU control unit Controls in the Check the cable harness to D7902/C1:3 11.6 Commu- 11.6.2
(D7902) missing. right dashboard the control unit. nication 1/XX, Redundant
panel or steering D7902/C1:4 page 8:85 CAN bus,
panel not working. Troubleshoot the CAN bus page 11:42
nication 2/XX,
D7902/C1:6 page 8:86
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
D 7930 31 2 1 Transmission control Gear selection not Check the cable harness to D7971/C1:31 11.6.2
unit (D7930) missing. working. the control unit. Redundant
D7971/C1:32 CAN bus,
page 11:42
D 7940 31 2 1 Engine control unit Engine does Check the cable harness to D7971/C1:31 11.6.2
(D7940) missing not respond to the control unit. Redundant
commands from D7971/C1:32 CAN bus,
the cab. page 11:42
D 7940 31 2 2 Control unit, engine Engine does Check the cable harness to D7971/C1:31 11.6.2
UDS (D7940) missing not respond to the control unit. Redundant
commands from D7971/C1:32 CAN bus,
the cab. page 11:42
VDU01.01GB
D:263
VDU01.01GB
D:264
and menu
components
D 7950 31 12 KID control unit Display not Check the cable harness to D7950/C1:3 11.6 Commu- 11.6.2
(D7950) missing working. the control unit. nication 1/XX, Redundant
D7950/C1:4 page 8:85 CAN bus,
nication 2/XX,
D7950/C1:7 page 8:86
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
and menu
components
D 7971 31 2 Control unit KFU Numerous Check the cable harness to D7971/C1:3 11.6 Commu- 11.6.2
(D7971) missing functions not the control unit. nication 1/XX, Redundant
working, engine, D7971/C1:4 page 8:85 CAN bus,
transmission, load Troubleshoot the CAN bus page 11:42
handling, etc. with the diagnostic menu. D7971/C1:6 11.6 Commu-
nication 2/XX,
D7971/C1:7 page 8:86
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
VDU01.01GB
D:265
VDU01.01GB
D:266
and menu
components
D 7972 31 2 Control unit KFU-2 Functions Check the cable harness to D7972/C1:3 11.6 Commu- 11.6.2
(D7972) missing connected to the control unit. nication 1/XX, Redundant
Control unit D7972/C1:4 page 8:85 CAN bus,
KFU-2 (D7972) Troubleshoot the CAN bus page 11:42
not working, e.g. with the diagnostic menu. D7972/C1:6 11.6 Commu-
turnable driver’s nication 2/XX,
D7972/C1:7 page 8:86
seat, etc.
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
and menu
components
D 7911 31 2 Control unit KAU Functions, Check the cable harness to D7911/C1:3 11.6 Commu- 11.6.2
(D7911) missing attachment not the control unit. nication 1/XX, Redundant
working. D7911/C1:4 page 8:85 CAN bus,
nication 2/XX,
D7911/C1:7 page 8:86
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
VDU01.01GB
D:267
VDU01.01GB
D:268
and menu
components
D 7912 31 2 Control unit KAU-2 Functions Check the cable harness to D7912/C1:3 11.6 Commu- 11.6.2
(D7912) missing connected to the control unit. nication 1/XX, Redundant
Control unit D7912/C1:4 page 8:85 CAN bus,
KAU-2 (D7912) Troubleshoot the CAN bus page 11:42
not working, e.g. with the diagnostic menu. D7912/C1:6 11.6 Commu-
combi attachment, nication 2/XX,
D7912/C1:7 page 8:86
etc.
11.6 Commu-
nication 3/XX,
page 8:86
11.6 Commu-
nication 4/XX,

page 8:86
11.6 Commu-
nication 5/XX,
page 8:86
11.6 Commu-
nication 6/XX,
page 8:87
11.6 Commu-
nication 7/XX,
page 8:87
A 7991 31 1 Control unit KEM Engine does Check cabling between D7991/C1:3
(D7991) missing not respond to the control unit and
commands from the component with D7991/C1:4
the cab. diagnostic menu. Check
the component.
A 7992 31 7 Control unit KEM-2 Levelling of load Check cabling between A7992/C1:3
(A7992) missing not working the control unit and
the component with A7992/C1:4
diagnostic menu. Check
the component.
A 7993 31 7 Control unit KEM-3 WTP (Wide Check cabling between D7993/C1:3
(D7993) missing Twistlock Position) the control unit and
not working. the component with D7993/C1:4
diagnostic menu. Check
the component.
and menu
components
E 8020 5 2 Electrically heated rear Electrically heated Check cabling between E8020 Rear view
view mirror (E8020), rear view mirror the control unit and the mirror,
open circuit. not working. component with diagnostic D7971/C2:22 description,
menu. page 9:74
E 8020 6 2 Electrically heated rear Electrically heated Check cabling between E8020-LE Rear view
view mirror (E8020-LE) rear view mirror the control unit and the mirror,
and (R8020-RI), short not working. component with diagnostic E8020-RI description,
D7971/C2:22
E 8050 11 2 Water heater air Heater unit not Check cabling between E8050 11.9 I/O

conditioning (E8050) providing any heat the control unit and the D7971 KFU
inoperative. in the cab. component with diagnostic D7971/C2:30 1–75/XX
menu. DIAGNOSE,
page 8:91
R 8070 3 11 1 Control levers (linear Lift and lower not Check cabling between Control Control Control
levers) working. the control unit and the levers (linear levers (linear lever (EGO),
component with diagnostic levers) levers) description,
Control lever menu. page 7:8
lifting/lowering R8070-1 7.1 Controls
(R8070-1), high signal Check the lever. and Instr 1/XX
voltage. D7902/C3:3 DIAGNOSE,
page 8:39
Control lever Control lever
(joystick) (joystick) Control lever
(joystick)
Control lever S8150/4
lifting/lowering 7.1 Controls
(S8150-R8070-1), D7902/C3:3 and Instr 5/XX
high signal voltage. DIAGNOSE,
page 8:40
VDU01.01GB
D:269
VDU01.01GB
D:270
and menu
components
R 8070 4 11 1 Control levers (linear Lift and lower not Check cabling between Control Control Control
Lift/lower control lever menu. page 7:8
(R8070-1). R8070-1 7.1 Controls
Check the lever. and Instr 1/XX
Control lever D7902/C3:3 DIAGNOSE,
(joystick) page 8:39
Control lever
Control lever (joystick) Control lever
lifting/lowering (joystick)
(S8150-R8070-1), S8150/4
low signal voltage. 7.1 Controls
D7902/C3:3 and Instr 5/XX

DIAGNOSE,
page 8:40
R 8070 3 11 2 Control levers (linear Tilt in/out not Check cabling between Control Control Control
Control lever tilt out/in menu. page 7:8
(R8070-2), high signal R8070-2 7.1 Controls
voltage. Check the lever. and Instr 1/XX
D7902/C3:4 DIAGNOSE,
Control lever page 8:39
(joystick) Control lever
Control lever tilt out/in (joystick)
(S8150-R8070-2), high S8150/3
signal voltage. 7.1 Controls
DIAGNOSE,
page 8:40
and menu
components
R 8070 4 11 2 Control levers (linear Tilt in/out not Check cabling between R8070-2 Control Control
levers) working. the control unit and the levers (linear lever (EGO),
component with diagnostic D7902/C3:4 levers) description,
Control lever tilt out/in menu. page 7:8
(R8070-2), low signal Control lever 7.1 Controls
voltage. Check the lever. (joystick) and Instr 1/XX
DIAGNOSE,
Control lever S8150/3 page 8:39
(joystick)
D7902/C3:4 Control lever
(joystick)
7.1 Controls
and Instr 5/XX

DIAGNOSE,
page 8:40
R 8070 3 11 3 Control levers (linear Side shift not Check cabling between Control Control Control
Control lever side shift menu. page 7:8
(R8070-3), high signal R8070-3 7.1 Controls
Control lever side shift (joystick)
(S8150-R8070-3), high S8150/3
DIAGNOSE,
page 8:41
VDU01.01GB
D:271
VDU01.01GB
D:272
and menu
components
R 8070 4 11 3 Control levers (linear Side shift not Check cabling between Control Control Control
Control lever side shift menu. page 7:8
(R8070-3), low signal R8070-3 7.1 Controls
Control lever side shift (joystick)
(S8150-R8070-3), low S8150/3

DIAGNOSE,
page 8:41
R 8070 3 11 4 Control lever Spreading/side Check cabling between Control Control Control
spreading/side shift shift not working. the control unit and the levers (linear levers (linear lever (EGO),
(R8070-4), high signal component with diagnostic levers) levers) description,
voltage. menu. page 7:8
R8070-4 7.1 Controls
page 8:40
Control lever
(joystick)
S8150/6
7.1 Controls
DIAGNOSE,
page 8:41
and menu
components
R 8070 4 11 4 Control lever Spreading/side Check cabling between Control Control Control
spreading/side shift shift not working. the control unit and the levers (linear levers (linear lever (EGO),
(R8070-4), low signal component with diagnostic levers) levers) description,
voltage. menu. page 7:8
R8070-4 7.1 Controls
page 8:40
Control lever
(joystick)
S8150/6
7.1 Controls

DIAGNOSE,
page 8:41
R 8070 3 11 5 Control lever 5th 5th function not Check cabling between R8070-5
function (R8070-5), working. the control unit and the
high signal voltage. component with diagnostic D7902/C3:7
menu.
Check the lever.
low signal voltage. component with diagnostic D7902/C3:7
menu.
Check the lever.
high signal voltage. component with diagnostic D7902/C3:8
menu.
Check the lever.
low signal voltage. component with diagnostic D7902/C3:8
menu.
VDU01.01GB
Check the lever.
D:273
VDU01.01GB
D:274
and menu
components
R 8092 3 11 1 Brake position A. Engine speed Check cabling between R8092 -
limited to idling the control unit and the
speed. component with diagnostic D7902/C8:8
menu.
Check the lever.
R 8092 4 11 1 Brake position A. Engine speed Check cabling between R8092 -
menu.
Check the lever.
R 8092 13 11 1 Brake position A, Engine speed Check cabling between R8092 -

calibration error. limited to idling the control unit and the
menu.
Check the lever.
R 8092 3 11 2 Brake position B. Engine speed Check cabling between R8092 -
menu.
Check the lever.
R 8092 4 11 2 Brake position B. Engine speed Check cabling between R8092 -
menu.
Check the lever.
R 8092 13 11 2 Brake position B, Engine speed Check cabling between R8092 -
calibration error. limited to idling the control unit and the
menu.
Check the lever.
M 8100 5 1 Condenser roof Climate system not Check cabling between M8100 Condenser
(M8100) working. the control unit and the unit,
component with diagnostic D7901/C2:36 description,
menu. page 9:32
and menu
components
M 8100 6 1 Condenser roof Climate system not Check cabling between M8100 Condenser
(M8100) working. the control unit and the unit,
component with diagnostic D7901/C2:36 description,
menu. page 9:32
R 8250 3 1 1 Control lever/mini- Joystick control Check cabling between R8250-1 Joystick
wheel channel 1 or mini-wheel not the control unit and the control:
(R8250-1), high signal working. component with diagnostic D7901/C1:37
voltage. menu. Mini-wheel:
Check the potentiometer.

R 8250 4 1 1 Control lever/mini- Joystick control Check cabling between R8250-1 Joystick

wheel channel 1 or mini-wheel not the control unit and the control:
(R8250-1), low signal working. component with diagnostic D7901/C1:37
voltage. menu. Mini-wheel:

R 8250 3 1 2 Mini-wheel channel 2 Mini-wheel not Check cabling between R8250-2
(R8250-2), high signal working. the control unit and the
voltage. component with diagnostic D7901/C1:38
menu.
R 8250 4 1 2 Mini-wheel channel 2 Mini-wheel not Check cabling between R8250-2
(R8250-2), low signal working. the control unit and the
voltage. component with diagnostic D7901/C1:38
menu.
H 8500 6 1 Horn (H8500), short Horn not working. Check cabling between H8500-1 9.7 Signalling Horn,
circuit to ground. the control unit and the Sys 1/XX description,
menu. page 8:73
K 8881 6 1 Relay heater rear Rear window Check cabling between K8881 Rear window,
VDU01.01GB
window (K8881), short heater not working. the control unit and the description,
circuit to ground. component with diagnostic D7901/C2:6 page 9:73
D:275
menu.
VDU01.01GB
D:276
and menu
components
D 9001 31 1 VDI, communication VDI not working. Check cabling between D9001 11.6 Com- Communica-
error. the control unit and the munication tion with the
component with diagnostic 12/XX, page machine, de-
menu. 8:89 scription, page
11:45
H 9003 5 7 Buzzer, automatic Buzzer for Check cabling between H9003 7.5 Spreading Buzzer
spreading 20'-40', open automatic the control unit and the 16/XX automatic
circuit spreading not component with diagnostic D7911/C1:43 DIAGNOSE, spreading
working. menu. page 8:45 20'-40',
description,

H 9003 6 7 Buzzer automatic Buzzer for Check cabling between H9003 7.5 Spreading Buzzer
spreading 20'-40', short automatic the control unit and the 16/XX automatic
circuit to ground. spreading not component with diagnostic D7911/C1:43 DIAGNOSE, spreading
working. menu. page 8:45 20'-40',
description,
page 7:61
D 9130 13 2 Sensor tyre pressure Tyre pressure Repeat the calibration of the D9130 6.3 Tyres and Tyre pressure
monitoring system, monitoring not sensors, see Maintenance Rims 6/XX monitoring,
calibration error. working. manual Diagnose, description,
page 8:38 page 6:18
D 9130 14 2 1 Sensor tyre pressure Tyre pressure Check the component. D9130-1 6.3 Tyres and Tyre pressure
left front outer monitoring for the Rims 1/XX monitoring,
(D9130-1), no contact wheel not working. Repeat the calibration of the Diagnose, description,
with the sensor sensors, see Maintenance page 8:36 page 6:18
manual
left front inner monitoring for the Rims 2/XX monitoring,
manual
right front inner monitoring for the Rims 3/XX monitoring,
manual
and menu
components
right front outer monitoring for the Rims 4/XX monitoring,
manual
right rear (D9130-1), no monitoring for the Rims 5/XX monitoring,
contact with the sensor wheel not working. Repeat the calibration of the Diagnose, description,
sensors, see Maintenance page 8:38 page 6:18
manual
left rear (D9130-1), no monitoring for the Rims 6/XX monitoring,
contact with the sensor wheel not working. Repeat the calibration of the Diagnose, description,

manual
D 9130 31 2 Sensor tyre pressure Tyre pressure Check the component. D9130 6.3 Tyres and Tyre pressure
monitoring system monitoring not Rims 6/XX monitoring,
communication error. working. Repeat the calibration of the D7971/C1:31 Diagnose, description,
manual D7971/C1:32
A 9150 31 1 Kalmar MTU (Machine Does not affect Check cabling between D9150 11.6 Com- Communica-
Telematic Unit), the machine's the control unit and the munication tion with the
communication error. functionality but component with diagnostic 11/XX, page machine, de-
no machine data is menu. 8:88 scription, page
sent to SmartFleet. 11:45
Check the component. 11.6 Com-
MTU is also munication
required for VGM 12/XX, page
(Verified Gross 8:89
Mass) when
you want to use 11.6 Com-
keyboard and munication
printer. 13/XX, page
8:89
11.6 Com-
munication
14/XX, page
8:89
VDU01.01GB
D:277
VDU01.01GB
D:278
and menu
components
A 9170 11 1 External scales, External scales not Check cabling between A9170 See separate
internal error. working. the control unit and the supplement.
menu.
A 9170 31 1 External scales, External scales not Check cabling between A9170 See separate
communication error. working. the control unit and the supplement.
menu.
A 9170 2 1 100 External scales, External scales not Check cabling between A9170 See separate

weighing unit working. the control unit and the supplement.
attachment, component with diagnostic
communication error. menu.
A 9170 2 1 110 External scales, Scales not Check cabling between A9170 See separate
attachment pin 0, component with diagnostic
A 9170 2 1 120 External scales, Scales not Check cabling between A9170 See separate
attachment pin 1, component with diagnostic
A 9630 5 2 Control unit fire Fire extinguishing Check cabling between A9630 See separate
extinguishing system system not the control unit and the supplement.
(A9630), open circuit. working. component with diagnostic D7971/C2:26
menu.
A 9630 6 2 Control unit fire Fire extinguishing Check cabling between A9630 See separate
extinguishing system system not the control unit and the supplement.
(A9630), short circuit to working. component with diagnostic D7971/C2:26
ground. menu.
and menu
components
H 9650 6 2 1 Reverse alarm (H9650) Reverse alarm not Check cabling between H9650 9.7 Signalling Reverse
working. the control unit and the Sys 5/XX alarm,
component with diagnostic D7971/C1p18 DIAGNOSE, description,
H 9650 6 3 2 Reverse alarm Reverse alarm Check cabling between H9650–2 Reverse
(H9650–2) front. front not working. the control unit and the alarm,
component with diagnostic D7972/C1p18 description,
At turnable operator's menu. page 9:64
station.
10001 54 1 Buffer overflow in - Connect the Kalmar Service -

error code issue VDI. tool and Repair or contact
System error. Cargotec support.
10001 55 1 No response to SPN - Connect the Kalmar Service -
request. System error. tool and Repair or contact
Cargotec support.
10001 56 1 Execution time for - Connect the Kalmar Service -
node exceeds max. tool and Repair or contact
permitted time. Error Cargotec support.
code issue to VDI
probably incorrect.
System error.
10002 14 1 Control unit KCU Speed limitation. Contact Cargotec support. D7901 11.5.3.1
(D7901), configuration Control unit
numbers do not match. KCU (D7901),
page 11:25
10002 14 2 Control unit KFU Speed limitation. Contact Cargotec support. D7971 11.5.3.4
(D7971), wrong Control unit
configuration number. KFU (D7971),
page 11:31
10002 14 3 Control unit KFU-2 Speed limitation. Contact Cargotec support. D7972
(D7972), wrong
configuration number.
VDU01.01GB
10002 14 6 Control unit KAU-2 Speed limitation. Contact Cargotec support. D7912
(D7912), wrong
D:279
configuration number.
VDU01.01GB
D:280
and menu
components
10002 14 7 Control unit KAU Speed limitation. Contact Cargotec support. D7911 11.5.3.8
configuration number. KAU (D7911),
page 11:36
10002 14 11 Control unit KPU Speed limitation. Contact Cargotec support. D7902 11.5.3.2
configuration number. KPU (D7902),
page 11:27
10002 14 12 Control unit KID Speed limitation. Contact Cargotec support. D7950 11.5.3.3
(D7950), wrong Control unit,
configuration number. KID (D7950),
page 11:29

10002 14 99 Incorrect configuration Speed limitation. Contact Cargotec support. D7950 11.5.3 Control
number in a control units, page
unit. 11:24
10003 14 1 Control unit KCU Speed limitation. Contact Cargotec support. D7901 11.5.3.1
software version. KCU (D7901),
page 11:25
10003 14 2 Control unit KFU Speed limitation. Contact Cargotec support. D7971 11.5.3.4
software version. KFU (D7971),
page 11:31
10003 14 3 Control unit KFU-2 Speed limitation. Contact Cargotec support. D7972
(D7972), wrong
software version.
10003 14 6 Control unit KAU-2 Speed limitation. Contact Cargotec support. D7912
(D7912), wrong
software version.
10003 14 7 Control unit KAU Speed limitation. Contact Cargotec support. D7911 11.5.3.8
software version. KAU (D7911),
page 11:36
10003 14 11 Control unit KPU Speed limitation. Contact Cargotec support. D7902 11.5.3.2
software version. KPU (D7902),
page 11:27
and menu
components
10003 14 12 Control unit KID Speed limitation. Contact Cargotec support. D7950 11.5.3.3
(D7950), wrong Control unit,
software version. KID (D7950),
page 11:29
10004 14 1 Control unit KCU Functions Contact Cargotec support. D7901 11.5.3.1
(D7901), set-up file connected to Control unit
missing. the KCU control KCU (D7901),
unit (D7901) not page 11:25
working.
10004 14 2 Control unit KFU Functions Contact Cargotec support. D7971 11.5.3.4
missing. the KFU control KFU (D7971),

working.
10004 14 3 Control unit KFU-2 Functions Contact Cargotec support. D7972
(D7972), set-up file connected to
missing. Control unit KFU-2
(D7972) not
working.
10004 14 6 Control unit KAU-2 Functions Contact Cargotec support. D7912
(D7912), set-up file connected to
missing. Control unit KAU-2
(D7912) not
working.
10004 14 7 Control unit KAU Functions Contact Cargotec support. D7911 11.5.3.8
missing. Control unit KAU (D7911),
KAU (D7911) not page 11:36
working.
10004 14 11 Control unit KPU Functions Contact Cargotec support. D7902 11.5.3.2
missing. the KPU control KPU (D7902),
working.
10004 14 12 Control unit KID Display not Contact Cargotec support. D7950 11.5.3.3
VDU01.01GB
(D7950), set-up file working. Control unit,

missing. KID (D7950),
D:281
page 11:29
VDU01.01GB
D:282
and menu
components
10005 14 1 1 Control unit KCU System error, Contact Cargotec support. D7901 11.5.3.1
(D7901), parameter file machine not Control unit
drive-train missing. drivable. KCU (D7901),
page 11:25
10005 14 2 1 Control unit KFU System error, Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter machine not Control unit
file drive-train missing. drivable. KFU (D7971),
page 11:31
10005 14 2 2 Control unit KFU Scales, OLS not Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter file working. Control unit
load sensor missing. KFU (D7971),
page 11:31

10005 14 2 3 Control unit KFU Fuel gauge Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter may display an Control unit
file fuel tank missing. incorrect value. KFU (D7971),
page 11:31
10005 14 2 4 Control unit KFU Central lubrication Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter frame not working. Control unit
file central lubrication KFU (D7971),
frame missing. page 11:31
10005 14 2 5 Control unit KFU Speedometer Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter may display an Control unit
file tyres front missing. incorrect value. KFU (D7971),
page 11:31
10005 14 2 6 Control unit KFU Overload system Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter not working, Control unit
file overload system lifting/lowering KFU (D7971),
missing. blocked. page 11:31
10005 14 2 7 Control unit KFU Eco Drive Mode Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter not working. Control unit
file Eco Drive Mode KFU (D7971),
missing. page 11:31
10005 14 3 1 Control unit KFU System error, Contact Cargotec support. D7971
(D7971), parameter machine not
file drive-train missing. drivable.
and menu
components
10005 14 7 4 Control unit KFU Central lubrication Contact Cargotec support. D7971 11.5.3.4
(D7971), parameter not working. Control unit
file central lubrication KFU (D7971),
missing. page 11:31
10005 14 11 1 Control unit KPU Machine not Contact Cargotec support. D7902 11.5.3.2
(D7902), parameter drivable. Control unit
file drive-train missing. KPU (D7902),
page 11:27
10005 14 11 7 Control unit KPU Control lever not Contact Cargotec support. D7902 11.5.3.2
(D7902), parameter file working. Control unit
control lever missing. KPU (D7902),
page 11:27

10005 14 12 1 Control unit KID Machine not Contact Cargotec support. D7950 11.5.3.3
(D7950), parameter drivable. Control unit,
file drive-train missing. KID (D7950),
page 11:29
10101 3 1 Control unit KCU Functionality of Check batteries and FA9968-RD:2 11.5 Distr of Ignition
(D7901), high battery controls in the cab alternator. Electr 1/XX voltage (15),
voltage. may be affected. D7901/C2:38 DIAGNOSE, function
Check the cable harness page 8:78 description,
between battery and control page 11:17
unit.
10101 4 1 Control unit KCU Functionality of Check fuse FA9968-RD:2. FA9968-RD:2 11.5 Distr of Ignition
(D7901), low battery controls in the cab Electr 1/XX voltage (15),
voltage. may be affected. Check the cable harness D7901/C2:38 DIAGNOSE, function
between battery and control page 8:78 description,
unit. page 11:17
Check the control unit.
10102 3 1 Control unit KCU KCU control Check batteries and F9954:2 11.5 Distr of Ignition
(D7901), high ignition unit (D7901) not alternator. Electr 1/XX voltage (15),
voltage. working. D7901/C3:1 DIAGNOSE, function
between electronic box page 11:17
frame and control unit.
10102 4 1 Control unit KCU KCU control Check fuse FA9954 2. F9954:2 11.5 Distr of Ignition
VDU01.01GB
(D7901), low ignition unit (D7901) not Electr 1/XX voltage (15),
voltage. working. Check the cable harness D7901/C3:1 DIAGNOSE, function
D:283
between electronic box page 8:78 description,
frame and control unit. page 11:17
VDU01.01GB
D:284
and menu
components
10102 4 1 1 Control unit KEM Control unit KEM Check fuse F9958-BK:5. F9958-BK:5 Ignition
(A7991), low ignition (A7991) not voltage (15),
voltage. working. Check the cable harness A7991/C1:2 function
between electronic box description,
frame and control unit. page 11:17
10102 3 2 Control unit KFU Control unit KFU Check batteries and F9954-1:3 11.5 Distr of Ignition
(D7971), high ignition (D7971) not alternator. Electr 4/XX voltage (15),
10102 4 2 Control unit KFU Control unit KFU Check the cable harness F9954-1:3 11.5 Distr of Ignition

(D7971), low ignition (D7971) not between electronic box Electr 4/XX voltage (15),
voltage. working. frame and control unit. D7971/C3:1 DIAGNOSE, function
page 8:79 description,
page 11:17
10102 6 2 2 Control unit KFU Engine cannot be Check cable harness D7940 11.9 I/O Ignition
(D7971), ignition started. between control unit and D7971 KFU voltage (15),
voltage to Control unit engine. D7971/C1:49 1–75/XX function
engine, short circuit to DIAGNOSE, description,
ground. Check the control unit. page 8:91 page 11:17
10102 3 3 Control unit KFU-2 Control unit KFU-2 Check batteries and F9954-1:3 Ignition
(D7972), high ignition (D7972) not alternator. voltage (15),
voltage. working. D7972/C3:1 function
Check the cable harness description,
10102 4 3 Control unit KFU-2 Control unit KFU-2 Check the cable harness F9954-1:3 Ignition
(D7972), low ignition (D7972) not between electronic box voltage (15),
voltage. working. frame and control unit. D7972/C3:1 function
description,
page 11:17
10102 3 6 Control unit KAU-2 Control unit KAU-2 Check batteries and F9954-1:3 Ignition
(D7912), high ignition (D7912) not alternator. voltage (15),
voltage. working. D7912/C3:1 function
Check the cable harness description,
and menu
components
10102 4 6 Control unit KAU-2 Control unit KAU-2 Check the cable harness F9954-1:3 Ignition
(D7912), low ignition (D7912) not between electronic box voltage (15),
description,
page 11:17
10102 3 7 Control unit KAU Control unit KAU Check batteries and F9954-1:3 11.5 Distr of Ignition
(D7911), high ignition (D7911) not alternator. Electr 13/XX voltage (15),
10102 4 7 Control unit KAU Control unit KAU Check the cable harness F9954-1:3 11.5 Distr of Ignition

page 11:17
10102 4 7 1 Control unit KEM-2 Control unit KEM-2 Check the cable harness F9954-1:3 Ignition
(A7992), low ignition (A7992), not between electronic box voltage (15),
description,
page 11:17
10102 4 7 2 Control unit KEM-3 Control unit KEM-3 Check the cable harness F9954-1:3 Ignition
(A7993), low ignition (A7993), not between electronic box voltage (15),
description,
page 11:17
10102 3 11 Control unit KPU KPU control Check batteries and F9968-BK:1 11.5 Distr of Ignition
(D7902), high ignition unit (D7902) not alternator. Electr 16/XX voltage (15),
10102 4 11 Control unit KPU KPU control Check the cable harness F9968-BK:1 11.5 Distr of Ignition
(D7902), low ignition unit (D7902) not between electronic box Electr 16/XX voltage (15),
VDU01.01GB
page 11:17
D:285
VDU01.01GB
D:286
and menu
components
10102 3 12 Control unit KID KID control unit Check batteries and F9968-BK:1 11.5 Distr of Ignition
(D7950), high ignition (D7950) not alternator. D7950/C1:2 Electr 23/XX voltage (15),
voltage. working. DIAGNOSE, function
10102 4 12 Control unit KID KID control unit Check the cable harness F9968-BK:1 11.5 Distr of Ignition
page 11:17
10103 6 1 Control unit KCU No control units Check the cable harness D7901/C2:35 11.5 Distr of Redundant

(D7901), redundant working. between Control unit KCU Electr 2/XX voltage feed
voltage feed from (D7901) and other units. DIAGNOSE, of control
control units, short page 8:78 units, function
circuit to ground. description,
page 11:15
10103 3 2 Control unit KFU Control unit KFU Check batteries and D7901/C2:35 11.5 Distr of Redundant
(D7971), high voltage (D7971) not alternator. Electr 4/XX voltage feed
redundant voltage working. D7971/C1:2 DIAGNOSE, of control
feed. Check the cable harness page 8:79 units, function
between Control unit KFU description,
(D7971) and Control unit page 11:15
KCU (D7901).
10103 4 2 Control unit KFU Control unit KFU Check the cable harness D7901/C2:35 11.5 Distr of Redundant
(D7971), low voltage (D7971) not between Control unit KFU Electr 4/XX voltage feed
redundant voltage working. (D7971) and Control unit D7971/C1:2 DIAGNOSE, of control
feed. KCU (D7901). page 8:79 units, function
description,
page 11:15
10103 3 3 Control unit KFU-2 Control unit KFU-2 Check batteries and D7901/C2:35 Redundant
(D7972), high voltage (D7972) not alternator. voltage feed
redundant voltage working. D7912/C1:2 of control
feed. Check the cable harness units, function
between Control unit KFU description,
KCU (D7901).
and menu
components
10103 4 3 Control unit KFU-2 Control unit KFU-2 Check the cable harness D7901/C2:35 Redundant
(D7972), low voltage (D7972) not between Control unit KFU voltage feed
redundant voltage working. (D7972) and Control unit D7912/C1:2 of control
feed. KCU (D7901). units, function
description,
page 11:15
10103 3 6 Control unit KAU-2 Control unit KAU-2 Check batteries and D7901/C2:35 Redundant
(D7912), high voltage (D7912) not alternator. voltage feed
redundant voltage working. D7912/C1:2 of control
feed. Check the cable harness units, function
between Control unit KAU description,
KCU (D7901).

10103 4 6 Control unit KAU-2 Control unit KAU-2 Check the cable harness D7901/C2:35 Redundant
(D7912), low voltage (D7912) not between Control unit KAU voltage feed
redundant voltage working. (D7912) and Control unit D7912/C1:2 of control
feed. KCU (D7901). units, function
description,
page 11:15
10103 3 7 Control unit KAU Control unit KAU Check batteries and D7901/C2:35 11.5 Distr of Redundant
between Control unit KAU description,
KCU (D7901).
10103 4 7 Control unit KAU Control unit KAU Check the cable harness D7901/C2:35 11.5 Distr of Redundant
(D7911), low voltage (D7911) not between Control unit KAU Electr 13/XX voltage feed
description,
page 11:15
10103 4 11 Control unit KPU KPU control Check the cable harness D7901/C2:35 11.5 Distr of Redundant
(D7902), low voltage unit (D7902) not between KPU control unit Electr 16/XX voltage feed
redundant voltage working. and KCU control unit. D7902/C1:7 DIAGNOSE, of control
feed. page 8:80 units, function
description,
VDU01.01GB
page 11:15
D:287
VDU01.01GB
D:288
and menu
components
10103 3 12 Control unit KID KID control unit Check batteries and D7901/C2:35 11.5 Distr of Redundant
between Control unit KID description,
KCU (D7901).
10103 4 12 Control unit KID KID control unit Check the cable harness D7901/C2:35 11.5 Distr of Redundant
(D7950), low voltage (D7950) not between Control unit KID Electr 23/XX voltage feed
description,
page 11:15

10104 3 1 5 V Reference voltage Analogue controls Check cabling between D7901/C1:8 11.5 Distr of 11.5.3.1
Control unit KCU in cab not the control unit and the Electr 1/XX Control unit
(D7901), above 5.1 V. working (mini- component with diagnostic A3720-1:4, DIAGNOSE, KCU (D7901),
wheel/steering menu. R8250-1/RD, page 8:78 page 11:25
lever and Y6720/10,
controls for air Check the component. Y6730/10
conditioning).
10104 4 1 5 V Reference voltage Analogue controls Check cabling between D7901/C1:8 11.5 Distr of 11.5.3.1
Control unit KCU in cab not the control unit and the Electr 1/XX Control unit
(D7901), below 4.9 V. working (mini- component with diagnostic A3720-1:4, DIAGNOSE, KCU (D7901),
wheel/steering menu. R8250-1/RD, page 8:78 page 11:25
lever and Y6720/10,
controls for air Check the component. Y6730/10
conditioning).
10104 3 1 1 5 V Reference voltage Transmission fan Check cabling between A7991/C1:8
Control unit KEM not working. the control unit and the
(A7991), above 5.1 V. component with diagnostic
menu.
10104 4 1 1 5 V Reference voltage Transmission fan Check cabling between A7991/C1:8
Control unit KEM not working. the control unit and the
(A7991), below 4.9 V. component with diagnostic
menu.
and menu
components
10104 3 2 5 V Reference voltage Sensor for Check cabling between D7971/C1:8 11.5 Distr of 11.5.3.4
Control unit KFU pressure lift the control unit and the Electr 4/XX Control unit
(D7971), above 5.1 V. cylinder, tilt component with diagnostic B2020/1, DIAGNOSE, KFU (D7971),
angle, lifting menu. B7228/1 page 8:79 page 11:31
height, fuel level, B7235-LE/1,
brake pressure, Check component. B7235-RI/1,
accumulator B7226-1/2,
pressure and B7226-2/2,
parking brake not B7226-3/2,
working. B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570,
B7681/2,

B7683/2,
10104 4 2 5 V Reference voltage Sensor for Check cabling between D7971/C1:8 11.5 Distr of 11.5.3.4
Control unit KFU pressure lift the control unit and the Electr 4/XX Control unit
(D7971), below 4.9 V. cylinder, tilt component with diagnostic B2020/1, DIAGNOSE, KFU (D7971),
angle, lifting menu. B7228/1 page 8:79 page 11:31
height, fuel level, B7235-LE/1,
brake pressure, Check component. B7235-RI/1,
accumulator B7226-1/2,
pressure and B7226-2/2,
parking brake not B7226-3/2,
working. B7238/2,
B7245-LE/1,
B7245-RI/1.
B7570,
B7681/2,
B7683/2,
10104 3 3 5 V Reference voltage Sensors Check the cable harness at D7972/C1:8
Control unit KFU-2 connected to the the control unit.
(D7972), above 5.1 V. control unit provide
incorrect signal
Control unit KFU-2 connected to the the control unit.
(D7972), below 4.9 V. control unit provide
incorrect signal
VDU01.01GB
D:289
Control unit KAU-2 connected to the the control unit.
(D7912), above 5.1 V. control unit provide
incorrect signal
VDU01.01GB
D:290
and menu
components
Control unit KAU-2 connected to the the control unit.
(D7912), below 4.9 V. control unit provide
incorrect signal
10104 3 7 5 V Reference voltage Sensors Check the cable harness at D7911/C1:8 11.5 Distr of 11.5.3.8
Control unit KAU connected to the the control unit. Electr 13/XX Control unit
(D7911), above 5.1 V. control unit provide DIAGNOSE, KAU (D7911),
incorrect signal page 8:79 page 11:36
10104 3 7 1 5 V Reference voltage Sensors Check the cable harness at D7911/C1:8
Control unit KEM-2 connected to the the control unit.
(A7992), above 5.1 V. control unit provide
incorrect signal

(A7993), above 5.1 V. control unit provide
incorrect signal
10104 4 7 5 V Reference voltage Sensors Check the cable harness at D7911/C1:8 11.5 Distr of 11.5.3.8
Control unit KAU connected to the the control unit. Electr 13/XX Control unit
(D7911), below 4.9 V. control unit provide DIAGNOSE, KAU (D7911),
incorrect signal page 8:79 page 11:36
(A7992), below 4.9 V. control unit provide
incorrect signal
(A7993), below 4.9 V. control unit provide
incorrect signal
10104 3 11 5 V Reference voltage Steering panel Check cabling between D7902/C2:1 11.5 Distr of 11.5.3.2
Control unit KPU up/down, right the control unit and the Electr 17/XX Control unit
(D7902), above 5.1 V. instrument component with diagnostic M6941/10, DIAGNOSE, KPU (D7902),
up/down and menu. M6942/10, page 8:80 page 11:27
forward/back do M6943/10
not work. Check component.
and menu
components
10104 4 11 5 V Reference voltage Steering panel Check cabling between D7902/C2:1 11.5 Distr of 11.5.3.2
Control unit KPU up/down, right the control unit and the Electr 17/XX Control unit
(D7902), below 4.9 V. instrument component with diagnostic M6941/10, DIAGNOSE, KPU (D7902),
up/down and menu. M6942/10, page 8:80 page 11:27
forward/back do M6943/10
not work. Check component.
10104 3 11 1 5 V Reference voltage Switches and Check cabling between D7902/C6:1 11.5 Distr of Cab overview,
from Control unit KPU controls on the the control unit and the Electr 18/XX page 9:5
(D7902) to steering steering panel do component with diagnostic A3700/1 DIAGNOSE,
panel, above 5.1 V. not work. menu. page 8:81
Check component.

10104 4 11 1 5 V Reference voltage Switches and Check cabling between D7902/C6:1, 11.5 Distr of Cab overview,
from Control unit KPU controls on the the control unit and the D7902/C7:01, Electr 18/XX page 9:5
(D7902) to steering steering panel do component with diagnostic D7902/C9:01 DIAGNOSE,
panel, below 4.9 V. not work. menu. page 8:81
A3700/1
Check component.
10104 6 11 2 Background lighting The lighting in Check cabling between D7902/C6:18, Cab overview,
steering wheel panel, the steering the control unit and the D7902/C7:20, page 9:5
short circuit to ground. panel does not component with diagnostic D7902/C7:22
illuminate. menu.
A3700/1
Check component.
10104 6 11 3 Function lighting The function Check cabling between D7902/C6:19, Cab overview,
steering wheel panel, lighting in the control unit and the D7902/C7:21, page 9:5
short circuit to ground. the steering component with diagnostic D7902/C7:23
panel does not menu.
illuminate. A3700/1
Check component.
10104 3 12 5 V Reference voltage Control wheel Check cabling between D7950/C1:8 11.5 Distr of 11.5.3.3
Control unit KID panel does not the control unit and the Electr 23/XX Control unit,
(D7950), below 4.9 V. work. component with diagnostic S1017/2 DIAGNOSE, KID (D7950),
Check component.
VDU01.01GB
D:291
VDU01.01GB
D:292
and menu
components
10104 4 12 5 V Reference voltage Control wheel Check cabling between D7950/C1:8 11.5 Distr of 11.5.3.3
from Control unit KID panel does not the control unit and the Electr 23/XX Control unit,
(D7950), above 5.1 V. work. component with diagnostic S1017/2 DIAGNOSE, KID (D7950),
Check component.
10105 2 2 1 Control unit KFU Lift, lower, tilt in/out Check cabling between D7971/C1:10 11.5 Distr of 11.5.3.4
(D7971) reference do not work. the control unit and the Electr 28/XX Control unit
ground 1, loose component with diagnostic Y6004/2, DIAGNOSE, KFU (D7971),
connection. menu. Y6005/2, page 8:83 page 11:31
Y6010/2 and
Check component. Y6011/2
10105 6 2 1 Control unit KFU Lift, lower, tilt in/out Check cabling between D7971/C1:10 11.5 Distr of 11.5.3.4

(D7971) reference do not work. the control unit and the Electr 28/XX Control unit
ground 1, high current. component with diagnostic Y6004/2, DIAGNOSE, KFU (D7971),
menu. Y6005/2, page 8:83 page 11:31
Y6010/2 and
Check component. Y6011/2
10105 2 2 2 Control unit KFU Side shift, Check cabling between D7971/C1:30 11.5 Distr of 11.5.3.4
(D7971) reference spreading, the control unit and the Electr 29/XX Control unit
ground 2, loose levelling, extra component with diagnostic Y6018:2, DIAGNOSE, KFU (D7971),
connection. hydraulic function menu. Y6018-LE:2, page 8:83 page 11:31
do not work. Y6018-RI:2,
Check component. Y6019:2,
Y6019-LE:2,
Y6019-RI:2,
Y6020:2,
Y6021:2,
Y6022:2,
Y6023:2,
Y6035:2,
Y6036:2
and menu
components
10105 6 2 2 Control unit KFU Side shift, Check cabling between D7971/C1:30 11.5 Distr of 11.5.3.4
ground 2, high current. levelling, extra component with diagnostic Y6018:2, DIAGNOSE, KFU (D7971),
hydraulic function menu. Y6018-LE:2, page 8:83 page 11:31
do not work. Y6018-RI:2,
Check component. Y6019:2,
Y6019-LE:2,
Y6019-RI:2,
Y6020:2,
Y6021:2,
Y6022:2,
Y6023:2,
Y6035:2,
Y6036:2

10105 2 3 1 Control unit KFU-2 No limitation. Check cabling between D7972/C1:10
(D7972) reference the control unit and the
ground 1, loose component with diagnostic
connection. menu.
Check component.
ground 1, high current. component with diagnostic
menu.
Check component.
10105 2 3 2 Control unit KFU-2 No limitation. Check cabling between D79712C1:30
ground 2, loose component with diagnostic
connection. menu.
Check component.
ground 2, high current. component with diagnostic
menu.
Check component.
VDU01.01GB
D:293
VDU01.01GB
D:294
and menu
components
10105 2 6 Control unit KAU-2 No limitation. Check cabling between D7912/C2:35
ground indicator lights, component with diagnostic
loose contact. menu.
Check component.
10105 6 6 Control unit KAU-2 No limitation. Check cabling between D7912/C2:35
ground indicator lights, component with diagnostic
high current. menu.
Check component.
10105 2 6 1 Control unit KAU-2 Lift legs left side Check cabling between D7912/C1:10

(D7912) reference not working. the control unit and the
ground 1, loose component with diagnostic Y6056-LF/2,
connection. menu. Y6056-LR/2,
Y6057-LR/2,
Check component. Y6057-LF/2,
Y6058-LF/2,
Y6058-LR/2,
Y6059-LF/2,
Y6059-LR/2
10105 6 6 1 Control unit KAU-2 Lift legs left side Check cabling between D7912/C1:10
ground 1, high current. component with diagnostic Y6056-LF/2,
menu. Y6056-LR/2,
Y6057-LR/2,
Check component. Y6057-LF/2,
Y6058-LF/2,
Y6058-LR/2,
Y6059-LF/2,
Y6059-LR/2
10105 2 6 2 Control unit KAU-2 Lift legs right side Check cabling between D7912/C1:30
ground 2, loose component with diagnostic Y6056-RF/2,
connection. menu. Y6056-RR/2,
Y6057-RF/2,
Check component. Y6057-RR/2,
Y6058-RF/2,
Y6059-RF/2
and menu
components
10105 6 6 2 Control unit KAU-2 Lift legs right side Check cabling between D7912/C1:30
ground 2, high current. component with diagnostic Y6056-RF/2,
menu. Y6056-RR/2,
Y6057-RF/2,
Y6058-RF/2,
Y6059-RF/2
10105 2 6 3 Control unit KAU-2 Clamping function Check cabling between D7912/C2:37
(D7912) reference lift legs side not the control unit and the
ground 3, loose working. component with diagnostic Y6053-LE/2,
connection. menu. Y6053-RI/2,
Y6054-LE/2,

Check component. Y6054-RI/2,
Y6055-LE/2,
Y6055-RI/2
10105 6 6 3 Control unit KAU-2 Clamping function Check cabling between D7912/C2:37
(D7912) reference lift legs side not the control unit and the
ground 3, high current. working. component with diagnostic Y6053-LE/2,
menu. Y6053-RI/2,
Y6054-LE/2,
Check component. Y6054-RI/2,
Y6055-LE/2,
Y6055-RI/2
10105 2 7 1 Control unit KAU Side shift, Check cabling between D7971/C1:10 11.5 Distr of 11.5.3.8
ground 1, loose rotation, component with diagnostic Y6020/2, DIAGNOSE, KAU (D7911),
connection. controllable tilt, menu. Y6012/2, page 8:84 page 11:36
hydraulic levelling, Y6018/2,
twistlock not Check component. Y6019/2,
working. Y6008/2,
Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,
VDU01.01GB
D:295
VDU01.01GB
D:296
and menu
components
10105 6 7 1 Control unit KAU Side shift, Check cabling between D7971/C1:10 11.5 Distr of 11.5.3.8
ground 1, high current. rotation, component with diagnostic Y6020/2, DIAGNOSE, KAU (D7911),
controllable tilt, menu. Y6012/2, page 8:84 page 11:36
hydraulic levelling, Y6018/2,
twistlock not Check component. Y6019/2,
working. Y6008/2,
Y6009/2,
Y6010/2,
Y6011/2,
Y6035/2,
Y6036/2,
Y6039/2,
Y6040/2,

10105 2 7 2 Control unit KAU Lift legs right side, Check cabling between D7971/C1:30 11.5 Distr of 11.5.3.8
(D7911) reference not working. the control unit and the Electr 44/XX Control unit
ground 2, loose component with diagnostic H5780-LE/2, DIAGNOSE, KAU (D7911),
connection. menu. H578-RI/2, page 8:85 page 11:36
H5760/2,
Y6013-RR/2,
Y6065/2,
Y6058-RR/2,
Y6059-RR/2
10105 6 7 2 Control unit KAU Lift legs right side, Check cabling between D7971/C1:30 11.5 Distr of 11.5.3.8
(D7911) reference not working. the control unit and the Electr 44/XX Control unit
ground 2, high current. component with diagnostic H5780-LE/2, DIAGNOSE, KAU (D7911),
menu. H578-RI/2, page 8:85 page 11:36
H5760/2,
Y6013-RR/2,
Y6065/2,
Y6058-RR/2,
Y6059-RR/2
10105 2 7 3 Control unit KAU The indicator lights Check cabling between D7971/C2:35 11.5.3.8
(D7911) reference on the boom are the control unit and the Control unit
ground 3, loose not working. component with diagnostic H5620-1/2, KAU (D7911),
connection. menu. H5630-1/2, page 11:36
H5640-1/2,
Check component. H5001-1/2
and menu
components
10105 6 7 3 Control unit KAU The indicator lights Check cabling between D7971/C2:35 11.5.3.8
(D7911) reference on the boom are the control unit and the Control unit
ground 3, high current. not working. component with diagnostic H5620-1/2, KAU (D7911),
menu. H5630-1/2, page 11:36
H5640-1/2,
Check component. H5001-1/2
10105 5 7 2 Control unit KEM-3 WTP not working. Check cabling between A7993/C2:9
(A7993) reference the control unit and the
ground, open circuit. component with diagnostic Y6046-1
menu.
Y6046-2
Check component.
10105 6 7 2 Control unit KEM-3 WTP not working. Check cabling between A7993/C2:9

(A7993) reference the control unit and the
ground, high current. component with diagnostic Y6046-1
menu.
Y6046-2
Check component.
10106 6 1 24 V voltage feed Mini-wheel/joystick Check cabling between D7901/C2:5 11.5 Distr of
mini-wheel/joystick control do not the control unit and the Electr 3/XX
control, short circuit to work. component with diagnostic S1130/1, DIAGNOSE,
ground. menu. S1310-3/+, page 8:78
S1992/1,
Check component. S1470/2.
B7250/1,
M6501-
LE/53a,
M6501-
RI/53a,
M6502/53a,
M6503/53a,
B2190/1,
B2460/1
10106 6 2 1 24 V voltage feed Central lubrication Check cabling between D7971/C2/32 11.5 Distr of
sensor frame, short frame and tilt the control unit and the Electr 5/XX
circuit to ground. angle sensor not component with diagnostic B7242/BN, DIAGNOSE,
working. menu. B7229/2 page 8:79
VDU01.01GB
Check component.
D:297
VDU01.01GB
D:298
and menu
components
10106 6 2 2 24 V voltage feed Mast position Check cabling between D7971/C2:33 11.5 Distr of
sensor mast, short sensor not the control unit and the Electr 6/XX
circuit to ground. working. component with diagnostic B7226-4/BN, DIAGNOSE,
menu. B7239/BN, page 8:79
B7240/BN,
Check component. B7246/BN,
B7639/BN,
B7690/BN,
B7684/BN,
B7685/BN.
10106 6 6 LF 24 V voltage feed Lift leg left front not Check cabling between D7912/2:32
sensor attachment working. the control unit and the
left-hand side, short component with diagnostic B7212-LE/A,

circuit to ground. menu. B7213-LF/A,
B7215-LF/A,
Check component. B7217-LF/A,
B7219-LF/A
10106 6 6 RF 24 V voltage feed Lift leg right front Check cabling between D7912/2:33
sensor attachment not working. the control unit and the
right-hand side, short component with diagnostic B7213-RF/A,
circuit to ground. menu. B7215-RF/A,
B7217-RF/A,
Check component. B7219-RF/A
10106 6 6 LR 24 V voltage feed Lift leg left rear not Check cabling between D7912/2:26
sensor attachment working. the control unit and the
left-hand side, short component with diagnostic B7213-LR/A,
circuit to ground. menu. B7215-LR/A,
B7217-LR/A,
Check component. B7219-LR/A
10106 6 6 RR 24 V voltage feed Lift leg right rear Check cabling between D7912/2:27
sensor attachment not working. the control unit and the
right-hand side, short component with diagnostic B7212-RI/A,
circuit to ground. menu. B7213-RF/A,
B7215-RF/A,
Check component. B7217-RF/A,
B7219-RF/A
and menu
components
10106 6 7 2 24 V voltage feed WTP WTP not working. Check cabling between A7993/C2:10
sensor, short circuit to the control unit and the
ground. component with diagnostic B7693–LF
menu.
B7693–LR
Check component.
B7693–RF
B7693–RR
B7694–LF
B7694–LR
B7694–RF

B7694–RR
10106 6 7 10 24 V voltage feed Twistlocks, Check cabling between D7911/2:32 11.5 Distr of
sensor attachment spreading stop the control unit and the Electr 14/XX
left-hand side, short and damping as component with diagnostic B7202-FL/BN, DIAGNOSE,
circuit to ground. well as rotation menu. B7202-RL/BN, page 8:80
stop not working. B7204-LE/BN,
Check component. B7205-LE/BN,
B7225/BN,
B7690/BN,
B7770/BN
10106 6 7 20 24 V voltage feed Twistlocks, Check cabling between D7911/2:33 11.5 Distr of
sensor attachment spreading stop and the control unit and the Electr 15/XX
right-hand side, short damping as well as component with diagnostic B7202-RR, DIAGNOSE,
circuit to ground. central lubrication menu. B7202- page 8:80
attachment not FR/BN,
working. Check component. B7204-RI/BN,
B7205-RI/BN,
B7242/BN
10106 6 7 1 24 V voltage feed Attachment Check cabling between
sensor attachment functions not the control unit and the
ELME, short circuit to working. component with diagnostic
ground. menu.
Check component.
VDU01.01GB
D:299
VDU01.01GB
D:300
and menu
components
10106 6 11 1 24 V voltage feed to Switches and Check cabling between D7902/C3:9 11.5 Distr of
switches and controls controls in the the control unit and the Electr 19/XX
in the cab, short circuit cab not working. component with diagnostic S1004/3, DIAGNOSE,
to ground. menu. S1006FR/1, page 8:81
S1006R/3,
Check component. S1006-FR/3,
S1008/3,
S1008-2/3,
S1010/3,
S1010-2/3,
S1012-2/3,
S1013/3, S10
15/3,S1014/3,
S1023-1/3,

S1024/1,
S1031/2,
S1046/3,
S1028/3, S10
29/3,S1037/3,
S1049/3,
S1310-2/6,
S1490/1,
S1690/3,
S1750/3,
S1751/3,
S1752/3,
S1990-1/3,
S1990-2/3,
S1990-3/3,
S1990-4/3,
S1990-5/3,
S1990-6/3,
S1990-7/3,
S2992/3,
S8150/7,
S8070-1/1,
S8070-2/1,
S8070-3/1,
S8070-4/1,
S8070-5/1,
and menu
components
10106 6 11 2 24V voltage feed to Bypass safety Check cabling between D7902/C4:1 11.5 Distr of
switches in the cab, system, lock the control unit and the Electr 20/XX
short circuit to ground. twistlocks, switch component with diagnostic S1003/3, DIAGNOSE,
off sounds in cab menu. S1005/3, page 8:81
do not work. S1047/3
Check component.
10106 6 11 3 24V voltage feed to Mini-wheel/joystick Check cabling between D7902/C5:1 11.5 Distr of
switches and controls control, travel the control unit and the Electr 21/XX
in the cab, short circuit direction selector, component with diagnostic B7700-1/BN, DIAGNOSE,
to ground. direction indicators menu. B7700-2/BN, page 8:81
do not work. S1310/1,
Check component. S1600/31,
S1600/49a

10106 6 11 4 24V voltage feed to Control breaker Check cabling between D7902/C8:1 11.5 Distr of Control
switch, control breaker cannot be the control unit and the Electr 22/XX breaker
(S2500), short circuit to disengaged. component with diagnostic S2500/1 DIAGNOSE, voltage,
ground. menu. page 8:82 function
description,
Check component. page 11:19
10107 6 11 1 Lighting switch, short Lighting switch is Check cabling between D7902/C3:10 8.1 Controls Cab overview,
circuit to ground. not working. the control unit and the & Instr 3/XX page 9:5
component with diagnostic S1006R/6, DIAGNOSE,
menu. S1006FR/6, page 8:51
S1008/6,
Check component. S1008-2/6,
S1010/6,
S1012/6,
S1013/6,
S1028/6,
S1029/6, S10
31/6,S1690/6,
S1750/6,
S1751/6,
S1752/6,
S1990-2/6,
S1990-5/6,
S1990-6/6,
S1990-7/6,
VDU01.01GB
S2992/6
D:301
VDU01.01GB
D:302
and menu
components
10201 35 12 RedCAN, CAN error. No limitation. Use diagnostic menu to find - 11.6 Commu- 11.6.2
incorrect segment. nication 1/XX, Redundant
page 8:85 CAN bus,
page 11:42
11.6 Commu-
nication 6/XX,
page 8:87
10201 40 12 Control unit KID Display not Use diagnostic menu to find - 11.6 Commu- 11.6.2
(D7950), has lost working. incorrect segment. nication 8/XX, Redundant
contact with the CAN page 8:87 CAN bus,
bus after start-up. page 11:42
-
10201 41 12 Control unit KID Display not Use diagnostic menu to find 11.6 Commu- 11.6.2

(D7950), the control working. incorrect segment. nication 7/XX, Redundant
unit could not be page 8:87 CAN bus,
identified during page 11:42
start-up of the CAN
bus.
10201 42 12 Control unit KID No limitation. Use diagnostic menu to find - 11.6 Commu- 11.6.2
(D7950), segment incorrect segment. nication 6/XX, Redundant
error redundant CAN page 8:87 CAN bus,
bus normal side. page 11:42
10201 43 12 Control unit KID No limitation. Use diagnostic menu to find - 11.6 Commu- 11.6.2
(D7950), segment incorrect segment. nication 6/XX, Redundant
error redundant CAN page 8:87 CAN bus,
bus redundant side. page 11:42
10201 44 12 Control unit KID Display not Use diagnostic menu to find - 11.6 Commu- 11.6.2
(D7950), control unit working. incorrect segment. nication 2/XX, Redundant
incorrectly located on page 8:86 CAN bus,
the CAN bus. page 11:42
11.6 Commu-
nication 4/XX,
page 8:86
10202 31 2 CAN bus drivetrain Communication Check the cable harness D7971/C1:31, 11.6.3 CAN
open circuit. error. and termination resistance. D7971/C1:32 bus drive-
train, page
If the error persists, contact D7940, D7930 11:45
Cargotec.
and menu
components
10202 35 2 CAN bus drivetrain Gear selection not Check the cable harness D7971/C1:31, 11.6.3 CAN
open circuit. working. and termination resistance. D7971/C1:32 bus drive-
train, page
Engine does If the error persists, contact D7940, D7930 11:45
not respond to Cargotec.
commands from
the cab.
communication error. working. and termination resistance. D7971/C1:32 bus drive-
train, page
commands from

the cab.
train, page
commands from
the cab.
train, page
commands from
the cab.
10204 35 1 CAN bus customer Customer Check the cable harness D7901/C1:26, 11.6.2
equipment, open circuit equipment cannot and termination resistance. D7901/C1:27 Redundant
receive information CAN bus,
from the machine Disconnect any customer D7950/C1:12, page 11:42
via the CAN bus equipment in order to D7950/C1:13
isolate the source of the
error.
Cargotec.
VDU01.01GB
D:303
VDU01.01GB
D:304
and menu
components
10204 36 1 CAN bus customer Some optional Check the cable harness D7901/C1:26, 11.6.2
equipment, functions do not and termination resistance. D7901/C1:27 Redundant
communication error. work. If the error persists, contact CAN bus,
Cargotec. D7950/C1:12, page 11:42
D7950/C1:13
D7950/C1:13

D7950/C1:13
10301 2 1 Control unit KCU Memory errors can Connect the Kalmar Service D7901 11.5.3.1
(D7901) memory error disrupt machine Tool and Repair. If the error Control unit
non-volatile memory. operations. persists, replace the control KCU (D7901),
unit. page 11:25
10301 2 2 Control unit KFU Memory errors can Connect the Kalmar Service D7971 11.5.3.4
non-volatile memory. operations. persists, replace the control KFU (D7971),
unit. page 11:31
10301 2 3 Control unit KFU-2 Memory errors can Connect the Kalmar Service D7972
(D7972) memory error disrupt machine Tool and Repair. If the error
non-volatile memory. operations. persists, replace the control
unit.
10301 2 6 Control unit KAU-2 Memory errors can Connect the Kalmar Service D7912
(D7912) memory error disrupt machine Tool and Repair. If the error
non-volatile memory. operations. persists, replace the control
unit.
10301 2 7 Control unit KAU Memory errors can Connect the Kalmar Service D7911 11.5.3.8
non-volatile memory. operations. persists, replace the control KAU (D7911),
unit. page 11:36
10301 2 11 Control unit KPU Memory errors can Connect the Kalmar Service D7902 11.5.3.2
non-volatile memory. operations. persists, replace the control KPU (D7902),
unit. page 11:27
and menu
components
10301 2 12 Control unit KID Memory errors can Connect the Kalmar Service D7950 11.5.3.3
(D7950) memory error disrupt machine Tool and Repair. If the error Control unit,
non-volatile memory. operations. persists, replace the control KID (D7950),
unit. page 11:29
10302 2 1 Control unit KCU Memory errors can Connect the Kalmar Service D7901 11.5.3.1
(D7901), application disrupt machine Tool and Repair. If the error Control unit
log. operations. persists, replace the control KCU (D7901),
unit. page 11:25
10302 2 2 Control unit KFU Memory errors can Connect the Kalmar Service D7971 11.5.3.4
log. operations. persists, replace the control KFU (D7971),
unit. page 11:31

10302 2 3 Control unit KFU-2 Memory errors can Connect the Kalmar Service D7972
(D7972), application disrupt machine Tool and Repair. If the error
log. operations. persists, replace the control
unit.
10302 2 6 Control unit KAU-2 Memory errors can Connect the Kalmar Service D7912
(D7912), application disrupt machine Tool and Repair. If the error
log. operations. persists, replace the control
unit.
10302 2 7 Control unit KAU Memory errors can Connect the Kalmar Service D7911 11.5.3.8
log. operations. persists, replace the control KAU (D7911),
unit. page 11:36
10302 2 11 Control unit KPU Memory errors can Connect the Kalmar Service D7902 11.5.3.2
log. operations. persists, replace the control KPU (D7902),
unit. page 11:27
10302 2 12 Control unit, KID Memory errors can Connect the Kalmar Service D7950 11.5.3.3
(D7950), application disrupt machine Tool and Repair. If the error Control unit,
log. operations. persists, replace the control KID (D7950),
unit. page 11:29
10303 0 1 Control unit KCU None when the Clean dirt and dust from D7901 11.5.3.4
(D7901), high error becomes the control unit and its Control unit
active, but may KFU (D7971),
VDU01.01GB
temperature circuit immediate surroundings.

board. affect the lifespan page 11:31
D:305
of the control unit.
VDU01.01GB
D:306
and menu
components
10303 0 2 Control unit KFU None when the Clean dirt and dust from D7971 11.5.3.4
temperature circuit active, but may immediate surroundings. KFU (D7971),
10303 0 3 Control unit KFU-2 None when the Clean dirt and dust from D7972
(D7972), high error becomes the control unit and its
temperature circuit active, but may immediate surroundings.
board. affect the lifespan
10303 0 6 Control unit KAU-2 None when the Clean dirt and dust from D7912
(D7912), high error becomes the control unit and its

temperature circuit active, but may immediate surroundings.
board. affect the lifespan
10303 0 7 Control unit KAU None when the Clean dirt and dust from D7911 11.5.3.8
temperature circuit active, but may immediate surroundings. KAU (D7911),
10303 0 11 Control unit KPU None when the Clean dirt and dust from D7902 11.5.3.2
temperature circuit active, but may immediate surroundings. KPU (D7902),
10303 0 12 Control unit KID None when the Clean dirt and dust from D7950 11.5.3.3
(D7950), high error becomes the control unit and its Control unit,
temperature circuit active, but may immediate surroundings. KID (D7950),
10304 2 1 Control unit KCU Slow response on Fully de-energise the D7901 11.5.3.1
(D7901), long machine functions. machine by switching off Control unit
processing time for the ignition and switching KCU (D7901),
programs. off the main switch. Restart page 11:25
the machine. If the error
persists, contact Cargotec
support.
and menu
components
10304 2 2 Control unit KFU Slow response on Fully de-energise the D7971 11.5.3.4
processing time for the ignition and switching KFU (D7971),
support.
10304 2 3 Control unit KFU Slow response on Fully de-energise the D7972
(D7972), long machine functions. machine by switching off
processing time for the ignition and switching
programs. off the main switch. Restart

support.
10304 2 11 Control unit KPU Slow response on Fully de-energise the D7902 11.5.3.2
processing time for the ignition and switching KPU (D7902),
support.
10304 2 12 Control unit KID Slow response on Fully de-energise the D7950 11.5.3.3
(D7950), long machine functions. machine by switching off Control unit,
processing time for the ignition and switching KID (D7950),
support.
10305 6 1 Control unit KCU Fuses can blow If there are other error D7901 11.5.3.1
(D7901), high power and functionality codes, check these first. Control unit
consumption. can be lost. KCU (D7901),
Check the wiring. page 11:25
10305 6 2 Control unit KFU Fuses can blow If there are other error D7971 11.5.3.4
consumption. can be lost. KFU (D7971),
VDU01.01GB
10305 6 3 Control unit KFU-2 Fuses can blow If there are other error D7972
(D7972), high power and functionality codes, check these first.
D:307
consumption. can be lost.
Check the wiring.
VDU01.01GB
D:308
and menu
components
10305 6 6 Control unit KAU-2 Fuses can blow If there are other error D7912
(D7912), high power and functionality codes, check these first.
consumption. can be lost.
Check the wiring.
10305 6 7 Control unit KAU Fuses can blow If there are other error D7912 11.5.3.8
consumption. can be lost. KAU (D7911),
10305 6 11 Control unit KPU Fuses can blow If there are other error D7902 11.5.3.2
consumption. can be lost. KPU (D7902),
Check the wiring.
page 11:27

10305 6 12 Control unit KID Fuses can blow If there are other error D7950 11.5.3.3
(D7950), high power and functionality codes, check these first. Control unit,
consumption. can be lost. KID (D7950),
10306 3 2 1 Control unit KFU No limitation, Check the supply voltage to D7971/C1:27, 11.5 Distr of 11.5.3.4
(D7971), control but may affect the control unit, connection C1:28, C1:29, Electr 25/XX Control unit
breaker voltage group 1 the control unit's C3:1. C1:33, C1:34, DIAGNOSE, KFU (D7971),
short circuit to voltage. function in the long C1:35, C1:36, page 8:82 page 11:31
term. Check the wiring. C1:37, C1:38,
C1:40, C1:41
10306 4 2 1 Control unit KFU Check the supply voltage to D7971/C1:27, 11.5 Distr of 11.5.3.4
(D7971), control the control unit, connection C1:29, C1:33, Electr 25/XX Control unit
breaker voltage group 1 C3:1. C1:34, C1:35, DIAGNOSE, KFU (D7971),
short circuit to ground. C1:36, C1:37, page 8:82 page 11:31
Check the wiring. C1:38, C1:40,
C1:41
10306 3 2 2 Control unit KFU No limitation, Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4
(D7971), control but may affect the control unit, connection C1:48, C1:50 Electr 26/XX Control unit
breaker voltage group 2 the control unit's C3:1. DIAGNOSE, KFU (D7971),
short circuit to voltage. function in the long page 8:83 page 11:31
term. Check the wiring.
10306 4 2 2 Control unit KFU Check the supply voltage to D7971/C1:47, 11.5 Distr of 11.5.3.4
(D7971), control the control unit, connection C1:48, C1:50 Electr 26/XX Control unit
breaker voltage group 2 C3:1. DIAGNOSE, KFU (D7971),
short circuit to ground. page 8:83 page 11:31
Check the wiring.
and menu
components
10306 3 2 3 Control unit KFU No limitation, Check the supply voltage to C7971/C2:35, 11.5 Distr of 11.5.3.4
(D7971), control but may affect the control unit, connection C2:37 Electr 27/XX Control unit
10306 4 2 3 Control unit KFU Check the supply voltage to C7971/C2:35, 11.5 Distr of 11.5.3.4
(D7971), control the control unit, connection C2:37 Electr 27/XX Control unit
breaker voltage group 3 C3:1. DIAGNOSE, KFU (D7971),
short circuit to ground. page 8:83 page 11:31
Check the wiring.
10306 3 3 1 Control unit KFU-2 No limitation, Check the supply voltage to D7972/C1:27,
(D7972), control but may affect the control unit, connection C1:28, C1:29,

breaker voltage group 1 the control unit's C3:1. C1:33, C1:34,
short circuit to voltage. function in the long C1:35, C1:36,
C1:40, C1:41
short circuit to ground. function in the long C1:36, C1:37,
C1:41
(D7972), control but may affect the control unit, connection C1:48, C1:50
breaker voltage group 2 the control unit's C3:1.
short circuit to voltage. function.
Check the wiring.
(D7972), control but may affect the control unit, connection C1:48, C1:50
short circuit to ground. function.
Check the wiring.
10306 3 3 3 Control unit KFU-2 No limitation, Check the supply voltage to C7972/C2:35,
(D7972), control but may affect the control unit, connection C2:37
short circuit to voltage. function in the long
Check the wiring.
VDU01.01GB
term.
D:309
VDU01.01GB
D:310
and menu
components
10306 4 3 3 Control unit KFU-2 No limitation, Check the supply voltage to C7972/C2:35,
short circuit to ground. function in the long
10306 3 6 1 Control unit KAU-2 No limitation, Check the supply voltage to D7912/C1:27,
short circuit to voltage. function in the long C1:35, C1:36,
C1:40, C1:41
10306 4 6 1 Control unit KAU-2 Lift legs not Check the supply voltage to D7912/C1:27,

(D7912), control working. the control unit, connection C1:29, C1:33,
breaker voltage group 1 C3:1. C1:34, C1:35,
short circuit to ground. C1:36, C1:37,
Check the wiring. C1:38, C1:40,
C1:41
10306 3 6 2 Control unit KAU-2 No limitation, Check the supply voltage to D79172/C1:47
(D7912), control but may affect the control unit, connection , C1:48, C1:50
10306 4 6 2 Control unit KAU-2 Lift legs not Check the supply voltage to D7912/C1:47,
(D7912), control working. the control unit, connection C1:48, C1:50
breaker voltage group 2 C3:1.
Check the wiring.
10306 3 6 3 Control unit KAU-2 No limitation, Check the supply voltage to C7912/C2:35,
10306 4 6 3 Control unit KAU-2 Lift legs not Check the supply voltage to C7912/C2:35,
(D7912), control working. the control unit, connection C2:37
breaker voltage group 3 C3:1.
Check the wiring.
and menu
components
10306 3 7 1 Control unit KAU No limitation, Check the supply voltage to D7971/C1:27, 11.5 Distr of 11.5.3.4
(D7911), control but may affect the control unit, connection C1:28, C1:29, Electr 40/XX Control unit
breaker voltage group 1 the control unit's C3:1. C1:33, C1:34, DIAGNOSE, KFU (D7971),
short circuit to voltage. function in the long C1:35, C1:36, page 8:84 page 11:31
C1:40, C1:41
10306 4 7 1 Control unit KAU Side shift, Check the supply voltage to D7971/C1:27, 11.5 Distr of 11.5.3.4
(D7911), control spreading, the control unit, connection C1:29, C1:33, Electr 40/XX Control unit
breaker voltage group 1 rotation, C3:1. C1:34, C1:35, DIAGNOSE, KFU (D7971),
short circuit to ground. controllable tilt and C1:36, C1:37, page 8:84 page 11:31
hydraulic levelling Check the wiring. C1:38, C1:40,
not working. C1:41

short circuit to ground. function in the long page 8:84 page 11:31
10306 3 7 3 Control unit KAU No limitation, Check the supply voltage to C7911/C2:35, 11.5 Distr of 11.5.3.4
10306 4 7 3 Control unit KAU No limitation, Check the supply voltage to C7911/C2:35, 11.5 Distr of 11.5.3.4
short circuit to ground. function in the long page 8:84 page 11:31
10307 2 1 Control unit KCU No limitation. Fully de-energise the D7901 11.5.3.1
(D7901), memory machine by switching off Control unit
error. the ignition and switching KCU (D7901),
off the main switch. Restart page 11:25
VDU01.01GB

D:311
support.
VDU01.01GB
D:312
and menu
components
10307 2 2 Control unit KFU No limitation. Fully de-energise the D7971 11.5.3.4
error. the ignition and switching KFU (D7971),
support.
10307 2 3 Control unit KFU-2 No limitation. Fully de-energise the D7972
(D7972), memory machine by switching off
error. the ignition and switching
off the main switch. Restart

support.
10307 2 6 Control unit KAU-2 No limitation. Fully de-energise the D7912
support.
10307 2 7 Control unit KAU No limitation. Fully de-energise the D7911 11.5.3.8
(D7911), memory error. machine by switching off Control unit
the ignition and switching KAU (D7911),
support.
10307 2 11 Control unit KPU No limitation. Fully de-energise the D7902 11.5.3.2
error. the ignition and switching KPU (D7902),
support.
and menu
components
10307 2 12 Control unit, KID No limitation. Fully de-energise the D7950 11.5.3.3
(D7950), memory machine by switching off Control unit,
error. the ignition and switching KID (D7950),
support.

support.
support.
support.
support.
VDU01.01GB
D:313
VDU01.01GB
D:314
and menu
components
support.

support.
support.
support.
support.
and menu
components
support.

support.
support.
support.
support.
VDU01.01GB
D:315
D:316
E:1
E Diagrams
Contents E Diagrams
Diagrams ............................................................................................................ E:3
Common hydraulics ........................................................................................ E:3
Hydraulic diagrams, compilation ................................................................ E:3
Hydraulic diagram, basic machine ............................................................. E:4
Hydraulic diagram, attachment................................................................... E:6
Common electrics ........................................................................................... E:8
Circuit diagrams, subdivision...................................................................... E:8
Circuit diagram, description ....................................................................... E:8
Component designations ......................................................................... E:10
Circuit diagrams, compilation ................................................................... E:10

E:2

E Diagrams – Diagrams E:3
E Diagrams
Common hydraulics
Hydraulic diagrams, compilation
Designation Drawing number
Hydraulic diagram, basic machine, page E:4 A65176.0100
Hydraulic diagram, attachment, page E:6 A65211.0200

E:4 E Diagrams – Common hydraulics
Hydraulic diagram, basic machine

E Diagrams – Common hydraulics E:5
1. Steering cylinder 19. Main valve

2. Priority valve and Control valve steering • Accumulator charging valve
3. Steering valve • Control valve, lift and tilt
4. Lift cylinder • Valve block servo pressure
5. Hose rupture valve 20. Shuttle valve
6. Accumulator damping 21. Accumulator servo pressure
7. Tilt cylinder 22. Hydraulic oil filter
8. Return from attachment 23. Hydraulic oil pump 2
9. Pressure feed to attachment 24. Hydraulic oil pump 1
10. Wheel brake 25. Oil pump brake system
11. Brake pressure sensor (B7681) 26. Hydraulic oil tank
12. Drive axle block 27. Breather filter hydraulic oil tank
13. Brake cylinder 28. High-pressure filter
14. Brake valve 29. Fine filter hydraulic oil
15. Parking brake caliper 30. Cooler hydraulic oil
16. Accumulator brake pressure 31. Thermal bypass valve
17. Accumulator pressure sensor (B7683)
18. Sensor parking brake pressure (B7682)

E:6 E Diagrams – Common hydraulics
Hydraulic diagram, attachment

E Diagrams – Common hydraulics E:7
1. Spreading cylinder right

2. Cylinder twistlock/lock lug
3. Spreading cylinder left
4. Side shift cylinder
5. Control valve, attachment
a Spreading in (Y6019RI)
b Spreading out (Y6018RI)
c Open twistlock/lock lug (Y6039)
d Lock twistlock/lock lug (Y6040)
e Spreading in (Y6019LE)
f Spreading out (Y6018LE)
g Side shift right (Y6021)
h Side shift left (Y6020)
6. Pressure feed to attachment
7. Return from attachment

E:8 E Diagrams – Common electrics
Common electrics
Circuit diagrams, subdivision
Circuit diagrams are subdivided by cab and frame. The different parts
can cover more than one machine model, it is therefore important to
be observant that certain components may not be fitted on the current
machine, the same also applies to options and variants.
Circuit diagram, description

A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 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
The following is an explanation of symbols and texts in a circuit diagram:

Connectors
Connectors
Connectors in the wiring start with an X followed by a number and end
with f = female or m = male. If a connector is connected to a component
then the component number is inherited into the connector's number,
e.g. XB72002Rm which is the connector for Sensor, contact front right
(B7202R).
Under the connector's number the pin is specified with numbers or

letters depending on the connector.
• X000-X199: In the cab.
• X200-X299: On the frame.
• X400-: On the attachment.
• X37-: All grounding points start with X37, e.g. X37-201, which is a
grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in electronic
box, cab.
Zero references are in the control units.
Components
Components
Components are described with component number (S220-2) and a
short descriptive text. Components (sensors, switches, etc.) are shown
in standby mode i.e. de-energised mode or mechanical standby mode.
• S indicates the type of component, see Component designations,
page E:10.
• 220 is component number and indicates the function the
component has.
• -2 indicates that it is the second component of this type for the
specific diagram.

E Diagrams – Common electrics E:9
Cable marking
Cable marking
The cables are colour coded in accordance with the following: Red =
battery voltage. White = ignition voltage or signal. Black = grounding.
Cable numbering is interpreted as follows:

• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
• W212: cables that start with W and serial number cannot be
traced directly to a connector.
• A01012: cables that start with A are in the electronic box in the cab.
• W212D: cables that end with a capital letter are jointed in the
wiring from a main cable with the same number. Each joint will
have its own letter.
Jointed cables are only located inside the cab, outside of the cab
the joints are routed out to a separate connector with strappings.
References
References
An arrow symbol means that the circuit continues on another page in
the circuit diagram at the specified coordinates. Sometimes there are
also references for components that can then be part of a component
whose other parts are on a different diagram. In some cases there is
also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.

Connection to control unit
Connection to control unit

Connections to control units are described as a table with two fields;
the upper one shows the type of connection, the lower one has a
reference to the compilation of the control unit's connections. Together
with this there are descriptive texts that specify control unit and signal.
For more information about the different connection types on the

control units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F99. Example: F9958-RD means a fuse
box with 8 fuses for battery voltage.
For most fuse boxes there is also a table and an explanation of the
circuits that the various fuses protect.

E:10 E Diagrams – Common electrics
Component designations
The components in circuit diagrams have a prefix and number, the
prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is

provided as an appendix after the circuit diagrams.
Prefix Description
A Control panel Drive-train/Wiper
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 White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
Q Battery disconnector
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
V Diode
W Antenna
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation

Circuit diagrams are attached as an appendix in the following order.
• A66424.0100 Circuit diagram cab
• A55039.1500 Circuit diagram frame
• A65001.0100 Circuit diagram attachment

1 2 3 4 5 6 7 8
A A
B B
DCG/DRG C
not be imparted to a third party nor be used for any
written permission and the contents thereof must
unauthorized purpose. Contravention will be pro-

This document must not be copied without our
Wiring CAB
D D
secuted.
E E
hörigen användas. Överträdelse härav beivras med
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe-
stöd av gällande lag.
F F
Benämning Produkt/Product Blad/Sheet

Ref. Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Kretsschema DCG,DRG DRG-T,DCG-T 0 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
6 Ritn.nr./ Drawing No. Utgåva/Issue
R
Konstr/Design
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr

RSO 120416 Klass/Class
Wiring Diagram DCG,DRG A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A A
12/24V Climate
Door switches
A55184.5200 Wiper
B B
Washers
C
EL-Central Accelerator
C
Brake pedal
Cabin floor
D D
Electric mirror switch

A55185.5200
Seat
E
Interface chassi Fuse box E
harness A55186.0100
KCU A57059.0100
Electric mirrors
Ignition
MATA MED 5:1
A59534.5200 A67671.5100 Electric main switch
FNR
Gnd KID #1
F Steering sensor F
Multi light
Horn
STD harness switches Indicator
Ind Panel 24V Ref C4p01 24V REF C5p01
G
KID #2 G
Radio
A55179.0100
A55190.5100 A55180.0200
Interface right
A55183.5200 Manouver panel
H
KPU-1 Joystick/levers
H
A55181.0200
24V Ref C3p09
A55182.0100
Interior light X063 to splice in
Extra KPU
Speaker Right Manouvre switch
J
24V Ref C8p01 J
A55187.5100 Rear wiper

Layout harnesses lights roof

secuted.
K
Interior light K
Speaker Left
Wiper roof
Temp ambient
L L
A55190.5100
Interface left
All red texts are linked to docment

M Ref. Ändring
Benämning Produkt/Product Blad/Sheet M
Nr Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Sign.
Ruta
Kablage översikt DCG/DRG DRG-T,DCG-T 0.0_0 1
E³ DRAWING
Design change
Sq.
No. Change No. Date Ritad/Drawn RSO 120416 A66423.1600
Name
1 See ECO 1034014 RSO 171130 Konstr/Design H.Grp:
R

Harnesses overview DCG/DRG A66424.0100 04
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
A A
-D7901
Pin Number Drawing Function Type Pin Number Drawing Function Type
1:1 /9.4_3.A2 Sw. AC pressure in range=clutch active Dig In 2:1 /7.9_2.C1 Ind. unlocked TW 0,5A / Dig out
B 1:2 /9.4_3.B2 Sw. AC pressure >16 bar Max fan speed Dig In 2:2 /7.9_2.D1 Ind. locked TW 0,5A / Dig out B
1:3 /11.6_1.B8 CAN CAN Clamp pressure ok
1:4 See pin K1:3 2:3 /7.9_2.D1 Ind. alignment 0,5A / Dig out
1:5 CAN Shield / Ana In
1:6 See pin K1:3 Tilt control
1:7 See pin K1:3 2:4 /7.9_2.B1 Ind. support jacks down 0,5A / Dig out
1:8 /11.5_5.D1 Ref Air distr. / heat valve 5V Ref 2:5 /11.5_5.B1 24V Supply Lever/Micro steering 0,5A
1:9 /11.5_5.B8 Ref Sensors 0V Ref 2:6 /9.9_2.C1 Rear window heater 0,5A
1:10 /9.5_2.B8 Single wiper front feedback Dig In 2:7 /9.3_2.C1 Lamp fasten seat belt 1,5A
2:8 /9.5_2.A1 Single wiper front 1,5A
1:11 Double wiper front right feedback Dig In 2:9 Double wipers front right 1,5A
1:12 /9.5_1.B8 Wiper rear feedback Dig In 2:10 /9.5_2.C1 Motor washer single wiper front 1,5A
1:13 /9.5_1.C8 Wiper roof feedback Dig In
1:14 Washer fluid level switch Dig In 2:11 /11.5_1.E1 Main relay ignition K3150 1,5A
1:15 2:12 /9.7_1.D1 Horn 3A
KCU D7900-1, Main C1 connector pinout
Climate Air Filter Ind. Pressure Sw Dig In

1:16 Cab in upper position (tilt) Dig In 2:13 /9.7_2.B1 Rotating beacon 3A
C 1:17 /9.3_5.B1 Seat in driving position Dig In 2:14 /9.4_4.D1 Paus heater 3A C
KCU D7900-1, Main C2 connector pinout

1:18 /5.2_2.D12 Mini/Leversteering on/off Dig In 2:15 /9.5_1.E1 Motor washer front/roof 6A
1:19 /5.2_2.D12 Mini/Leversteering gear forward Dig In 2:16 /9.5_1.D1 Motor washer rear 6A
1:20 /5.2_2.E12 Mini/Leversteering gear neutral Dig In 2:17 /9.5_1.B1 Wiper rear 6A
2:18 /9.6_4.A1 Extra worklight left C 6A
1:21 /5.2_2.E12 Mini/Leversteering gear reverse Dig In 2:19 /9.5_1.C1 Wiper roof/combined front/roof 6A
1:22 /5.2_2.F12 Mini/Leversteering indicator left Dig In 2:20 /9.6_2.B1 Working light reverse left 6A
1:23 /5.2_2.F12 Mini/Leversteering indicator right Dig In
1:24 /5.2_2.E12 Mini/Leversteering aut. Head light Dig In 2:21 /9.6_2.C1 Working light reverse right 6A
1:25 /5.2_2.G12 Armrest in position Dig In 2:22 /9.6_3.A1 Extra worklight left A 6A
See pin K1:3 2:23 /9.6_3.D1 Extra worklight right B 6A

1:26
1:27 See pin K1:3 2:24 /9.4_2.A1 Air distributor valve close PWM
1:28 /9.4_2.B8 Air distributor valve Dig In / Ana In 2:25 /9.4_2.A1 Air distributor valve open PWM
1:29 /9.4_2.C8 Heat valve(air mix) Dig In / Ana In 2:26 /9.4_2.B1 Heat valve Close PWM
1:30 /11.5_4.E7 Dig In / Ana In 2:27 /9.4_2.B1 Heat valve Open PWM
2:28 /9.4_2.E1 Motor, recirculation PWM
1:31 /9.10_1.E8 Cab pos (tilt) Dig In / Ana In 2:29 /9.4_2.D1 Motor, recirculation PWM
D 1:32 /9.10_1.E8 Cab moving damp sens/Length sens Dig In / Ana In 2:30 /9.6_1.E1 Interior light, step light PWM D
secuted.
1:33 /9.4_1.C8 Temp. indoor Resistance In

1:34 /9.4_1.C8 Temp. fan air Resistance In 2:31 /2.1.F1 Output status FWD 0,5A / Dig In
1:35 /9.4_1.D8 De-icing Resistance In 2:32 /2.1.F1 Output status REV 0,5A / Dig In
1:36 /9.4_1.D8 Temp. ambient Resistance In 2:33 /5.2_2.D2 Indication Mini/Leversteering on/off 0,5A / Dig Out
1:37 /5.2_2.C12 Micro/Lever-Steering sensor Ch1 Dig In / Ana In 2:34 /9.3_5.C1 Seat Unlock (TDS 15/30deg) 0,5A / Dig In
1:38 /5.2_2.C12 Micro-Steering sensor Ch2 Dig In / Ana In 2:35 /11.6_1.C7 Dig Out CPU Power
1:39 /8.2_1.E8 Key switch override Dig In / Ana In 2:36 /9.6_4.D1 Extra worklight right D PWM 15A
1:40 Dig In / Ana In Condenser roof
2:37 /9.4_2.C1 Heating fan PWM 15A
1:41 Dig In / Ana / Freq 2:38 /11.5_1.C4 CPU Power
1:42 Dig In / Ana / Freq
1:43 /9.6_1.D8 Steplight Dig In Start up M5: 24V See pin K1:2
1:44 /9.4_4.B7 External heater Dig In Start up M5: GND See pin K1:2
1:45 /11.5_3.C8 Door switch right Dig In Start up
1:46 /11.5_3.B8 Door switch left Dig In Start up
E 1:47 /11.5_3.D8 Startup hazard Dig In Start up E
1:48 /11.5_3.D8 Interior light Dig In Start up
1:49 /11.5_3.A8 Ignition key Dig In Start up

1:50 /9.3_1.E8 Seat switch Dig In Start up

F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Korsreferenser DRG-T,DCG-T 0.0_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Cross References A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7902
C1 1:1-1:2 /11.5_1.D5 Power C4 4:10 /7.5_1.B8 Option 5 Dig In

A 1:3-1:7 /11.6_1.E8 CAN-BUS Spreading 20-40 A
1:8 Ana In
PLH+
1:9 Steering panel up/down feedback Ana In
1:10 /11.5_3.D5 Sw interior light S1160 In (Sw Inside light) Clamp legs
1:11 /11.5_3.D5 Sw. hazard S1090 In(Sw. Hazard) 4:11 /9.10_1.A8 Cab moving left/reverse/Up Dig In
1:12 /11.5_3.D4 Supply +30 Supply +30 4:12 /9.10_1.B8 Cab moving right/forward/Down Dig In
4:13 /8.2_3.A8 Dead mans grip Dig In
C2 2:1 Motors 5V Ref 4:14 /9.10_1.C8 Option 6 Dig In
2:2 Motors Console/Seat 0V Ref
2:3 Motor canoe fwd/rev feedback Ana In Cabtilt up
2:4 Motor canoe up/down feedback Ana In Turible seat C.C.W
2:5 Steering panel up/down NPN / PNP 3A 4:15 /9.10_1.C8 Option 6 Dig In
2:6 Steering panel up/down NPN / PNP 3A Cab tilt down
2:7 /9.3_3.B1 Motor canoe fwd/rev NPN / PNP 3A Turnible seat C.W
2:8 /9.3_3.B8 Motor canoe fwd/rev NPN / PNP 3A 4:16 /5.2_1.D8 Sensor steering wheel Dig In
2:9 /9.3_3.C1 Motor canoe up/down NPN / PNP 3A
B 2:10 /9.3_3.C8 Motor canoe up/down NPN / PNP 3A B
4:17 /7.10_1.A8 Option 7 Dig In
C3 3:1 /11.5_5.C1 Lever/Joystick 5V Ref Support jacks up
3:2 /11.5_5.B8 Lever/Joystick 0V Ref
Upper Arms Height up
3:3 /7.1_1A.D8 Sensor Lift/lower Ana In 4:18 /7.10_1.B8 Option 7 Dig In
3:4 /7.1_1A.C8 Sensor Boom/tilt - in/out Ana In
3:5 /7.1_1A.D8 Sensor Sideshift Ana In Support jacks down
3:6 /7.1_1A.E8 Rotation Ana In Upper Arms Height down
Spread(L)
C5 5:1 /11.5_5.B1 24V Supply Island 4 0,5A
Extension left
5:2 /4.5.B8 Sw. parking brake Dig In
Clamp(L) 5:3 /2.1.B8 Sw. forward gear Dig In
3:7 /7.1_1B.D8 Levelling/5th funct/ Ana In 5:4 /2.1.A8 Sw. neutral gear Dig In
5:5 /2.1.B8 Sw. center gear Dig In
Rear legs up/Spread R/ 5:6 /2.1.A8 Sw. reverse gear Dig In
Clamp R 5:7 /9.6_1.B8 Sw. indicator right Dig In
C 3:8 /7.1_1B.E8 Extension R Ana In C
6th funct 5:8 /9.6_1.B8 Sw. indicator left Dig In
5:9 /9.6_1.C8 Sw. High Low Beam Dig In
Rear legs down
5:10 /9.7_1.A8 Sw. horn Dig In
3:9 /7.1_1A.B1 24V Supply Island 1 0,5A 5:11 /11.5_1.A8 Operating switch Dig In
3:10 /11.5_5.B1 Lever/Joystick PWM 1,5A 5:12 /5.2_1.B8 Sensor steering wheel Dig In
3:11 /8.2_1.B8 Sw. override safety keyswitch Dig In 5:13 /9.2_1.A8 Start interlock device Dig In
3:12 /7.9_1.B8 Sw. lock TW Dig In 5:14 /9.3_2.B8 Seat belt Dig In
PLH on/off
C8 8:1 /11.5_5.A1 24V Supply Island 2 0,5A
3:13 /7.1_1A.B8 Option 1 Dig In

8:2 Seat switch Dig In

Lock Levelling 8:3 /1.1_1.E8 Pedals 0V Ref

Lock arm 1 8:4 /11.5_5.C1 Supply pedals 5V Ref
3:14 /7.10_2.C7 Option 1/Front legs up/ Dig In 8:5 /1.1_1.D8 Throttle position B Ana In
Overheight up 8:6 /1.1_1.E8 Throttle position A Ana In
8:7 /4.1.D8 Brake pedal pos. B Ana In
D 3:15 /8.2_2.B8 Override height/Override rotation/ Dig In 8:8 /4.1.E8 Brake pedal pos. A Ana In D
Lock arm 2
secuted.
C6 6:1-6:20 Wiper & drive train control panel Ribbon cable

3:16 /7.5_2.B8 Aut 20-40 on-off Dig In C7 5:1-5:30 Climate control panel Ribbon cable
Differential lock
3:17 /9.10_2.B8 Aut cab tilt on/off Dig In C9 6:1-6:20 Light control panel Ribbon cable
Diffrential Lock
3:18 /7.5_3.B8 Sw. 30-35 stop Dig In
3:19 /1.3_1.B8 DPF Regen Inhibit Dig In
3:20 /9.9_2.B8 Sw. window heater & mirror heater Dig In
C4 4:1 /11.5_5.A1 24V Supply Island 3 0,5A

4:2 /7.1_1A.B1 LED right locked levelling/opt 0,5A
4:3 /7.1_1A.C1 LED left locked tilt/opt 0,5A
E 4:4 /7.1_1A.A8 Shift button Dig In E
4:5 /7.1_1A.B8 Switch Auto clamp Dig In
Release in lever 1
Switch Unlock TW
4:6 /7.10_2.C7 Opt. 1/Front legs down/ Dig In
Overheight down
4:7 /7.1_1A.C8 Sw. lock tilt/extender Dig In
4:8 /7.1_1A.C8 Sw. horn Dig In

4:9 /7.5_1.B8 Option 5 Dig In
Spreading 40-20
PLH-
Release legs
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Korsreferenser DRG-T,DCG-T 0.0_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Cross References A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X106m -XD7902-6 -XA3700f -A3700

1/20 1 1 1/20
2/20 2 2 2/20
3/20 3 3 3/20
C 4/20 4 4 4/20 C
5/20 5 5 5/20
6/20 6 6 6/20
7/20 7 7 7/20
8/20 8 8 8/20
9/20 9 9 9/20
10/20 10 10 10/20
11/20 11 11 11/20
12/20 12 12 12/20
13/20 13 13 13/20
14/20 14 14 14/20
15/20 15 15 15/20
D 16/20 16 16 16/20 D
secuted.
17/20 17 17 17/20
18/20 18 18 18/20
19/20 19 19 19/20
20/20 20 20 20/20
-D7902 -Drive_Train_Panel
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Manöverpanel Drive train/Wipers DRG-T,DCG-T 1.1_0 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Control Panel Drive Train A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
0544A D7902-804-5VRef
/4.1.C2
0544C D7902-804-5VRef
/4.1.C2
C C
-X054f -X054m
D7902-804-5VRef 7902-804 4 4 0544 -XSP544 544D
/11.5_5.C3

-XR6900m -XR6900f
1 1
D 5V 0544B D
secuted.
-X054m -X054f -XD7902-8

2 2 1 1 5 Ana In
APS2 0541 7902-805 C8:5
/0.0_2.D5
-D7902
Throttle position B
3 3
0V 0543C
4 4
5V 544D
-X054m -X054f -XD7902-8

5 5 2 2 6 Ana In
E
APS1 0542 7902-806 C8:6
/0.0_2.D5
-D7902
E
Throttle position A
6 6
-R6900
0V 543D
Speed control -X054m -X054f -XD7902-8

-XSP3 0543 3 3 7902-803 3 C8:3 0V Ref
-D7902
/0.0_2.D5
Pedals
0543A D7902-303-0VRef
/4.1.F7
F F
0543B D7902-303-0VRef
/4.1.F7

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Gaspedal DRG-T,DCG-T 1.1_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Speed Control A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1049
C
A
-XS1049 -XS1049 -XS8150-4f -XS8150-4m -XD7902-3
D7902-309-24V 8150-47H 3 3 4 4 8150-413 13 13 7902-319 19 C3:19 Dig In
/7.5_3.B2 -D7902
1 1 8150-42H /0.0_2.E3
D7902-309-24V 8150-47J
B /9.9_2.B2 DPF Regen Inhibit DPF Regen Inhibit
B
D7902-302-0VRef
/7.5_3.B7
8150-42J D7902-302-0VRef
/9.9_2.B7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Regen Inhibit DRG-T,DCG-T 1.3_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Regen Inhibit A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
0551B D7902-501-24V
/9.6_1.A2
160031-1,0551C D7902-501-24V
/9.6_1.D2
D7902-501-24V
/5.2_1.B1
D7902-501-24V
/5.2_1.C1
-S1310 -XD7902-5
A 4 C5:4 Dig In A
-D7902
/0.0_2.C5
-X055f -X055m -X055Af -X055Am -XS1310f -S1310 N1
D7902-501-24V 7902-501 1 1 0551 1 1 055A1 -XSP0551 0551A 1 1 Sw. neutral gear
/11.5_5.B3
N2 -S1310 -XS1310f -XD7902-5
5 5 055A4 6 C5:6 Dig In
-D7902
/0.0_2.C5
R -S1310
3 3 055A3 Sw. reverse gear
F -S1310 -XD7902-5
2 2 055A2 3 C5:3 Dig In
-D7902
/0.0_2.C5
Q -S1310
6 6 Sw. forward gear
-X055Am -X055Af -X055m -X055f -XD7902-5

B 055A5 5 5 0555 5 5 7902-505 5 C5:5 Dig In B
-D7902
/4.5.B3 /0.0_2.C5
Sw. center gear
-X055Am
-X055Am
-X055Am
2
3
Opt. Lift lever
-S1310-2
-X055Af
-X055Af
-X055Af
Gear selector
3
-XR8070-1f -XS1310-1m
F WH 7 13102 2
N1 8 1305B
0552
0553
-XR8070-1f
GY
0554
D7902-309-24V 8150-17H 6 +
C /9.7_1.B5 BU C
N2 9 13105A 5
R 10 13103 3
-X055m
-X055m
-X055m
2
3
GN
-X055f
-X055f
-X055f
2
3
-XS1310-1f
2 7902-503B
7902-503A
5 7902-504B
Opt. Joystick 7902-504A
3 7902-506B
D -S1310-2 Gear selector D
7902-506A
-XS1310-1m
secuted.
F 13102 2
N1
+
N2 13105 5
R 13103 3
-XS1310-1f
13101 1 1 7902-101C 9968-BK:1
/11.5_1.D2
E E
-XD7901-2 -X036f
0,5A / Dig In C2:31 31 7901-231 3
-D7901 /8.2_7.C1
/0.0_1.D5
Output status FWD
F -XD7901-2 -X036f
0,5A / Dig In C2:32 32 7901-232 4
F
-D7901
/0.0_1.D5
Output status REV

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Växling DRG-T,DCG-T 2.1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Gear A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
D7902-804-5VRef
/1.1_1.B4
D7902-804-5VRef
/1.1_1.C4

D D
-XR8092m -XR8092f
secuted.
RD 1 1
5V 0544C
-X054m -X054f -XD7902-8

BU 2 2 5 5 7 Ana In
Out B 0545 7902-807 C8:7
/0.0_2.D5
-D7902
Brake pedal pos. B

BK 3 3
0V 0543B
4
5V 0544A
-X054m -X054f -XD7902-8

E WH 5 5 6 6 8 Ana In E
Out A 0546 7902-808 C8:8
/0.0_2.D5
-D7902
-R8092 Brake pedal pos. A

6
Brake control 0V 0543A
D7902-303-0VRef
/1.1_1.F7
D7902-303-0VRef
/1.1_1.F7
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Broms DRG-T,DCG-T 4.1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Brake A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1310
/2.1.B4
B P -S1310 -XS1310f -X056Am -X056Af -X056m -X056f -XD7902-5 B
4 4 056A2 2 2 0562 2 2 7902-502A 2 C5:2 Dig In
-D7902
/0.0_2.C5
Sw. parking brake
-XS1310-1m -XS1310-1f
13104 4 4
7902-502
-XS1310-1m
6 D7902-502 Switch P-brake
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Paerkeringsbroms DRG-T,DCG-T 4.5 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Parking Brake A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XB7700-1f -XB7700-1m
D7902-501-24V 0551D 1 1
/2.1.A4
BN
-B7700-2 -XB7700-1m -XB7700-1f -X055Am -X055Af -X055m -X055f -XD7902-5
BK 3 3 055A7 7 7 0557 7 7 7902-512 12 C5:12 Dig In
B -D7902 B
/0.0_2.C5
Sensor steering wheel
BU Sensor steering wheel
-XB7700-1m -XB7700-1f -X055Am -X055Af -X055m -X055f -X060m -X060f -X035m -X035f
2 2 558A 055A8 8 8 0558 8 8 06012 12 12 0354 4 4 9937-00108 CHASSIS
/11.5_6.A5
-XSP9
C C
558B CHASSIS
/11.5_4.A7
-XB7700-2f -XB7700-2m
D7902-501-24V 0551E 1 1
/2.1.A4

BN
-B7700-1 -XB7700-2m -XB7700-2f -X055Am -X055Af -X055m -X055f -XD7902-4
BK 3 3 055A6 6 6 0556 6 6 7902-416 16 C4:16 Dig In
-D7902
/0.0_2.B5
Sensor steering wheel
BU Sensor steering wheel
-XB7700-2m -XB7700-2f
D 2 2 558C D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets ministyrning DRG-T,DCG-T 5.2_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring ministeering A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
A A
B Leversteering -X066m B
WH 3
-R8250-1
-X066m -X066m
1 RD BK 2
Sensor Ch1
-X066m -X066f -X058m -X058f -X040m -X040f -XD7901-1
Microwheelsteering WH 3 3 0584 4 4 0404 4 4 7901-137 37 C1:37 Dig In / Ana In
-D7901
/0.0_1.D2
-R8250-1 Micro/Lever-Steering sensor Ch1

-X040f -X040m -X058f -X058m -X066f -X066m -X066m -X066f -X058m -X058f -X040m -X040f
D7901-108-5VRef 7901-108C 2 2 0402 2 2 0582 1 1 RD BK 2 2 0581 1 1 0401 1 1 7901-109D 50-BK/C:2
/11.5_5.E3 /9.4_1.B4
C Sensor Ch1 C
-X065m -X065f -X059f -X059m -X040m -X040f -XD7901-1
BU 3 3 0598 8 8 0405 5 5 7901-138 38 C1:38 Dig In / Ana In
-R8250-2 -D7901
/0.0_1.D2
Micro-Steering sensor Ch2
Sensor Ch2
-H5992
-XD7901-2 -X040f -X040m -X059m -X059f -X067f -X067m -0673 -0671 -X067m -X067f -X059f -X059m -X040m -X040f
0,5A / Dig Out C2:33 33 7901-233 6 6 0406 9 9 0599 3 3 0673 2 1 0671 1 1 05910 10 10 0407 7 7 9937-00203 CHASSIS
-D7901 /11.5_6.A8
/0.0_1.D5 + -S1130
Indication Mini/Leversteering on/off
-X040f -X040m -X058f -X058m -X067f -X067m -0672A -0674 -X067m -X067f -X059f -X059m -X040m -X040f -XD7901-1
7901-205A 3 3 0403 3 3 0583 -XSP058 0583A 2 2 0672 -XSP067 0672A 1 1 2 2 0674 4 4 05911 11 11 0408 8 8 7901-118 18 C1:18 Dig In
D D7901-205-24V 7901-205 -XSP0025 -D7901 D
/11.5_5.B3 /0.0_1.C2
Ministeering on/off
Mini/Leversteering on/off
-X067m -X067f -X059f -X059m -X040m -X040f -XD7901-1

0675 5 5 0591 1 1 0409 9 9 7901-119 19 C1:19 Dig In
-S1310-3 Gear selector -D7901
/0.0_1.C2
-0675 Mini/Leversteering gear forward
0672B
F 5 1
7901-205B D7901-205-24V
/9.5_1.C2 -0672B N1 6
1234
-X059f -X059m -X041m -X041f -XD7901-1
+ 0592 2 2 0411 1 1 7901-120 20 C1:20 Dig In
-0676 -X067m -X067f -D7901
N2 8 0676 6 6 /0.0_1.C2
7901-205C D7901-205-24V
/9.10_1.E2 R 7 1 Mini/Leversteering gear neutral
-0677
-X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1
E 7901-205D D7901-205-24V 0677 7 7 0593 3 3 0412 2 2 7901-121 21 C1:21 Dig In E
/8.2_1.E1 -D7901
0672C /0.0_1.C2
-S1992 Mini/Leversteering gear reverse
-0672C -06711 -X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1

1 1 2 06711 11 05912 12 12 0416 6 6 7901-124 24 C1:24 Dig In
-D7901
0583B /0.0_1.D2
Lever/mini steering Head Light
Mini/Leversteering aut. Head light
-S1470
-X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1

1
0 0678 8 8 0594 4 4 0413 3 3 7901-122 22 C1:22 Dig In
2 -XS1470-3 -D7901
-X067f -X067m -XS1470-2 3 3 /0.0_1.C2
10 10 06710 2 2
1 1 Mini/Leversteering indicator left
11
-X067m -X067f -X059f -X059m -X041m -X041f -XD7901-1
F Ministeering direction indicator 0679 9 9 0595 5 5 0414 4 4 7901-123 23 C1:23 Dig In F
-D7901
secuted.
0583C /0.0_1.C2
Mini/Leversteering indicator right
-B7250
-XB7250f -XB7250m -XB7250m -XB7250f -X059f -X059m -X041m -X041f -XD7901-1

1 1 1 2 2 2 0596 6 6 0415 5 5 7901-125 25 C1:25 Dig In
-D7901
Switch armrest in position /0.0_1.D2
Armrest in position
G G
H H

Sign.
Ruta
Krets ministyrning DRG-T,DCG-T 5.2_2 1
E³ DRAWING
Design change
Sq.
Name
R

Wiring ministeering A66424.0100 04
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
A A
-XS8150-3
D7902-309-24V 7902-309C 1
/7.5_2.A2
D7902-302-0VRef 7902-302D 2
/11.5_5.B6
D7902c3p16 7902-316A 3
/7.5_2.A7
D7902c3p18 7902-318A 4
/7.5_3.A7
D7902c4p17 7902-417A 5
/7.10_1.A7
B B
D7902c4p18 7902-418A 6
/7.10_1.B7
D7902c3p17 7902-317A 7
/9.10_2.B7
D7902c3p20 7902-320A 8
/9.9_2.A7
D7902-310-24V 7902-310C 9
/9.10_1.B2
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 160920 A66423.1600 Krets Alt button pos DRG-T,DCG-T 7.0_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Alt button pos A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1008
A
B
C
-XS1990-5 -XS8150-2m
-XS8150-2m -XS1990-5 4 4 8150-26 6
7 8150-27A 3 3 /7.5_1.B6
/7.5_1.A3 2 2 8150-25 5
/7.5_1.A6
6 6 1 1 8150-22A 2
10 8150-210A /7.1_1A.D7
/7.5_1.B3 Clamp/Release legs
B B
-S1006-RE
A
B
C
-XS1006-RE -XS8150-2m
-XS1006-RE 4 4 8150-23 3
8150-27B 3 3 /7.1_1B.D6
2 2 8150-24 4
/7.1_1B.E6
6 6 1 1 8150-22B
8150-210B
Rear legs
C C
-S1990-7/S1013
A
B
C
-XS1990-7 -XS8150-2m
-XS1990-7 4 4 8150-212 12
8150-27C 3 3 /7.10_1.A6
2 2 13
8150-213
/7.10_1.B6
6 6 1 1 8150-22C
8150-210C
Option 7
Support jacks
D D
secuted.
-S1990-2/S1006-FR/S1031
A
B
C
-XS1990-2 4 -XS1990-2 -XS8150-2m
8150-27D 3 3 4 8150-28 8
2 /7.10_2.C5
2 8150-29 9
8150-210D 6 6 1 /7.10_2.C5
1 8150-22D
Opt 2
Front legs
Overheight
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets kombi funktioner DRG-T,DCG-T 7.0_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Combi/OHC functions A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Joystick 8150 /7.1_1C.C7 -XD7902-4

D7902-309 D7902-404 7902-404 4 C4:4 Dig In
/7.1_1D.B1 /7.1_1D.B8 -D7902
S1991 /0.0_2.E3
-XD7902-3 -XS8150-1f -XS8150-1f
0,5A 815007 815008 Shift button
C3:9 9 7902-309 7 8
-D7902
/0.0_2.C3 -XD7902-4
/7.1_1C.A7 7902-405 5 C4:5 Dig In
24V Supply Island 1 S1002/S1020 D7902-405 -D7902
815009 /7.1_1D.B8 /0.0_2.E3
9
Switch Auto clamp
Release in lever 1
S1037 /7.1_1D.C8 Switch Unlock TW
B D7902-313
815010 /7.1_3.C6 -XD7902-3 B
D7902-402 10 7902-313 13 C3:13 Dig In
/7.1_1D.C1 -D7902
/0.0_2.D3
-XD7902-4
0,5A 815012 S1037 LED Green Option 1
C4:2 2 7902-402 12 +
-D7902 Lock Levelling
/0.0_2.E3
Lock arm 1
LED right locked levelling/opt
S7251 D7902-407
/7.1_1D.C8 -XD7902-4
815011 Dig In
D7902-403 11 7902-407 7 C4:7
/7.1_1D.C1 /7.1_1C.B7 -D7902
D7902-302-0VRef /0.0_2.E3
-XD7902-4 /7.1_1D.C1
0,5A 815013 S5993 LED Green 815014 Sw. lock tilt/extender
C4:3 3 7902-403 13 + 14 7902-302A D7902-302-0VRef
-D7902 /11.5_5.B6
/0.0_2.E3
LED left locked tilt/opt
S1490 D7902-408
/7.1_1C.B2 /7.1_1D.B8 -XD7902-4
815015 Dig In
C D7902-301-5VRef 15 7902-408 8 C4:8
C
/7.1_1D.C1 -D7902
/0.0_2.F3
RD x2 Sw. horn
D7902-301-5VRef 7902-301A 1
/11.5_5.C4 S8070-2
/7.1_1C.B7
D7902-304 -XD7902-3
BU /7.1_1D.D8
3 7902-304 4 C3:4 Ana In
-D7902
/0.0_2.B3
D7902-302
BK x2 /7.1_3.C6 Sensor Boom/tilt - in/out
2
7902-302B -XS8150-2f
D7902-301-5VRef 7902-301B
/7.1_1B.D2 S8070-1 7902-302C 2

/7.0_2.B6 -XD7902-3
YE Ana In
4 7902-303 3 C3:3
/7.1_1C.B7 -D7902
D7902-303 /0.0_2.B3
/7.1_1D.C8
Sensor Lift/lower
D D
S8070-3 /7.1_1C.D7
secuted.
D7902-305 -XD7902-3
BU /7.1_1D.D8
5 7902-305 5 C3:5 Ana In
-D7902
/0.0_2.B3
Sensor Sideshift
S8070-4 /7.1_1C.D7
D7902-306 -XD7902-3
YE /7.1_1D.D8
6 7902-306 6 C3:6 Ana In
-D7902
/0.0_2.B3
Rotation
Spread(L)
Extension left
Clamp(L)
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Joystick DRG-T,DCG-T 7.1_1A 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Joystick A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XR8070-1m -XR8070-1f -XS8150-1m -XS8150-1f -XD7902-3

A WH 3 3 8150-14 4 4 7902-303 3 C3:3 Ana In A
-D7902
/7.1_1A.D8
Sensor Lift/lower
-XD7902-3 -XS8150-1f -XS8150-1m
5V Ref -XSP8150-11 -R8070-1
C3:1 1 7902-301A 1 1 8150-11A 8150-11B-XR8070-1f -XR8070-1m -XR8070-1m -XR8070-1f -XD7902-3
-D7902
/11.5_5.C2 1 1 GY BN 2 2 8150-114B -XSP8150-114 8150-114A 14 14 2 C3:2 0V Ref
-D7902
Lever/Joystick 7902-302B /11.5_5.B7
Lift / Lower D7902-302-0VRef 2 Lever/Joystick
/7.1_3.B6
7902-302C
-XR8070-2m -XR8070-2f -XD7902-3

WH 3 3 8150-13 3 3 7902-304 4 C3:4 Ana In
-D7902
/7.1_1A.C8
-R8070-2 Sensor Boom/tilt - in/out

-XR8070-2f -XR8070-2m -XR8070-2m -XR8070-2f
B 8150-11C 1 1 GY BN 2 2 8150-114C B
Tilt
-XR8070-3m -XR8070-3f -XD7902-3

WH 3 3 8150-15 5 5 7902-305 5 C3:5 Ana In
-D7902
/7.1_1A.D8
-R8070-3 Sensor Sideshift

-XR8070-3f -XR8070-3m -XR8070-3m -XR8070-3f
8150-11D 1 1 GY BN 2 2 8150-114D
Sideshift (Rotation paper)
C C
-XR8070-4m -XR8070-4f -XD7902-3
WH 3 3 8150-16 6 6 7902-306 6 C3:6 Ana In
-D7902
/7.1_1A.E8
-R8070-4 Rotation
-XR8070-4f -XR8070-4m -XR8070-4m -XR8070-4f
Spread(L)
8150-11E 1 1 GY BN 2 2 8150-114E
Extension left
Clamp(L)
Extension left / Spreading(left) / Clamp paper (left)
/7.0_2.C6
-XR8070-5m -XR8070-5f -XS8150-2m -XS8150-2f -XD7902-3

WH 3 3 8150-23 3 3 7902-307A 7 C3:7 Ana In
-D7902
/0.0_2.C3
-R8070-5 Levelling/5th funct/

-XS8150-2f -XS8150-2m -XR8070-5f -XR8070-5m -XR8070-5m -XR8070-5f
D 7902-301B 1 1 8150-21A -XSP8150-21 8150-21B 1 1 GY BN 2 2 8150-22D -XSP8150-22 8150-22C 2 2 7902-302C
Rear legs up/Spread R/ D
Clamp R
secuted.
-XS8150-2f 7902-302E D7902-302-0VRef

5th function/Levelling/Spreading right/Rotation paper /7.5_2.B8
D7902-301-5VRef 7902-301B 1
/7.1_1A.D2 8150-22A D7902-302-0VRef
/7.5_1.C7
-XR8070-6m -XR8070-6f -XD7902-3
WH 3 3 8150-24 4 4 7902-308A 8 C3:8 Ana In
-D7902
/0.0_2.C3
-R8070-6 Extension R
-XR8070-6f -XR8070-6m -XR8070-6m -XR8070-6f
6th funct
8150-21C 1 1 GY BN 2 2 8150-22E /7.0_2.C6
Rear legs down
Extension right / 6th funct.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Spakar DRG-T,DCG-T 7.1_1B 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Levers A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -S1020 A
-XR8070-1/8070-2f -XR8070-1/8070-2m -XR8070-1/8070-2m -XR8070-1/8070-2f -XS8150-1m

D7902-309-24V 8150-17C 4 4 GN 1 2 BK 5 5 8150-19 9 D7902-405
/9.7_1.C5 /7.1_1A.B6
Switch Auto clamp
Release in lever 1
Unlock TW lock
-XR8070-1/8070-2m -XR8070-1/8070-2f -XS8150-1m
BK 3 3 8150-14 4 D7902-303
/7.1_1A.D6
-R8070-1
-XS8150-1m -XR8070-1/8070-2f -XR8070-1/8070-2m -XR8070-1/8070-2m -XR8070-1/8070-2f
D7902-301-5VRef 1 8150-11A -XSP8150-11 8150-11B 1 1 GN YE 2 2 8150-114B -XSP8150-114 8150-114A 14 D7902-302-0VRef
B /7.1_1A.C3 /7.1_1A.C6 B
Lift / Lower
-XR8070-1/8070-2m -XR8070-1/8070-2f
OG 6 6 8150-13 3 D7902-304
/7.1_1A.C6
-R8070-2
Tilt
C C
-S1991
-XR8070-3/8070-4f -XR8070-3/8070-4m -XR8070-3/8070-4m -XR8070-3/8070-4f -XS8150-1m

D7902-309-24V 8150-17E 4 4 GN 1 2 BK 5 5 8150-18 8 D7902-404
/9.7_1.C5 /7.1_1A.A6
Tilt control
-XR8070-3/8070-4m -XR8070-3/8070-4f

BK 3 3 8150-16 6 D7902-306
/7.1_1A.E6
-XR8070-3/8070-4f -XR8070-3/8070-4m-R8070-4 -XR8070-3/8070-4m -XR8070-3/8070-4f

8150-11E 1 1 GN YE 2 2 8150-114E
D D
Extension left
secuted.
Spreading(left)
Clamp paper (left)
-XR8070-3/8070-4m -XR8070-3/8070-4f
OG 6 6 8150-15 5 D7902-305
/7.1_1A.D6
-R8070-3
Sideshift (Rotation paper)
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MAC 150821 A66423.1600 Krets Joystick x 2 DRG-T,DCG-T 7.1_1C 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

MAC 150821 Klass/Class
Wiring Joystick x 2 A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XS8150-42f -XS8150-42m
WH 0.75 1 1 8150-44A WH 0.75 D7902-315
/8.2_2.A7
Lever 8150 Caldaro
-XS8150-1m -XS8150f T1-1 -XS8150f
D7902-309 7 8150-107 WH 0.75 15 15 14 14 8150-421
/7.1_1A.A3
T1-2 -XS8150f -XS8150-1m

16 16 8150-115 WH 0.75 15 D7902-408
/7.1_1A.C6
T2 -XS8150f -XS8150-1m
20 20 8150-109 WH 0.75 9 D7902-405
B /7.1_1A.B6 B
T4 -XS8150f -XS8150-1m
19 19 8150-108 WH 0.75 8 D7902-404
/7.1_1A.A6
T3-1 -XS8150f -XS8150-1m

17 17 8150-110 WH 0.75 10
-XS8150-1m -XS8150f D7902-313
D7902-402 12 8150-112 WH 0.75 7 7 /7.1_1A.B6
/7.1_1A.B3
T3-2 -XS8150f -XS8150-1m

18 18 8150-111 WH 0.75 11 D7902-407
-XS8150-1m -XS8150f /7.1_1A.B6
D7902-403 13 8150-113 WH 0.75 5 5
/7.1_1A.C3
C -XS8150-1m -XS8150f C
D7902-302-0VRef 14 8150-114 WH 0.75 6 6
/7.1_1A.C6 -XS8150f -XS8150-1m
P1 8 8 8150-104 WH 0.75 4 D7902-303
-XS8150-1m -XS8150f /7.1_1A.D6
D7902-301-5VRef 1 8150-101 WH 0.75 9 9
/7.1_1A.C3
-XS8150f -XS8150-1m
P2 4 4 8150-103 WH 0.75 3 D7902-304
/7.1_1A.C6

-XS8150f -XS8150-1m
P3 11 11 8150-105 WH 0.75 5 D7902-305
/7.1_1A.D6
D D
-XS8150f -XS8150-1m
secuted.
P4 1 1 8150-106 WH 0.75 6 D7902-306

/7.1_1A.E6
-XS8150-1m -XS8150f
D7902-302-0VRef 2 8150-102 WH 0.75 10 10
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 2017-10-25 A66423.1600 Krets Joystick Caldaro DCG,DRG,ECG 7.1_1D 1
Name
1 See EO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

MLG 170110 Klass/Class
Wiring Joystick Caldaro A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S8070-2
-XR8070-2f -XR8070-2m -XR8070-2m -XR8070-2f -XS8150-1m -XS8150-1f -XD7902-4

D7902-309-24V 8150-17E 4 4
RD 1 2
GY 5 5 8150-18 8 8 7902-404 4 C4:4 Dig In
/9.7_1.B5 -D7902
/7.1_1A.A8
Tilt control
Shift button
B B
-S8070-3

D7902-309-24V 8150-17F 4 4
RD 1 2
GY 5 5 8150-111 11 11 7902-407 7 C4:7 Dig In
/9.7_1.B5 -D7902
/7.1_1A.C8
Extender
Sw. lock tilt/extender
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Spakbrytare DRG-T,DCG-T 7.1_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Lever Switches A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1990-1/S1037/S1023-1
C
A
-XS1990-1 -XS1990-1 -XS8150-1m -XS8150-1f -XD7902-3
D7902-309-24V 8150-17D 3 3 4 4 8150-110 10 10 7902-313 13 C3:13 Dig In
/9.7_1.B5 -D7902
1 1 8150-12 2 D7902-302-0VRef /7.1_1A.B8
/7.1_1B.B6
Option 1 Option 1
B Lock Levelling
B
Lock levelling Lock arm 1
Arm lock 1
-S1990-1/S1037/S1023-1
C
A
-XS1990-1 -XS1990-1 -XS8150-1m
D7902-309-24V 8150-17D 3 3 4 4 8150-110 10 D7902-313
/9.7_1.C5 /7.1_1A.B6
1 1 8150-12 2 D7902-302
/7.1_1A.D6
Option 1
C Lock levelling C
Doubble joystick Arm lock 1

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Skevningslås DRG-T,DCG-T 7.1_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Lock Levelling A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7902-309-24V 8150-27B
/7.10_2.C2
D7902-309-24V
/7.10_1.A2
-S1990-5/S1012/S1008/1028-29 /7.0_2.B6
A
/7.0_2.B3 B
C
-XS1990-5 -XS8150-2m -XS8150-2f -XD7902-4
-XS8150-2f -XS8150-2m -XS1990-5 4 Dig In
4 8150-25 5 5 7902-409A 9 C4:9
D7902-309-24V 7902-309B 7 7 8150-27A 3 3 -D7902
/7.5_2.B2 2 2 8150-26 6 6 /0.0_2.F3
8150-210A 6 6 1 1 Option 5
Spreading 40-20
D7902-309-24V 7902-309A Option 5
/9.7_1.A3 /7.0_2.B6 PLH-
Spreading 20-40/40-20 Release legs
Release/clamp legs -XD7902-4
B 7902-410A 10 C4:10 Dig In B
PLH +/- -D7902
/0.0_2.A5
-XS8150-2f -XS8150-2m Option 5
D7902-310-24V 7902-310A 10 10 Spreading 20-40
/11.5_5.B3
PLH+
Clamp legs
/7.0_2.B3
D7902-310-24V 8150-210B
/7.10_2.C2
8150-22A D7902-302-0VRef
/7.1_1B.D7
C C
D7902-310-24V 7902-310B
/9.10_1.B2
8150-22B D7902-302-0VRef
/7.10_2.D7

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets spridning 20-40 DRG-T,DCG-T 7.5_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Spreading 20-40 A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
7902-316A D7902c3p16
/7.0_1.B3
-S1012-2
C
D7902-309-24V 7902-309C A -XD7902-3
/7.0_1.A3 -XS8150-4m -XS8150-4f -XS1012 -XS1012 -XS8150-4f -XS8150-4m 7902-316 16 C3:16 Dig In
-D7902
D7902-309-24V 7902-309B 7 7 8150-47A 3 3 4 4 8150-43 3 3 /0.0_2.D3
/7.5_1.B1
D7902-309-24V 8150-47B 1 1 8150-42A 2 2 Aut 20-40 on-off
/8.2_2.B2 Differential lock
Aut. spreading on-off
7902-302E D7902-302-0VRef
/7.1_1B.D7
7902-302F D7902-302-0VRef
/8.2_1.C8
B B
8150-42B D7902-302-0VRef
/8.2_2.B8
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Automatisk Spridning DRG-T,DCG-T 7.5_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Automatic Spreading A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
7902-318A D7902c3p18
/7.0_1.B3
-S1004
C
A
-XS1004 -XS1004 -XS8150-4f -XS8150-4m -XD7902-3
D7902-309-24V 8150-47G 3 3 4 4 8150-412 12 12 7902-318 18 C3:18 Dig In
/9.10_1.C2 -D7902
1 1 8150-42G /0.0_2.E3
D7902-309-24V 8150-47H
/1.3_1.B2 30-35 stop Sw. 30-35 stop
B B
D7902-302-0VRef
/9.10_1.D8
8150-42H D7902-302-0VRef
/1.3_1.B7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets 30-35 Stopp DRG-T,DCG-T 7.5_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring 30-35 Stop A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S1027
C
A
3 4
A A
1
PLH on/off
D7902-401-24V 7902-401E
/9.8_2.B3 -S1003
A
B -XD7902-3
C 7902-312A 12 C3:12 Dig In
-D7902
-XS1003 4 4 7902-312B /0.0_2.C3
D7902-401-24V 7902-401D 3 3
/8.2_1.B2 2 2 Sw. lock TW
10 5 PLH on/off
10 5
Lock TW 7902-302G D7902-302-0VRef
/8.2_1.C8
B B
1 7902-302H
7902-302I D7902-302-0VRef
/9.8_2.B7
7902-312C
C C
-S8070-1

D7902-309-24V 8150-17C 4 4
RD 1 2
GY 5 5 8150-19 9 9 7902-405 5 C4:5 Dig In
/9.7_1.B5 -D7902
/7.1_1A.B8
Switch Auto clamp
Switch Auto clamp
Release in lever 1 Release in lever 1
Unlock TW lock
Switch Unlock TW
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Twistlock DRG-T,DCG-T 7.9_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Twistlock A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X049m -X049f
8 8 9937-00208 CHASSIS
/11.5_6.A8
Headup display
-XA3720-1m
B 1/4 B
-X097f -X097m -XA3720-1f
GND
0498 5 5 0975 2 2/4
-XD7901-2 -X049f -X049m -X097f -X097m H5740

0,5A / Dig out C2:4 4 7901-204 7 7 0497 6 6 0976 3 3/4
-D7901
/0.0_1.B5
Ind. support jacks down Support jacks down (GN)
-X047f -X047m -X097f -X097m
D7901-108-5VRef 7901-108B 9 9 0479 7 7 0977 4 4/4 5V
/11.5_5.D3
-XD7901-2 -X049f -X049m -X097f -X097m -XA3720-2f -XA3720-2m

0,5A / Dig out C2:1 1 7901-201 4 4 0494 8 8 0978 1 1/3
H5620-2
-D7901
/0.0_1.B5
C C
Ind. unlocked TW
Unlocked (RD)
-XD7901-2 -X049f -X049m -X097f -X097m

0,5A / Dig out C2:2 2 7901-202 6 6 0496 9 9 0979 2 2/3
H5630-2
-D7901
/0.0_1.B5

Ind. locked TW
Clamp pressure ok Locked (GN)
D -XD7901-2 -X049f -X049m -X097f -X097m

H5640-2 D
0,5A / Dig out C2:3 3 7901-203 5 5 0495 10 10 09710 3 3/3
secuted.
-D7901
/0.0_1.B5
Ind. alignment
Tilt control Alignment (YE)
-A3720
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Indikeringslampor DRG-T,DCG-T 7.9_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Indication Lamps A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
7902-417A D7902c4p17
/7.0_1.B3
-S1990-7/S1013/S2992 /7.0_2.D6
A
B -XD7902-4
C 17 C4:17 Dig In
-XS1990-7 -XS8150-2m -XS8150-2f -D7902
-XS1990-7 4 4 8150-212 12 12 7902-417 /0.0_2.B5
D7902-309-24V 8150-27D 3 3
/7.5_1.A3 2 2 8150-213 13 13 7902-418 Option 7
6 1 Support jacks up
D7902-310-24V 8150-210C 6 1
/7.10_2.C2 Upper Arms Height up
Option 7 -XD7902-4
Support jacks /7.0_2.D6 18 C4:18 Dig In
-D7902
Upper arms height 7902-418A D7902c4p18 /0.0_2.B5
/7.0_1.B3
Option 7
Support jacks down
B Upper Arms Height down B
8150-22C D7902-302-0VRef
/7.10_2.D5
-S8070-4/S1024
C C
-XR8070-4f -XR8070-4m -XR8070-4m -XR8070-4f -XS8150-2m -XS8150-2f
D7902-309-24V 8150-17G 4 4
RD 1 2
GY 5 5 8150-215 15 15 7902-314B D7902-314
/9.7_1.B5 /7.10_2.B7
Short arm on/off

-S8070-5/S1006-FR
-XR8070-5f -XR8070-5m -XR8070-5m -XR8070-5f -XS8150-2m -XS8150-2f

D7902-309-24V 8150-27C 4 4
RD 1 2
GY 5 5 8150-211 11 11 7902-406B D7902-406
D /7.10_2.C2 /7.10_2.C7 D
Extra function/Front legs down
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Stödben/Option DRG-T,DCG-T 7.10_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Support jacks/Option A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
7902-314B D7902-314
/7.10_1.C7
-S1990-2 -XD7902-3
A
B
/7.0_2.D6 7902-314A 14 C3:14 Dig In
-D7902
D7902-309-24V 8150-27C C /0.0_2.D3
/7.10_1.D2 -XS1990-2 -XS8150-2m -XS8150-2f
-XS1990-2 4 4 8150-28 8 8 Option 1/Front legs up/
D7902-309-24V 8150-27B 3 3 Overheight up
/7.5_1.A3 2 2 8150-29 9 9
D7902-310-24V 8150-210B 6 6 1 1
/7.5_1.C4 -XD7902-4
C Opt 2 7902-406A 6 C4:6 Dig In C
D7902-310-24V 8150-210C -D7902
/7.10_1.B2 /7.0_2.E6 /0.0_2.E3
Opt. 1/Front legs down/
Overheight down
7902-406B D7902-406
/7.10_1.D7

8150-22B D7902-302-0VRef
/7.5_1.C7
D 8150-22C D7902-302-0VRef D
/7.10_1.B7
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets OPT 1 DRG-T,DCG-T 7.10_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring OPT 1 A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X1830f
PWR 1 RD 1
/8.2_5.C6
CHASSIS 2 BK 2
C /8.2_5.C6 C
Tx 3 BU 3
/8.2_5.C6
Rx 4 OG 4
/8.2_5.C6

-A910
D Printer Ap1310DC D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 16020 A66423.1600 Krets Printer DRG-T,DCG-T 7.10_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Printer A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1017 Toggle wheel
-XS1017 -X7950
1 1 7950-10 10 C1:10 5V Dig In
-D7950
-XS1017 /11.6_1.C2
D7902-804-5VRef 7950-08 2 2
B /11.5_5.D4 Toggle wheel
B
3 3
-X7950
7950-11 11 C1:11 5V Dig In
-D7950
/11.6_1.C2
Toggle wheel
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Toggle Wheel DRG-T,DCG-T 8.1_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Thoggle Wheel A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1005
B C B
D7902-401-24V 7902-401D -XD7902-3
/7.9_1.B2 A
7902-311A 11 C3:11 Dig In
-XS1005 -XS1005 -D7902
D7902-401-24V 7902-401 3 3 4 4 /0.0_2.C3
/11.5_5.A3
6 6 1 1 Sw. override safety keyswitch
Override safety keyswitch

7902-302F D7902-302-0VRef
/7.5_2.B8
7902-311B
7902-302G D7902-302-0VRef
/7.9_1.B8
C C

D D
secuted.
-S1005-2
-X053f -X053m -XS1005-2f -XS1005-2m -XS1005-2m -XS1005-2f -X053m -X053f -XD7901-1
D7901-205-24V 7901-205D WH 0.75 2 2 0532 WH 0.75 1 1 1 WH 0.75 1 2 2 WH 0.75 2 2 0534 WH 0.75 4 4 7901-139 WH 0.75 39 C1:39 Dig In / Ana In
/5.2_2.E4 -D7901
/0.0_1.E2
3 4
Key switch override
Key switch override
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Förbikoppling DRG-T,DCG-T 8.2_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Override A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A -S1023-2 A
C
A
3 4
1
8150-44A D7902-315
Lock Arm 2 /7.1_1D.A8
-S1990-3/S1015/1014
C
D7902-309-24V 8150-47C A -XS8150-4f -XS8150-4m -XD7902-3
/9.10_2.B2 -XS1990-3 -XS1990-3 8150-44B 4 4 7902-315 15 C3:15 Dig In
-D7902
D7902-309-24V 8150-47B 3 3 4 4 /0.0_2.D3
B /7.5_2.B2 B
6 6 1 1 8150-42B Override height/Override rotation/
Lock arm 2
Option 3
Override height
Override rotation D7902-302-0VRef
/7.5_2.B8
8150-44C
8150-42C D7902-302-0VRef
/9.10_2.C8
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Förbikoppling Höjd/OPT2 DRG-T,DCG-T 8.2_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Override Height/OPT2 A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1752
C
D7902-309-24V 8150-47F A
/9.10_1.C2 -XS1752 -XS1752 -XS8150-4f -XS8150-4m -XD7902-4
D7902-309-24V 8150-47E 3 3 4 4 8150-49 9 9 7902-413 13 C4:13 Dig In
/9.10_1.A2 -D7902
D7902-310-24V 8150-41B 6 6 1 1 8150-42E /0.0_2.A5
/9.10_1.B2
Dead mans grip Dead mans grip
D7902-310-24V 8150-41C
/9.10_1.C2
D7902-302-0VRef
/9.10_1.B7
B 8150-42F D7902-302-0VRef
/9.10_1.C8 B
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Dödmans grepp DRG-T,DCG-T 8.2_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Dead man grip A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
08712
08713
B B
-D7950-2
-X087f -X087f 0876
13 K1:13 CAN 2 K1:6 6
L+ + -XSP087-06
12 K1:12 CAN K1:5 5 0875
L- -
8 K1:8 K1:4 -XSP087-05
+ Shield
RS232
K1:11 K1:3 3 30
R+ TX
K1:10 CAN K1:2 2
R- RX
K1:7 K1:1 1
+ GND
9 K1:9 0V REF BUZZER K1:14
C KID C
0871
0391
0878
0879
0872
0392

-X088f
25 0872
TX2
26 0873 -X039m
RX2 30 1 CAN+
/11.6_1.A4 CAN+
30 08830 -XSP088-30 0871 2 CAN-
D GND /11.6_1.A4 CAN- D
secuted.
0878 3 9968-BK-B:1
3 0883
/11.5_2.B7 IGNITION
+15 0879 5 CHASSIS
GND
13 08813 /11.5_2.B7 GND
14 0399 -X039f
Batt+ 9 9
28 08828
TX1
0895
-A9110
29 08829
MIU RX1
E E
09915A
30
-X089m
4
3
5
6
7
8
9
1
F See circuit -X099m

15 09915 -XSP09915 09915B X09915
F
chassi /9.4_4.C5
Batt. + before main switch (fuse 5A)

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets RMI DRG-T,DCG-T 8.2_4 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring RMI A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
2
-R9031
A A
PTC
1
-XR092-A1m
2
1
-XR092-A1f
1
2
-X039/X077m -X092f -X092m
9 0399 092A1A 092A1 A1 A1/30
B 8 -XSP092A1 092A2 A2 A2/30 B
7 A3 A3/30
-XSP092A2
6 092B1 B1 B1/30
5 092A2C 1-XSP092B1 B2/30
4 B3/30
3 C1/30
092B1B
092B1A
C2/30
C3 C3/30
-X039/X077-2f D1 D1/30
1 30 0391-2
-X1830m D2/30
2 0392-2 RFid -X094f -X094m PWR 1 D3/30
3 0393-2 YELLOW 1 1 092A1B /7.10_3.C2
CHASSIS 2 092A2A 092A2B E1 E1/30
/7.10_3.C2
C 4
5
6
0394-2
0395-2
0396-2
BROWN
GREEN
WHITE
2
3
4
3
2
4
092C3
092D1
092G3
/7.10_3.C2
/7.10_3.C2
Tx
Rx
3
4
092E2
092E3
E2
E3
E2/30
E3/30
MTU C
F1/30
7 0397-2 GRAY 5 5 092H1
F2/30
8 0398-2
F3/30
9 0399-2
G1/30
G2/30
G3 G3/30
H1 H1/30
USB_Interface H2/30
-X096m H3/30
+5V 1 09601 J1 J1/30
D 2 30 09602 J2 J2/30 D
USB HAD-
secuted.
USB HAD + 3 09603 J3 J3/30

-X039/X077m 4 09604 K1/30
GND 30
1 092K2 K2 K2/30
2 092K3 K3 K3/30
-A9150
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 140707 A66423.1600 Krets TelliQ DRG-T,DCG-T 8.2_5 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring TelliQ A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X039/X077m
9
8
7
B 6 B
5
4 -XD9001-1
3 9001-11 WH 0.75 1
2
D9001
9001-13 BK 0.75 3
-X039/X077-2f
1 0391-2 GN 0.75 30
4 Åkerströms
2
3
0392-2
0393-2
YE 0.75
WH 0.75 -XD9001-2
remote control
4 1
5
0394-2
0395-2
WH 0.75
BK 0.75 2 T-RX 100
C 6 0396-2 WH 0.75 3 C
7 0397-2 WH 0.75 9001-24 GN 0.75 4
8 0398-2 WH 0.75 9001-25 YE 0.75 5
9 0399-2 RD 0.75

-X039/X077m
1 30
2
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 150213 A66423.1600 Krets fjärrstyrning DRG-T,DCG-T 8.2_6 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr Klass/Class

Wiring Remote control A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-H5720
-X9937-005:7 -XH5720:2 -XH5720:1
1 9937-0057 BK 0.75 1 1 2 1
-X036-3m
1 0363 WH 0.75
/2.1.F4
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 150213 A66423.1600 Krets option extra lampa höjd DRG-T,DCG-T 8.2_7 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr Klass/Class

Wiring opt. extra lamp height A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Connect interlock device

A instead of jumper. A
-XA9120f-1
-1 RD 9968-RD:1
/11.5_2.A5 -X110m -X110f -XD7902-5
2 2 7902-513 13 C5:13 Dig In
-XA9120f-2 -D7902
-2 BK /0.0_2.C5
1102 1 1 1101
Start interlock device
-XA9120f-3
-3 BU 9968-BK:1
/11.5_2.C5
B B
-A9120
Dräger Interlock device
-XA9120f-13 -X110-1Am -X110-1m -X110-1f

-13 1 BN 1 110-11 1 1 0612
-XA9120f-14
-14 GY 2 2 2 0356
-X9937-005:3
C C
-X099m -X035f -X035m -X061m -X061f
3
See circuit 5 0356 6 6 2 2
-X9937-005 CHASSIS
chassi
-XA9120Af-1
-1A 1 RD 9968-RD:1
/11.5_2.A5

-S1061
-3A 1 BK
-12A 1 RD 1 2
D D
-13A 1 GN 9968-BK:1
secuted.
/11.5_2.C5
-18A 1 GY
-X9120B -X110-1m
-A9120 -1B 1 BK 1
Foxguard Interlock device
-2B 2 BK 2
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Startlås DRG-T,DCG-T 9.2_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Start Lock A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
9968-GN:8 9968-GN-H1 -XSP9968-GN8 9968-GN:8

/11.5_2.F5 /9.3_4.B1
A A
/11.5_6.A3
9968-GN-H1A
0617C
B B
-S2680
-M6700
P COMPRESSOR
-X037f -X037m -X061m -X061f -XE8030m -XE8030f AIR-SUSPENDED SEAT -XE8030f -XE8030m -X061f -X061m -X037m -X037f
3 3 0373 6 6 0616 5 5 GN 1 2 + - BK 6 6 0617A 0617 7 7 0374 4 4 9937-00204
M -XSP0617
/11.5_6.A8
COMPRESSOR
AIR CUSHIONED SEAT
C C
-S2680-2

0617B
P
-X038f -X038m -X061m -X061f -XE8030m -XE8030f -XE8030f
9968-BK:5 9968-BK-E1 -XSP9968-1 9968-BK-E1B 2 2 0382 11 11 06111 11 11 1 2 12
/11.5_2.C5 To external compressor
D D
secuted.
-X037f -X037m -X061m -X061f -XE8030m -XE8030f -S1650 -E8030 -XE8030f -XE8030m
9968-BK-E1A 5 5 0375 8 8 0618 1 1 BU 1 2 1 2 BK 2 2
Seat heater
E E
-XE8030m -XE8030f -B2300 -XE8030f -XE8030m -X061f -X061m -X038m -X038f -XD7901-1
YE BK Dig In Start up
9968-RD:1 0613C 3 3 1 2 4 4 06112 12 12 0388 8 8 7901-150 50 C1:50
/11.5_3.E4 -D7901
/0.0_1.E2
Seat switch
Seat switch
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Stolsfunktioner DRG-T,DCG-T 9.3_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Seat Functions A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XE8030m -XE8030f -B2250 -XE8030f -XE8030m -XD7902-5

9968-RD:1 0631D 7 7 1 2 8 8 7902-514 14 C5:14 Dig In
/11.5_3.E4 -D7902
/0.0_2.C5
Safety belt
Seat belt
B B
-H5991
-XD7901-2 -X048f -X048m -XH5991-1 -XH5991-2 -X048m -X048f
1,5A C2:7 7 7901-207 4 4 59911 1 1 2 2 59912 5 5 9937-00403 CHASSIS
-D7901 /11.5_6.C8
/0.0_1.C5
C C
Lamp fasten seat belt Fasten seat belt

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Indikering Säkerhetsbälte DRG-T,DCG-T 9.3_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Indication Safety Belt A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M6941
-XD7902-2 -XM6941-1f -XM6941-1m -XM6941-1m -XM6941-1f -XD7902-2
NPN / PNP 3A C2:7 7 7902-207 1 1 BN WH 2 2 7902-208 8 C2:8 NPN / PNP 3A
-D7902 M -D7902
/0.0_2.B3 /0.0_2.B3
Motor canoe fwd/rev Motor canoe fwd/rev
Motor Console FWD/REV
B B
C C
-XM6942
-XD7902-2 -XM6942-1f -XM6942-1m -XM6942-1m -XM6942-1f -XD7902-2
NPN / PNP 3A C2:9 9 7902-209 1 1 BN WH 2 2 7902-210 10 C2:10 NPN / PNP 3A
-D7902 M -D7902
/0.0_2.B3 /0.0_2.B3
Motor canoe up/down Motor canoe up/down
Motor Console Up/Down

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 2016-11-01 A66423.1600 Krets Motor Armstöd DCG,DRG 9.3_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Motor Armrest A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-M6570-
-X037f -X037m -X061m -X061f -XE8030m -XE8030f -XE8030f -XE8030m -X061f -X061m -X038m -X038f
9968-GN:8 9968-GN-H1B 9 9 0379 9 9 0619 9 9 1 2 1 2 10 10 06110 10 10 0381 1 1 9937-00305 CHASSIS
B /9.3_1.A8 M /11.5_6.B6 B
Ventilation seat
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Stolsventilation DRG-T,DCG-T 9.3_4 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Seat Air Ventilation A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X111f -X111m -S7212-2

9968-GN:5 9968-GN-E1 -XSP9968-GN:5 9968-GN-E1A 1 1
BK 1 2
GY
/11.5_2.E5
Seat unlocked
11123 2 2
B B
-S7212-1
3 3
BK 1 2
GY
-XD7901-1:17
Seat in driving pos
Dig In C1:17 1 7901-117 4 4
-D7901
/0.0_1.C2
Seat in driving position
-K3460
-XD7901-2:34 -XK3460 -XK3460
0,5A / Dig In C2:34 1 7901-234 86 86 85 85 3460-85 CHASSIS
C -D7901 /11.5_6.C5 C
/0.0_1.D5 /9.3_5.D3
Seat Unlock (TDS 15/30deg)
Seat unlock device

-XM3460f -XM3460m
-M3460
-XK3460 -K3460 -XK3460 3460-30 1 1/4 WH Sig

30 30 87 87 3460-87 2 2/4 WH Sig
/9.3_5.C3 3 3/4
/11.5_6.D5
CHASSIS 9937-00501A BK Gnd
9968-GN-E1B 4 4/4 RD 24V
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Stolsvridning DRG-T,DCG-T 9.3_5 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Seat Rotation A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XD7902-7m -XD7902-7f -XA3702f -AX3702m
1 1 1/31
2 2 2/31
3 3 3/31
4 4 4/31
5 5 5/31
6 6 6/31
7 7 7/31
8 8 8/31
9 9 9/31
10 10 10/31
C 11 11 11/31 C
12 12 12/31
13 13 13/31
14 14 14/31
15 15 15/31
16 16 16/31
17 17 17/31
18 18 18/31

19 19 19/31
20 20 20/31
21 21 21/31
22 22 22/31
D 23 23 23/31 D
/1.1_0.E1 24 24 24/31
secuted.
/9.6_0.F1 25 25 25/31
-D7902 26 26 26/31
-A3702-ECC_Panel
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Manöverpanel Klimatsystem DRG-T,DCG-T 9.4_0 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Panel Climate Control A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
50-BK/C:2 7901-109 -XSP00191 7901-109D 50-BK/C:2

/11.5_5.B6 /5.2_2.C12
7901-109C 50-BK/C:2
/9.4_2.A8
-B7751
-X081f -X081m -XB7751 -XB7751 -X081m -X081f -X031m -X031f -XD7901-1
0301B 6 6 19 1 1 T 2 2 20 7 7 0318 8 8 7901-133 33 C1:33 Resistance In
-D7901
U /0.0_1.D2
C C
Temp. indoor Temp. indoor
-B7752
-X030f -X030m -X080f -X080m -X082f -X082m -XB7752 -XB7752 -X082m -X082f -X080m -X080f -X030m -X030f -XD7901-1
7901-109B1 1 0301 -XSP0301 0301A 1 1 29 -XSP_A1 6 2 2 6 1 1 T 2 2 5 1 1 5 2 2 0302 2 2 7901-134 34 C1:34 Resistance In
-D7901
U /0.0_1.D2
Temp. fan air (distributor) Temp. fan air

-B7753
-XB7753 -XB7753 -X080m -X080f -X030m -X030f -XD7901-1
7 2 2 T 1 1 8 3 3 0303 3 3 7901-135 35 C1:35 Resistance In
-D7901
U /0.0_1.D2
D D
De-icing sensor De-icing
secuted.
-B7740
-X045f -X045m -X7740 -X7740 -X045m -X045f -XD7901-1
7901-109A 1 1 0451 1 1 T 2 2 0452 2 2 7901-136 36 C1:36 Resistance In
-D7901
U /0.0_1.D2
Temp. ambient (outdoor) Temp. ambient
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Klimatsystem DRG-T,DCG-T 9.4_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Climate Control A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-2 -X030f -X030m -X080f -X080m -X082f -X082m

PWM C2:24 24 7901-224 7 7 0307 7 7 14 3 3 14
-D7901
/0.0_1.D5
A A
Air distributor valve close
-XD7901-2 -Y6720 Air distributor
PWM C2:25 25 7901-225 8 8 0308 8 8 15 7 7 15
-D7901 5 M 6
/0.0_1.D5
Air distributor valve open
-X082m -X082f -X080m -X080f -X031m -X031f
D7901-108-5VRef 7901-108A 9 9 0309 9 9 28 -XSP_A2 16 6 6 16 17 4 4 17 30 10 10 0311 1 1 7901-109C 50-BK/C:2
/11.5_5.D3 10 8 /9.4_1.B4
-XSP_A3
9
-X082m -X082f -X080m -X080f -X031m -X031f -XD7901-1

18 5 5 18 11 11 0312 2 2 7901-128 28 C1:28 Dig In / Ana In
-D7901
/0.0_1.D2
-XD7901-2 -X030f -X030m -X080f -X080m
PWM C2:26 26 7901-226 4 4 0304 4 4 9 Air distributor valve
-D7901
/0.0_1.D5
B B
Heat valve Close
-XD7901-2 -X030f -X030m -X080f -X080m -Y6730 Water Valve
PWM C2:27 27 7901-227 5 5 0305 5 5 10
-D7901 A M F
/0.0_1.D5
Heat valve Open
12 13
E C
D
-X080m -X080f -X030m -X030f -XD7901-1
11 6 6 0306 6 6 7901-129 29 C1:29 Dig In / Ana In
-D7901
/0.0_1.D2
Heat valve(air mix)
-XD7901-2
PWM 15A C2:37 37 7901-237
-D7901
/0.0_1.E5 -M6570-1
C -X032f -X032m -X081f -X081m -X082f -X082m -XXM6570-1f -XM6570-1m C
Heating fan 1 1 0321 1 1 26 8 8 26a 3 3 OR
1
CHASSIS 9937-00104 2 2 0322 2 2 27 9 9 27a 1 1 BK

/11.5_6.A5 31
Heating fan
-M6570-2
-XM6570-2f -XM6570-2m
3 3
26b OR
1
27b 1 1 BK
31
Heating fan
D D
-XD7901-2 -X031f -X031m -X081f -X081m -Y6120
secuted.
PWM C2:29 29 7901-229 5 5 0315 3 3 21 10 +12V

-D7901
/0.0_1.D5
Motor, recirculation CHASSIS 9937-00207 7 7 0317 5 5 23 7 GND
/11.5_6.A8 M
-XD7901-2
PWM C2:28 28 7901-228 6 6 0316 4 4 22 8 Signal
-D7901
/0.0_1.D5
Motor, recirculation MOTOR, RECIRCULATION
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S2460
P
A A
-XD7901-1 -X036f -X036m -X081f -X081m -XS2460f -XS2460f
Dig In C1:1 1 7901-101 6 6 0366 11 11 32 2 2 1 1 34
-D7901
/0.0_1.B2
PRESSURE SENDER AC
Sw. AC pressure in range=clutch active
-X099m
7901-101A 7 See circuit chssis
P
-XD7901-1 -X036f -X036m -X081f -X081m -XS2460f -XS2460f
B Dig In C1:2 2 7901-102 7 7 0367 12 12 33 3 2 1 4 35 -XSP_A4 B
-D7901
/0.0_1.B2
PRESSURE SENDER AC
Sw. AC pressure >16 bar Max fan speed
C C
-X034m -X081f -X081m
D7901-205-24V 9 0349 10 10 31
/9.5_1.A2

-M810-1
D -XM8100m + - D
D7901-C2p36 1
secuted.
/9.6_4.F4
CHASSIS 2
/9.6_4.F6
-M810-2
+ -
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-X099m -XD7901-1
See circuit chssis 11 7901-144 44 C1:44 Dig In Start up
-D7901
/0.0_1.E2
External heater
B B
-X053f -X053m -XD7440f -XD7440m

X09915 09915B 1 1 RD 1 1/9
/8.2_4.F8
-X053f -X053m 2/9
9937-0054 3 3 BN 3 3/9
C -X099m -X053f -X053m 4/9 C
-X9937-005:4
12 09912 5 5 BU/WH 5 5/9
See circuit chssis 6/9
7/9
1
8/9
CHASSIS 9/9
Eberspächer Easystart T
-D7440

D D
secuted.
-M6670
-XD7901-2 -X036f -X036-5m -XM6670f
3A C2:14 14 7901-214 5 1 0365 1
-D7901
/0.0_1.C5
Paus heater
M
-XM6670f =
CHASSIS 9937-00408 2
/11.5_6.B8
Pause Heater Pump

E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7901-205-24V 0336
/9.4_3.C3
-X033f -X033m
0492 6 6 0336 D7901-205-24V
/9.5_2.B4
-M6502
-XD7901-2 -X049f -X049m -XM6502m -XM6502f -XM6502f -XM6502m
6A C2:17 17 7901-217 1 1 0491 30 2 2 RD 53 31 BK 3 3 30 0458A
-D7901 M
/0.0_1.C5 0458A 0491
Wiper rear -
B -X049f -X049m -XM6502m -XM6502f 31b -XM6502f -XM6502m -X049m -X049f -XD7901-1 B
2 2 0492 1 1 YE 53a GN 4 4 0493 3 3 7901-112 12 C1:12 Dig In
-D7901
Rear wiper /0.0_1.C2
Wiper rear feedback
0457
-M6503
-XD7901-2 -X045f -X045m -X097f -X097m -XM6503f -XM6503m -XM6503m -XM6503f -X097m -X097f -X045m -X045f
6A C2:19 19 7901-219 6 6 0456 30 2 2 30 0972 2 2 YE 53 31 BN 3 3 0973 30 3 3 30 0458B 8 8 9937-00206 CHASSIS
-D7901 M /11.5_6.A8
/0.0_1.C5 0458B 0973 0972 0456
Wiper roof/combined front/roof -
-X045f -X045m -X097f -X097m -XM6503f -XM6503m 31b -XM6503m -XM6503f -X097m -X097f -X045m -X045f -XD7901-1
7 7 0457 1 1 0971 1 1 BK/GN 53a BK 4 4 0974 4 4 0459 9 9 7901-113 13 C1:13 Dig In
-D7901
D7901-205-24V 7901-205B Roof wiper /0.0_1.C2
/5.2_2.E4
Wiper roof feedback
C C

0332A CHASSIS
/9.5_2.D6
-M6512
Rear washer
-XD7901-2 -X033f -X033m -XM6512f -XM6512f -X033m -X033f
6A C2:16 16 7901-216 3 3 0333 1 + - 2 0332B 2 2 9937-00103 CHASSIS
D -D7901 M /11.5_6.A5 D
/0.0_1.C5
secuted.
Motor washer rear
-M6513
Front/Roof washer
-XD7901-2 -X033f -X033m -XM6513f -XM6513f
6A C2:15 15 7901-215 4 4 0334 1 + - 2 0332C
-D7901 M
/0.0_1.C5
Motor washer front/roof
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Torkare & Spolare DRG-T,DCG-T 9.5_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Wiper & Washer A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-K6501
-XD7901-2 -XK6501 -XK6501
1,5A C2:8 8 7901-208 86 86 85 85 9937-0047A CHASSIS
-D7901 /11.5_6.B8
/0.0_1.C5
A /9.5_2.B3 A
Single wiper front
-M6501
-XK6501 -K6501 -XK6501 -X033f -X033m -XM6501-LEf -XM6501-LEm -XM6501-LEm -XM6501-LEf
9968-GN:2 9968-GN-B1 -XSP65001 9968-GN-B1A 30 30 87 87 6501-LE-87 5 5 0335 2 2 RD 53 31 BK 4 4 0338
/11.5_2.E5 M
B /9.5_2.A3 B
-XM6501-LEf -XM6501-LEm - -XM6501-LEm -XM6501-LEf -X033m -X033f -XD7901-1
31b
D7901-205-24V 0336 1 1 YE 53a GN 3 3 0337 7 7 7901-110 10 C1:10 Dig In
/9.5_1.A5 -D7901
Single wiper front /0.0_1.C2
Single wiper front feedback
9968-GN-B1B
-X033m -X033f
8 8 9937-00105 CHASSIS
C -K6511 /11.5_6.A5 C
-XD7901-2 -XK6511 -XK6511
1,5A C2:10 10 7901-210 86 86 85 85 9937-0047B CHASSIS
-D7901 /11.5_6.B8
/0.0_1.C5 /9.5_2.D3
Motor washer single wiper front

-M6511
Motor washer single wiper front
-XK6511 -K6511 -XK6511 -X033f -X033m -XM6511f -XM6511f

D 30 30 87 87 6511-87 1 1 0331 1 + - 2 0332A CHASSIS D
/9.5_2.C3 M /9.5_1.D6
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Torkare & Spolare option fram DRG-T,DCG-T 9.5_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Wiper & Washer option front A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-XD7902-9m -XD7902-9f -XA3701f -XA3701m

1 1
2 2
3 3
4 4
C 5 5 C
6 6
7 7
8 8
9 9
10 10
11 11
12 12

13 13
14 14
15 15
16 16
D 17 17 D
18 18
secuted.
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
28 28
E 29 29 E
30 30
31 31
32 32
/9.4_0.D1
33 33
34 34
-D7902
-A3701Lights_Panel
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Manöverpanel belysning DRG-T,DCG-T 9.6_0 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Control panel Lights A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A D7902-501-24V 0551B
/2.1.A4 A
-S1600
INDICATOR -XS1600-49a
49a 49a -XD7902-5
8 C5:8 Dig In
-XS1600-R -X055Am -X055Af -X055m -X055f -D7902
R R 055A10 10 10 05510 10 10 7902-508 /0.0_2.C5
Sw. indicator left
-XS1600-L -X055Am -X055Af -X055m -X055f
L L 055A11 11 11 05511 11 11 7902-507 -XD7902-5
/9.6_1.C3 Dig In
7 C5:7
/9.7_1.A4 -D7902
/0.0_2.C5
Sw. indicator right
B B
-S1600
/9.6_1.B3
HEAD LIGHT -XS1600-56d -X055Am -X055Af -X055m -X055f -XD7902-5
56d 56d 055A12 12 12 05512 12 12 7902-509 9 C5:9 Dig In
-D7902
-XS1600-31 /0.0_2.C5
C 31 31 C
Sw. High Low Beam
/9.7_1.A4
D7902-501-24V 160031-1,0551C
/2.1.A4
-X099m -XD7901-1
D See circuit 10 7901-143 43 C1:43 Dig In Start up D
-D7901
chassi
secuted.
/0.0_1.E2
Steplight
-E4340
-S4340 -XE4340-2f -X045m -X045f
1 2 1 0454B 4 4 9937-00205 CHASSIS
-XD7901-2 -X045f -X045m -XE4340-1f /11.5_6.A8
PWM C2:30 30 7901-230A 3 3 0453A 1
-D7901 Interior light
/0.0_1.D5
Interior light, step light
E Std bypass switch E

0454A CHASSIS
/9.7_2.B7
-X099m
7901-230B 9
See circuit
F chassi F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets belysning DRG-T,DCG-T 9.6_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Lights A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-E4050-LE
-XD7901-2 -X047f -X047m -X090Lf -X090m -XE4050f -XE4050f -X090m -X090Lf -X047m -X047f
6A C2:20 20 7901-220A 1 1 0471 5 5 0905 1 1 2 2 0906 6 6 0473 3 3 9937-00301A CHASSIS
-D7901 /11.5_6.C6
/0.0_1.C5
Working light reverse left Working light reverse left (FLT)
B -X099m
See circuit B
7901-220B 31
chassi
Reversing light rear left (FLT)
Tilt suspension
-E4050-RI
C -XD7901-2 -X047f -X047m -X090Rf -X090Rm -XE4050-RIf -XE4050-RIf -X090Rm -X090Rf -X047m -X047f C
6A C2:21 21 7901-221A 2 2 0472 5 5 0905 1 1 2 2 0906 6 6 0474 4 4 9937-00301B CHASSIS
-D7901 /11.5_6.C6
/0.0_1.C5
Working light reverse right Working light reverse right (FLT)
-X099m
See circuit
7901-221B 30
chassi
Reversing light rear right (FLT)
Tilt suspension
D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Belysning DRG-T,DCG-T 9.6_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-2 -X048f -X048m -X090Lf -X090m -X090m -X090Lf -X048m -X048f

6A C2:22 22 7901-222A 6 6 0486 1 1 2 2 0488 8 8 9937-00309
A -D7901 A
/0.0_1.D5
Extra worklight left A 7901-222B
0901 0902
-E4042-LE
-X099m -XE4042f -XE4042f
28
See circuit 1 1 2 2
chassi
Work light left Work light roof rear
Tilt suspension
B B
-E4042-LE
-XE4042-LEm -XE4042LEf -XE4042LEf -XE4042-LEm
1 40421 1 1 2 2 40422 2
Work light roof front
-E4042-LEA
-XE4042-LEm -XE4042-LEAf -XE4042-LEAf -XE4042-LEm
1 40421 -XSP4042-1 40421A 1 1 2 2 4042A -XSP4042-2 40422 2
Work light roof rear

C -E4042LEB C
-XE4042-LEBf -XE4042-LEBf
40421B 1 1 2 2 4042B


-XD7901-2 -X048f -X048m -X090Rf -X090Rm -X090Rm -X090Rf -X048m -X048f

6A C2:23 23 7901-223A 7 7 0487 1 1 2 2 0489 9 9 9937-00308 CHASSIS
-D7901 /11.5_6
/0.0_1.D5
Extra worklight right B
7901-223B
D D
0901 0902
secuted.
-E4042-RI
-X099m -XE4042-RIf -XE4042-RIf
29
See circuit 1 1 2 2
chassi
Work light right Work light roof rear
Tilt suspension
-E4042-RI
-XE4042-RIm -XE4042-RIf -XE4042-RIf -XE4042-RIm
1 40421 1 1 2 2 40422 2
E E
Work light roof front
-E4042RIA
-XE4042-RIm -XE4042-RIAf -XE4042-RIAf -XE4042-RIm
1 40421 -XSP4042-1 4042A 1 1 2 2 4042A -XSP4042-2 4042 2
-E4042RIB
-XE4042-RIBf -XE4042-RIBf
F 4042B 1 1 2 2 4042B F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Beslysning DRG-T,DCG-T 9.6_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7901-2 -X029f -X029m -X029m -X029f -X047f -X047m -X090Lf -X090m -X090m -X090Lf -X047m -X047f
6A C2:18 18 7901-218 3 3 0293 4 4 0294A -XSP13 0294B 5 5 0475 30 3 3 4 4 30 0476 6 6 9937-00302
-D7901
/0.0_1.C5
A A
Extra worklight left C 0903 30 30 0904
-X099m -E4042-1LE
CHASSIS
0294C 26 -XE4042-1f -XE4042-1f
1 1 2 2
Work light left
Tilt suspension
/11.5_6.C6
See circuit
chassi -E4042-1LEA
-XE4042-1m -XE4042-1LEAf -XE4042-1LEAf -XE4042-1m
1 40421 -XSP4042-1 40421A 1 1 2 2 40422A -XSP4042-2 40422 2
-X029m -X029m
3 4
B B
-E4042-1LEB
-XE4042-1LEBf -XE4042-1LEBf
0293 0294 40421B 1 1 2 2 40422B
-K3040
-E4042-1LEA
-XK3040 -XK3040 -XE4042-1m -XE4042-1Af -XE4042-1Am -XE4042-1LEAf -XE4042-1LEAf -XE4042-1Am -XE4042-1Af -XE4042-1m
86 86 85 85 3017-1-85 CHASSIS 1 40421 -XSP404-3 40421A 1 1 4042A1-XSP4042-1 4042A1A 1 1 2 2 4042A2A -XSP4042-2 4042A2 2 2 40422A -XSP404-4 40422 2
/11.5_6.B6
-XK3040 -XK3040 -E4042-1LEB
9968-BK:7 9968-BK-G1 30 30 87 87 -XE4042-1LEBf -XE4042-1LEBf
C /11.5_2.D5 4042A1B 1 1 2 2 4042A2B C
Work light 4x70W
-E4042-1RIA
-XE4042-1Bf -XE4042-1Bm -XE4042-1RIAf -XE4042-1RIAf -XE4042-1Bm -XE4042-1Bf
40421B 1 1 4042B1-XSP4042-1 4042B1A 1 1 2 2 4042B2A -XSP4042-2 4042B2 2 2 40422B

-E4042-1RIB
-XE4042-1RIBf -XE4042-1RIBf
4042B1B 1 1 2 2 4042B2B
D Used with relay K3040. Work light roof rear

D
secuted.
-E4042-1RI
-XD7901-2 -X047f -X047m -X090Rf -X090Rm -XE4042-1f -XE4042-1f -X090Rm -X090Rf -X047m -X047f
PWM 15A C2:36 36 7901-236A -XSP14 7901-236B 7 7 0477 30 3 3 0903 30 1 1 2 2 30 0904 4 4 30 0478 8 8 9937-00303
-D7901
/0.0_1.D5
Extra worklight right D Work light roof rear
Condenser roof
CHASSIS
-X099m
7901-236C 27
See circuit -E4042-1RIA
-XE4042-1m -XE4042-1RIAf -XE4042-1RIAf -XE4042-1m
1 40421-XSP404-1 40421A 1 1 2 2 40422A -XSP404-2 40422 2
Work light right chassi
/11.5_6.B6
E Tilt suspension Work light roof rear E
-E4042-1RIB
-XE4040L-4f1 -XE4040L-4f1
40421B 1 1 2 2 40422B

D7901-C2p36 CHASSIS
/9.4_3.D5 /9.4_3.D5
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B -E4370 B
-X050f -X050m -XE4370-1 -XE4370-2
9968-BK:8 9968-BK-H1 6 6 0506 1 2
/11.5_2.D5
Search light
-X050f -X050m
CHASSIS 0507 7 7 0507
/11.5_2.C7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S1600
/9.6_1.B3
HORN -XS1600-31b -X056Am -X056Af -X056m -X056f -XD7902-5

31b 31b 056A1 1 1 0561 1 1 7902-510 10 C5:10 Dig In
A -D7902 A
/0.0_2.C5
/9.6_1.C3
Sw. horn
7902-309A D7902-309-24V
/7.5_1.B1
-S1490
-XS8150-1f -XS8150-1m -XS1490f -XS1490f -XS8150-1m -XS8150-1f -XD7902-4

D7902-309-24V 7902-309 7 7 8150-17A 1 1 2 2 8150-115 15 15 7902-408 8 C4:8 Dig In
/11.5_5.A4 -D7902
/7.1_1A.C8
HORN
Sw. horn
B 8150-17C D7902-309-24V
/7.9_1.C2 B
8150-17D D7902-309-24V
/7.1_3.B2
8150-17B -XSP8150-17 8150-17E D7902-309-24V
/7.1_2.A2
8150-17F D7902-309-24V
/7.1_2.B2
8150-17G D7902-309-24V
/7.10_1.C2
8150-17H D7902-309-24V
/2.1.C1
-S1490
-XS8150-1m -XS1490f -XS1490f -XS8150-1m

7 8150-17A 1 1 2 2 8150-115 15
HORN
C C
8150-17C D7902-309-24V
/7.1_1C.A2
8150-17D D7902-309-24V
/7.1_3.C2
8150-17B -XSP8150-17 8150-17E D7902-309-24V 1
/7.1_1C.C2
Double joystick

-XD7901-2 -X032f -X032m -H8500-1

3A C2:12 12 7901-212A 3 3 0323 + +
-D7901
/0.0_1.C5 - -
Horn
Horn
D D
secuted.
-X032m -X032f
0324 4 4 9937-00101 CHASSIS
/11.5_6.A5
7901-212B D7902-212-24V
/9.7_1.E1
-X099m
7901-212C 21 See circuit chssis
E E
-K3016
-X029f -X029m
D7902-212-24V 7901-212B 7 7 0297 86 86 85 85 3016-85 CHASSIS
/9.7_1.E4 /11.5_6.C8
-X029m -X029f -X032f -X032m

9968-RD:8 9968-RD-H1 30 30 87 87 3016-87 8 8 0298 5 5 0325

/11.5_2.B5
87A
-M8500-2
Compressor horn
Compressor horn
F -X032m -X032f
+ + - - 0326A 6 6 9937-00102 CHASSIS
F
M /11.5_6.A5

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Signalhorn DRG-T,DCG-T 9.7_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Horn A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-H4282
ROT. BEACON
-XD7901-2 -X049f -X049m -X090Lf -X090m -XH4282+ -XH4282- -X090m -X090Lf
3A C2:13 13 7901-213A 9 9 0499 7 7 0907 + + - - 0908 8 8 0454A CHASSIS
-D7901 M /9.6_1.F7
/0.0_1.C5
Rotating beacon
B B
-X099m
7901-213B 22
See circuit
chassi
ROT. BEACON
TILT SUSPENSION
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Varningsljus DRG-T,DCG-T 9.7_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Beacon Light A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
VDO 24V
-XA9002Am -XA9002Bm -H9020R
1/8 1/8 BK/WH-R +
2/8 2/8 -XA9002Bf BK-R -
3/8 3/8 3
Speaker Right
4/8 4/8 4
5/8 5/8 5
B 6/8 6/8 6 B
7/8 7/8 -H9020L
8/8 8/8 BK/WH-L +
BK-L -
Speaker Left
-K1047
PK
-XK1047 -XK1047
90022A 1 1 2 2 90028B
/9.8_1.C5 Continental 24V
-XA9002A-2m
-XA9002Af -XA9002Am -K1047 1/8
24V_Mute 90022 2 2 3 3 5 5 90023 -XA9002A-2f 2/8
/9.8_2.B7
C -X048f -X048m 90028A 4 3 3/8 C
9968-BK:4 9968-BK-D1 1 1 0481 4 4 90024 /9.8_1.C5 4 4/8
/11.5_2.C5
5 5 90025 5 5/8
6/8
9968-RD:4 9968-RD-D1 2 2 0482 7 7 90027 7 7/8
/11.5_2.A5
CHASSIS 9937-00304 3 3 0483 8 8 90028 8 8/8
/11.5_6.B6
-A9002
-XW9030

1
Antenna remote
-R9030 -XW9030m -XW9030f

24V
1 2 1 1 90301
D 150 Ohm 2 2 90302 D

Gnd
secuted.
-W9030
1 2
Antenna
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Radio DRG-T,DCG-T 9.8_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Radio A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1047
C
A
-XS1047 -XS1047-4 -X060m -X060f -X035m -X035f -X045f -X045m
D7902-401-24V 7902-401E 3 3 4 4 06011 11 11 0353 3 3 0455 5 5 90022 24V_Mute
/7.9_1.A2 /9.8_1.C2
10473 6 6 1 1
Mute
B B
7902-302I D7902-302-0VRef
/7.9_1.B8
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets strömställare tystnad DRG-T,DCG-T 9.8_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Mute Switch A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
-X091Lf -X091Lm
0704 1 1 orange(out)
0703B 2 2 yellow(in)
-XSP0703 3 3 green(up)
0703A 4 4 brown(down) LEFT
099-18A 5 5 red(heater + )
0708A 6 6 black(heater -)
MIRROR
-XS1230-1m -XS1230-1f -X099-18
C
Orange 1 1 See circuit chssis 1 099-18 -XSP099-181
C
+
81A LH left/right (white) 2 2 0702
82A Left Common (Lt Blue) 3 3 0708 -XSP0708
88A LH up/down (Yellow) 4 4
88B RH up/down (yellow/black) 5 5 0706 -XSP0706

-X091Rf -X091Rm
0706A 1 1 orange(out)
82B Right Common (blue/black) 6 6 0707 2 2 yellow(in)
0703
0706B 3 3 green(down)
81B RH left/right (white/black) 0705 4 4 brown(up) RIGHT
7 7
D 099-18B 5 5 red(heater + ) MIRROR D
-S1230 Black 8 8 0708B 6 6 black(heater -)
Mirror Mini Joystick -
12301
12302
12303
12304
12305
12306
12307
12308
-X057m
4
3
5
6
7
8
1
E E
-X057f
1
2
3
4
5
6
7
8
0571
0572
0573
0574
0575
0576
0577
0578
9968-BK:6 9968-BK-F2
/11.5_2.C5

-X070m -X070f
1 1
2 2
F 3 3 F
secuted.
4 4
5 5
6 6
7 7
8 8
CHASSIS 9937-00406
/11.5_6.B8
G G
H H

Sign.
Ruta
Krets ställbara Backspeglar DRG-T,DCG-T 9.9_1 1
E³ DRAWING
Design change
Sq.
Name
R

Wiring adjustable Rear Mirrors A66424.0100 04
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
A A
7902-320A D7902c3p20
/7.0_1.B3
-S1046
C
A
-XS1046 -XS1046 -XS8150-4f -XS8150-4m -XD7902-3
D7902-309-24V 8150-47J 3 3 4 4 8150-414 14 14 7902-320 20 C3:20 Dig In
/1.3_1.B2 -D7902
8150-47K 6 6 1 1 8150-42J /0.0_2.E3
Rear window and mirror heater Sw. window heater & mirror heater
B B
D7902-302-0VRef
/1.3_1.B7
C C
-K8881
-XD7901-2 -X029f -X029m
0,5A C2:6 6 7901-206 5 5 3991-86 86 86 85 85 3991-85 CHASSIS
-D7901 /11.5_6.B8
/0.0_1.B5
Rear window heater
-XE8881-1 -E8881 -XE8881-2
9968-GN:1 9968-GN-A1 30 30 87 87 3991-87 1 1 2 2 9937-00402 CHASSIS
/11.5_2.D5 /11.5_6.C8
Heated window Window heater


D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Värme Bakruta & Backspeglar DRG-T,DCG-T 9.9_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Heat Rear Window & Mirrors A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XR8020-2LEf
-X099-18 09918A 1 1/2
1 09918 -XSP071-1 2 2/2
See circuit chssis 9937-0502B
B -R8020-2LE B
-XR8020-2RIf
-X9937-005:2 09918B 1 1/2
1 9937-00502 -XSP071-2 9937-0502A 2 2/2
-X9937-005
-R8020-2RI
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120503 A66423.1600 Krets Värme Backspeglar DRG-T,DCG-T 9.9_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Heat Mirrors A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-XD7902-4
7902-411 11 C4:11 Dig In
-D7902
-S1750/S1751 /0.0_2.A5
A Cab moving left/reverse/Up
D7902-309-24V 8150-47E B
/8.2_3.A2 C
-XS1751 -XS8150-4f -XS8150-4m
D7902-309-24V 8150-47D -XS1751 4 4 8150-46 6 6
/9.10_2.C2 3 3 -XD7902-4
2 2 8150-48 8 8 7902-412 12 C4:12 Dig In
-XS8150-4m -XS8150-4f -D7902
D7902-310-24V 7902-310B 1 1 8150-41A 6 6 1 1 8150-42D /0.0_2.A5
/7.5_1.C1
D7902-310-24V 7902-310C Cab moving Cab moving right/forward/Down
/7.0_1.C3
D7902-310-24V 8150-41B
/8.2_3.B2
B B
D7902-302-0VRef
/9.10_2.C8
8150-42E D7902-302-0VRef
/8.2_3.B8
-XD7902-4
7902-414 14 C4:14 Dig In
-D7902
-S1990-6/S1010/1690/1750 /0.0_2.A5
A Option 6
B
C Cabtilt up
D7902-309-24V 8150-47G -XS1990-6 -XS8150-4f -XS8150-4m
/7.5_3.B2 -XS1990-6 Turible seat C.C.W
4 4 8150-410 10 10
C D7902-309-24V 8150-47F 3 3 -XD7902-4 C
/8.2_3.A2 2 2 8150-411 11 11 7902-415 15 C4:15 Dig In
-D7902
D7902-310-24V 8150-41C 6 6 1 1 8150-42F /0.0_2.B5
/8.2_3.B2
Option 6
Cab tilt down
Option 6/Cab tilt/Turnable seat Turnible seat C.W
D7902-302-0VRef
/8.2_3.B8
8150-42G D7902-302-0VRef
/7.5_3.B7
D D
secuted.
-X099m
D7901-205-24V 7901-205C 23
See circuit
/5.2_2.E4 chassi
-X099m -XD7901-1
See circuit 17 7901-131 31 C1:31 Dig In / Ana In
-D7901
/0.0_1.D2
chassi
Cab pos (tilt)
-X099m -XD7901-1
25 7901-132 32 C1:32 Dig In / Ana In
E -D7901 E
/0.0_1.D2
Cab moving damp sens/Length sens

-X099m
24 9937-00202 CHASSIS
/11.5_6.A8
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Hytt Förflyttning DRG-T,DCG-T 9.10_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Cab Moving A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-S1260
C
A
3 4
6 1
Diffrential lock
7902-317A D7902c3p17
/7.0_1.B3
-S1990-4/S1010-2
B C B
A
-XS1990-4 -XS1990-4 -XS8150-4f -XS8150-4m -XD7902-3
D7902-309-24V 8150-47C 3 3 4 4 8150-45 5 5 7902-317 17 C3:17 Dig In
/8.2_2.B2 -D7902
1 1 8150-42C /0.0_2.D3
1990-436
Option 4 Aut cab tilt on/off
Diffrential Lock
Aut. cab tilt on/off
D7902-302-0VRef
/8.2_2.C8
D7902-309-24V 8150-47D 6
/9.10_1.B2
8150-42D D7902-302-0VRef
/9.10_1.B7
C C

D D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Hytt Förflyttning DRG-T,DCG-T 9.10_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Cab Moving A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
-X7950Am -X7950Af -X7950Bm -X7950Bf
1 7950A1 1 1 7950B1 1
2 7950A2 2 2 7950B2 2
3 7950A3 3 3 7950B3 3
4 7950A4 4 4 7950B4 4
6 7950A6 6 6 7950B6 6
7 7950A7 7 7 7950B7 7
8 7950A8 8 8 7950B8 8
9 7950A9 9 9 7950B9 9
10 7950A10 10 10 7950B10 10
D 11 7950A11 11 11 7950B11 11 D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 170905 A66423.1600 Krets Display position DRG-T,DCG-T 11.1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring distribution of electricity A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S2500
A -XS2500-1 -XS2500-2 -XD7902-5 A

D7902-801-24V 7902-801 1 1 2 2 7902-511 11 C5:11 Dig In
/11.5_5.A3 -D7902
/0.0_2.C5
Operating switch Operating switch
B B
-D7901
-XD7901:C3
09815 09815B 24V -XD7901:C4
/11.5_2.D5 24V IGNITION POWER
-XD7901-2 GND W09831C CHASSIS
Ground /11.5_6.E4
9968-RD:2 9968-RD-B1 38 C2:38
/11.5_2.A5 CPU POWER
/0.0_1.E5
CPU Power
C C
-D7902

KPU
-X034f -X034m -X060f -X060m -XD7902-1 Power -XD7902-1 -X060m -X060f -X034m -X034f
9968-BK:1 9968-BK-A1 5 5 0605 5 5 7902-101A 7902-101 1 C1:1 Main power Ground C1:2 2 7902-102 4 4 0604 4 4 9937-00201 CHASSIS
/11.5_2.B5 /11.5_6.A8
-XSP7
9968-BK:1 7902-101B /0.0_2.A3
D /11.6_1.B5 D
9968-BK:1 7902-101C
secuted.
/2.1.E7
-X050f
E 7901-211 8 E
-XD7901-2 -X099m
See circuit
1,5A C2:11 11 7901-211A 13

-D7901
/0.0_1.C5 chassi
Main relay ignition K3150
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets el-distribution DRG-T,DCG-T 11.5_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-F9968-RD 9968-RD:1
-XF9968-RD-AB /11.5_3.D1
5A A:1 9968-RD-A1
1:1 A:1 /9.2_1.A3
1:2 A:2 A:2 RD,RD 9968-RD:1
-F9968-RD /9.2_1.D3
A 1 Startup / Inter lock device 15A B:1 9968-RD-B1 9968-RD:2
A
2:1 B:1 /11.5_1.C1
2 KCU, D7901 2:2 B:2
3
4 Radio 3:1 C:1
5 Service / RMI 3:2 C:2
6 Customer 5A D:1 9968-RD-D1 9968-RD:4
7 4:1 D:1 /9.8_1.C1
4:2 D:2
8 Compressor horn
10A E:1 9968-RD-E1
/11.5_2.B4 5:1 E:1
5:2 E:2
10A F:1 9968-RD-F1
6:1 F:1
6:2 F:2
-X039f
7:1 G:1 0393 3 9968-BK-B:1
7:2 G:2 /8.2_4.D7
B 10A H:1 9968-RD-H1 9968-RD:8
B
8:1 H:1 /9.7_1.F1 0394 4
Moved to RD-3:1 when 8:2 H:2
BATTERY /11.5_2.B1
X098-30 5
battery power to converter 09830A
-XF9968:RDX:RD CHASSIS
/8.2_4.D7
is wanted.
-F9968-BK 9968-BK:1
-XF9968-BK-AB /11.5_1.D1
A:1 9968-BK-A1 9937-0036A CHASSIS
1:1
10A
A:1
/11.5_6.B6
/9.2_1.B3
1:2 A:2 A:2 BU,GN 9968-BK:1
-F9968-BK /9.2_1.D3
1 KPU, D7902 10A B:1 9968-BK-B1
2:1 B:1
2 Service / RMI 2:2 B:2 0507 CHASSIS
3 Display/Camera system
/9.6_5.C3
9968-BK-31 3:1 10A -X050f
4 Radio 3:1 C:1
5 Seat functions 9968-BK-32 3:2 3:2 C:2 0395 5
C 6 Customer 5A D:1 9968-BK-D1 9968-BK:4 C
7 Work light opt. 4:1 D:1 /9.8_1.C1 4
-XF9968-BK-5:1 4:2 D:2
8 Opt Search light
9968-BK-51 5:1 10A E:1 9968-BK-E1 9968-BK:5 3
/11.5_2.D4 5:1 E:1 /9.3_1.D1
5:2 E:2
10A F:1 9968-BK-F1
6:1 F:1 -X046f
6:2 F:2 F:2 9968-BK-F2 9968-BK:6
/9.9_1.E5 2
15A G:1 9968-BK-G1 9968-BK:7
/9.6_4.C1
7:1 G:1 9968-BK-F1A 9968-BK:6

/11.5_7.D2
7:2 G:2
1
10A H:1 9968-BK-H1 9968-BK:8
8:1 H:1 /9.6_5.B3 4
8:2 H:2
3
Dedicated for
X098-15 -X098-15-1 IGNITION /11.5_2.C1 use of customer
-XF9968:BK X:BK
09815A 0465 5
D D
09815B -XF9968:BK-1 09815 0466A 6
secuted.
/11.5_1.B1
-F9968-GN
-XF9968-GN-AB -XF9968-GN-AB 0466B CHASSIS
9968-BK-51 1:1 25A A:1 9968-GN-A1 9968-GN:1 /11.5_7.E2
1:1 A:1 /9.9_2.D2
-F9968-GN 1:2 A:2
-XF9968-GN-AB -XF9968-GN-AB
1 Rear window heater 9968-BK-32 2:1 B:1 9968-GN-B1 9968-GN:2
10A
2 Double front wipers/Single wiper flat screen 2:1 B:1 /9.5_2.B1
3 Converter 12/24V 2:2 B:2 -XF9968-GN-CD
4 9968-BK-31 3:1 C:1 9968-GN-C1 9968-GN:3
9968-BK-GN
25A 9937-0036B CHASSIS

5 Turnible seat 30 deg 3:1 C:1 /11.5_7.C2 /11.5_6.B6
3:2 C:2
6 Motor left armrest
7 Inverter 24-230V 4:1 D:1
8 Seat Air vent/Air cusioned seat 4:2 D:2 -XF9968-GN-EF
/11.5_2.F4 E:1 9968-GN-E1 9968-GN:5
E 5:1
5A
E:1 /9.3_5.B4 E
5:2 E:2 -XF9968-GN-EF
F:1
5A 9968-GN:6
6:1 F:1
6:2 F:2 -X9968-GN-H:1
20A G:1 9968-GN-H1 9968-GN:7
7:1 G:1 /11.5_8.C2
7:2 G:2 -XF9968-GN-GH 12V
10A H:1 9968-GN-H1 9968-GN:8 /11.5_7.B2
8:1 H:1 /9.3_1.A1

8:2 H:2
Option/ /11.5_2.E1
-XF9968:GN X:GN Ignition
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets el-distribution DRG-T,DCG-T 11.5_2 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S1500
A -X056Af -X056Am -XS1500-1 -XS1500-1 -X056Am -X056Af -X056m -X056f -X060m -X060f -X035m -X035f -XD7901-1 A
3 3 056A3 1 1 2 2 056A4 4 4 0564 4 4 0609 9 9 0351 1 1 7901-149 49 C1:49 Dig In Start up
-D7901
/0.0_1.E2
0563
3 4
Ignition key
Switch ignition key
-X056m
3
ONLY IF MOTORIZED LEFT ARMREST
-X056f
3 0613B
B B
-X037f -X037m -XS2660-LE-1 -S2660-LE -XS2660LE-2 -X037m -X037f -XD7901-1

0357B 1 1 0371 1 1 2 2 0372 2 2 7901-146 46 C1:46 Dig In Start up
-D7901
/0.0_1.E2
Braking cab door left
Door switch left
-X036f -X036m -XS2660RI-1 -S2660-RI -XS2660RI-2 -X036m -X036f -XD7901-1

0357A 1 1 0361 1 1 2 2 0362 2 2 7901-145 45 C1:45 Dig In Start up
-D7901
/0.0_1.E2
Braking cab door right
Door switch right
C C
Silicon panel

Hazard
-X035f -X035m -X061m -X061f -XD7902-1 -XD7902-1 -X061f -X061m -X035m -X035f -XD7901-1
9968-RD:1 9968-RD-A1 7 7 0357 3 3 0613 -XSP2 0613A 12 C1:12 Supply +30 In(Sw. Hazard) C1:11 11 7902-111 4 4 0614 8 8 7901-147 47 C1:47 Dig In Start up
/11.5_2.A5 -D7902 -D7902 -D7901
/0.0_2.A3 /0.0_2.A3 /0.0_1.E2
Supply +30 Sw. hazard S1090 Startup hazard
D D
secuted.
Interior light
0631D
0613C
-XD7902-1 -X061f -X061m -X035m -X035f -XD7901-1

In (Sw Inside light) C1:10 10 7902-110 5 5 0615 9 9 7901-148 48 C1:48 Dig In Start up
-D7902 -D7901
/0.0_2.A3 /0.0_1.E2
Sw interior light S1160 Interior light
9968-RD:1
/9.3_1.E1
E 9968-RD:1
/9.3_2.B2 E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets el-distribution Startup DRG-T,DCG-T 11.5_3 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring distribution of electricity Star A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X035f -X035m -X061m -X061f -X056f -X056m -X056Af -X056Am -XS1440-2m -XS1440-2s -S1440-2 -XS1440-2s -XS1440-2m
A 5 5 0611 1 1 0565 5 5 0565 5 5 056A5 1 1 1 2 2 2 558B CHASSIS
A
/5.2_1.C7
El. main switch Jord
CPU Power out -K3750

-X029m -XK3750 -XK3750
D7901-235-24V 6 0296 86 86 85 85 3750-85 CHASSIS
/11.6_1.C4 /11.5_6.B8
B B
85 på spole huvudrelä i ram
-X099m
See circuit 14 09914
chassi
-X053f -X053m -X053m -X053f -X029f -X029m

0355 7 7 0538 8 8 0299 9 9 0299 30 30 87 87 3750-87 CHASSIS
/11.5_6.B8
-X053m -X053m
Relay main switch
7 8
(holding circuit)
C C
0537 0538
Cable 0538 is removed when relay K3550 is used
-XK3550 -K3550 -XK3550


WH 0.75 30 30 87 87 WH 0.75
87A
/11.5_4.D3
-K3550
D -XK3550 -XK3550 D
0536A 86 86 85 85 9937-00508 BK 0.75 CHASSIS
secuted.
/11.5_6.D5
/11.5_4.D3
Relay fire extinguishing systems
WH 0.75
E -Fire -X053m -X053f -XD7901-1 E

1 0536 WH 0.75 6 6 7901-130 30 C1:30 Dig In / Ana In
-D7901
/0.0_1.D2
Fire extinguishing systems signal 24V when OK

-XK3550-30 -XK3550-87
1 30-87 WH 0.75 1
Cable 30-87 is used instead of the relay before external fire extinguishing system is installed.
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets el-distribution el. huvudbrytare DRG-T,DCG-T 11.5_4 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring distribution of electricity el. A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-XD7902-3
0,5A C3:9 9 7902-309 D7902-309-24V
-D7902 /9.7_1.B2
/7.1_1A.B2
24V Supply Island 1
-XD7902-8
0,5A C8:1 1 7902-801 D7902-801-24V
A -D7902 /11.5_1.A1 A
/0.0_2.D5
24V Supply Island 2
-XD7902-4
0,5A C4:1 1 7902-401 D7902-401-24V
-D7902 /8.2_1.B1
/0.0_2.E3
24V Supply Island 3 -XD7902-3
D7902-302-0VRef 7902-302A 7902-302 2 C3:2 0V Ref
-XD7902-5 /7.1_1A.C7 -D7902
0,5A C5:1 1 7902-501 D7902-501-24V -XSP7902-302 /0.0_2.B3
-D7902 /2.1.A1
/0.0_2.C5 Lever/Joystick
24V Supply Island 4
-XD7901-2 D7902-302-0VRef 7902-302D
0,5A C2:5 5 7901-205 D7901-205-24V /7.0_1.A3
-D7901 /5.2_2.D2
/0.0_1.B5
B 24V Supply Lever/Micro steering B
-XD7901-1
-XD7902-3 0V Ref
50-BK/C:2 7901-109 9 C1:9
PWM 1,5A C3:10 10 7902-310A D7902-310-24V /9.4_1.B1 -D7901
-D7902 /7.5_1.B1 /0.0_1.B2
/0.0_2.C3
Ref Sensors
Lever/Joystick
-XD7902-8
5V Ref C8:4 4 7902-804 D7902-804-5VRef
C -D7902 /1.1_1.C1 C
/0.0_2.D5
Supply pedals
-XD7902-3
5V Ref C3:1 1 7902-301A D7902-301-5VRef
-D7902 /7.1_1A.C2
/0.0_2.B3
Lever/Joystick
-X7950

Sensor supply 5V C1:8 8 7950-08 D7902-804-5VRef

-D7950 /8.1_1.B2
/11.6_1.B2
Toggle wheel
D D
secuted.
-XD7901-1
5V Ref C1:8 8 7901-108 -XSP00181 7901-108A D7901-108-5VRef
-D7901 /9.4_2.A2
/0.0_1.B2
7901-108B D7901-108-5VRef
Ref Air distr. / heat valve /7.9_2.C2
7901-108C D7901-108-5VRef
/5.2_2.C2
-X099m
7901-108D 8
See circuit chssis
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets el-distribution Ref DRG-T,DCG-T 11.5_5 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring distribution of electricity Ref A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
9937-00108 CHASSIS 9937-00208 CHASSIS

/5.2_1.B8 /7.9_2.A7
9937-00107 CHASSIS 9937-00207 CHASSIS
/11.6_1.F6 /9.4_2.D4
A 9937-00106 CHASSIS 9937-00206 CHASSIS
/11.5_7.C4 /9.5_1.C7 A
/9.3_1.B7 9937-00105 CHASSIS 9937-00205 CHASSIS
/9.5_2.C8 /9.6_1.E7
9937-00104 CHASSIS 9937-00204
/9.4_2.C3 /9.3_1.B8
9937-00103 CHASSIS 9937-00203 CHASSIS
/9.5_1.D7 /5.2_2.D12
-X9937-027 9937-00102 CHASSIS 9937-00202 CHASSIS
/9.7_1.F8 /9.10_1.E7
9937-00101 CHASSIS 9937-00201 CHASSIS
/9.7_1.D7 /11.5_1.D8
-X9937-001 -X9937-002
9937-00408 CHASSIS
/9.4_4.E2
9937-00308 CHASSIS 9937-0047A CHASSIS
B /9.6_3.D8 /9.5_2.A4 B
3017-1-85 CHASSIS
/9.6_4.C3
9937-0036A CHASSIS 9937-0047B CHASSIS
/11.5_2.C8 /9.5_2.C4
9937-0036B CHASSIS 9937-00406 CHASSIS
/11.5_2.E7 /9.9_1.G5
9937-00305 CHASSIS 3750-85 CHASSIS
/9.3_4.B8 /11.5_4.B7
/9.8_1.C1 /11.5_4.C7
/9.6_4.E8 /9.9_2.C5
9937-00302 CHASSIS 9937-00403 CHASSIS
/9.6_4.A8 /9.3_2.C7
9937-00301A CHASSIS 9937-00402 CHASSIS
/9.6_2.B8 /9.9_2.D7
9937-00301B CHASSIS 3016-85 CHASSIS
/9.6_2.C8 /9.7_1.E6
C -X9937-003 -X9937-004 C
3460-85 CHASSIS
/9.3_5.C4
9937-00501A CHASSIS
/9.3_5.D5
9937-00508 BK 0.75 CHASSIS

/11.5_4.D7
D D
secuted.
-X9937-005
-X9937-006
W09831A
E W09831B -X9937-000 Chassi cab E

W09831C CHASSIS
/11.5_1.B8
-098-31
F X098-31 F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets el-distribution Gnd DRG-T,DCG-T 11.5_6 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring distribution of electricity Gnd A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
12V 0464 -X038f -X038m -X083L-12

/11.5_2.E7
3 3 0383 1
B 0329B -X032f -X032m -X083R-12 B

9 9 0329 1
-U9010
-XU9010.1 -XU9010.4
9968-GN:3 9968-GN-C1 24V 24V 12V 12V 0329A
/11.5_2.E5 12V -X033f -X033m -X083R-GND-12
-XU9010.3 9937-0016B 9 9 0339 1
GND GND 9937-0016A
-XU9010.2
24V COM COM 9937-00106 CHASSIS
/11.5_6.A5
C Converter12/24V C
-X038f -X038m -X083L-GND-12

4 4 1
0384 0384

D D
secuted.
-X031f -X031m -X083R-24

9968-BK:6 9968-BK-F1A 9 9 0319 1
/11.5_2.D7
-X038f -X038m -X083L-24

9968-BK-F1B 5 5 0385 1
E E
-X038f -X038m -X083R-GND-24
6 6 1
CHASSIS 0466B 0386

/11.5_2.D7
-X038f -X038m -X083L-GND-24

0466C 7 7 0387 1
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 Krets Omvandlare 12/24V DRG-T,DCG-T 11.5_7 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring Converter 12/24V A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
-XU9010+
9968-GN:7 9968-GN-H1
/11.5_2.E5
-XU9010-
9937-0056
U9010

-X9937-005:6
6
D -X9937-005 D
secuted.
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 140521 A66423.1600 Krets inverter 24-230V DRG-T,DCG-T 11.5_8 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring inverter 24-230V A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-R8201
1 2
-X095f -X095m
0391 30 1 1 120 Ohm
0392 2 2 -X099m
A 9919 30 19
See circuit A
9920 20 chassi
7902-604 30
7902-603 -X039f -XD7901-1
CAN+ 1 7901-126 30 26 C1:26
/8.2_4.D7 + CAN
CAN- 2 7901-127 27 C1:27 CAN OPT.
/8.2_4.D7 -
-D7950
-XD7901-1
C2:1 Device
-X7950 -X060m -X060f -X034m -X034f 7901-103 30 3 C1:3
VBUS L+
C2:2 C1:3 3 30 0601 1 1 30 0341 1 1 30 7901-106 7901-104 4 C1:4 Normal CAN L
Data - Normal+ L-
C2:3 CAN C1:4 4 0602 2 2 0342 2 2 7901-107
Data + Normal-
C2:4 -D7901
Gnd -XD7901-1
30 6 C1:6 /0.0_1.B2
B C2:5 Host C1:6 6 7902-603 R+ B
Gnd Red+ 7 C1:7 RED CAN R
C2:6 CAN C1:7 7 7902-604 R-
Data- Red-
C2:7
Data+ C1:2 2 7902-101B 9968-BK:1
C2:8 Ign.Pwr /11.5_1.D2 CAN
VBUS C1:9 9 0603 3 3 0343 3 3 7902-135A
CAN Shield CPU Pwr
C1:1 1
/11.5_5.D1 5V Ref Gnd
5V Dig In
/8.1_1.B8 5V Dig In
7902-135B -XD7901-2
/8.1_1.B8 5V Dig In -XSP15 Dig Out CPU Power
7902-135 35 C2:35
KID 7902-135C -D7901
/0.0_1.D5
-X029f
C 6 D7901-235-24V
C
/11.5_4.B2 -X099m
30 2
1
7902-135E 6
See circuit
chassi
0347A 30 4
0346A 3
-X050f
7902-135D 9
30 0347B 2
D D
0346B 1
secuted.
-XD7902-1
7902-603 30 3 C1:3
L+
7902-604 4 C1:4 CAN
L- -D7902
E -X060f -X060m /0.0_2.A3 E
8 8 0348 8 8 7902-107 7 C1:7
+ CPU
-X034f -X034m -X060f -X060m

6 6 30 0346 6 6 7902-105 30 5 C1:5 CAN-BUS
R+
7 7 0347 7 7 7902-106 6 C1:6 CAN
R-
-X060m -X060f -X035m -X035f

06010 10 10 0352 2 2 9937-00107 CHASSIS
/11.5_6.A5
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn RSO 120416 A66423.1600 KretsCAN-BUS DRG-T,DCG-T 11.6_1 1
Name
1 See ECO 1034014 RSO 171130 H.Grp:
R
Konstr/Design

Wiring CAN-BUS A66424.0100 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
DRG 100-1300
A A
B B
C DCG80-100 C
Kretsar / Wiring

D D
secuted.
Chassie E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 150625 A55031.1500 KRETSSCHEMA,DRG, 2015 DRG100-1300, DCG80-100 0
Name
1 Added Volvo S.5 1035111 MLG 171121 MLG 150625 H.Grp:
R
Konstr/Design

WIRING DIAGRAM,DRG, 2015 A55039.1500 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
-D7971
1:1 /7.2_1.D1 DRG 450: Lift regenerating valve right Digital Output 1.5A 2:1 /9.6_1.D1 Roading light dipped, front left Digital Output 6A
DRG 100: Activate extra hydraulic pump lift 2:2 /9.6_1.C1 Roading light head, front left Digital Output 6A
2:3 /9.6_1.D1 Roading light dipped, front right Digital Output 6A
2:4 /9.6_1.D1 Roading light head, front right Digital Output 6A
1:2 /11.5_5.A5 CPU power startup from KCU Power Supply 2:5 /9.6_3.E1 Working light fender left option Digital Output 6A
1:3 /11.6_1.B1 CAN 2:6 /9.6_3.F1 Working light fender right option Digital Output 6A
1:4 See pin C1:3 2:7 /4.3.B8 Brake pressure Dig/Ana Input
1:5 Analog Input 2:8 /4.5.D8 Accumulator pressure Dig/Ana Input
1:6 See pin C1:3
B 2:9 /1.7.D8 Feedback CAC Left Dig/Ana Input B
1:7 See pin C1:3
1:8 /11.5_6.A1 5V Sensor supply 5V Analogue Ref 2:10 /8.2_1.A8 Lift pressure+ Left Dig/Ana Input
1:9 /11.5_6.B8 0V Sensor supply 0V Analogue Ref
1:10 /11.5_6.C8 Safe ground, group 1 Boom valves Digital Output NPN
1:11 /7.2_1.E1 DRG 450: Lift Regenerating Valve Left Digital Output 1.5A 2:11 /8.2_1.B8 Lift pressure- Left DRG /Tilt pressure DCGDig/Ana Input
1:12 /9.14.B8 Central lubrication feedback Digital Out/In 1.5A

1:13 /9.6_2.B1 Brake light rear Digital Out/In 1.5A 2:12 /5.2.D8 Steering axle feedback channel left Dig/Ana/Freq Input
1:14 /10.4.A1 DRG Cut pump bom in Digital Output 1.5A
1:15 /10.4.C1 DRG 100-450,: Activate pump attachment Digital Output 1.5A 2:13 /8.2_1.B8 Lift pressure+ Right Dig/Ana Input
2:14 /8.2_1.C8 Lift pressure- Right Dig/Ana Input

KFU7970, Main C1 connector pinout
1:16 /9.6_1.B1 Side position light x4 Digital Out/In 1.5A

1:17 /4.5.B1 Parking brake Digital Output 1.5A
C 1:18 /9.7.A1 Reversing alarm Digital Output 1.5A 2:15 /8.2_1.E8 Tilt/boom angle Dig/Ana Input C

1:19 /9.6_2.A1 Rear light x2 Digital Out/In 1.5A 2:16 /8.2_1.D8 Boom Extension Dig/Ana Input
1:20 /9.6_1.A1 Direction indicator left Digital Out/In 1.5A
1:21 Fan direction control Digital Output 1.5A
1:22 /11.1.A1 Output status signal F Digital Output 1.5A 2:17 /4.5.C8 P-brakepressure sensor 0-5V Dig/Ana Input
1:23 /11.1.A1 Output status signal R Digital Output 1.5A
1:24 /7.3.D1 Digital Output 1.5A
1:25 2:18 Dig/Ana Input
/11.4.B8 Engine running D+ Digital Input D+
1:26 /9.6_1.A1 Direction indicator right Digital Out/In 1.5A

/7.2_1.A1 Lift PWM Output Group1

1:28 /7.2_1.B1 Lower PWM Output Group1 2:20 /1.7.B8 Visco Fan speed feedback Dig/Ana/Freq Input
1:29 /7.3.B1 Boom in PWM Output Group1
1:30 /11.5_6.D8 Safe ground, group 2 Digital Output NPN
1:31 See pin C1:3 2:21 /1.7.D8 Feedback CAC Right Dig/Ana/Freq Input
D 1:32 See pin C1:3 2:22 /9.9_2.B1 Rear view mirror heating Digital Output 6A D
1:33 /7.3.B1 Boom out PWM Output Group1 2:23 /5.2.C8 EHPS error Dig/Ana Input
secuted.
1:34 /1.7.D1 CAC PWM Output Group1 2:24 /1.2.C8 Fuel level Ana/Temp/Rheo Input
1:35 /7.3.E1 Boom in block valve PWM Output Group1 2:25 /10.6.C1 Hydraulic oil temperature Ana/Temp/Rheo Input
1:36 /7.2_1.B1 Boom down block valve Left PWM Output Group1 2:26 /9.2_2.E1 option Digital Output 0.5A
2:27 Digital Output 0.5A
1:37 /7.2_1.C1 Boom down block valve Right PWM Output Group1 2:28 /5.2.E8 Dig/Ana/Freq Input
2:29 /4.8.B1 Hydraulic brake oil temperature Ana/Temp/Rheo Input
1:38 /10.4.D1 Variable activation of pump attachment PWM Output Group1 2:30 Digital Output 1.5A
2:32 /11.5_6.E1 Supply sensors frame Digital Output 0.5A
1:39 PWM Output Group1 2:33 Digital Output 0.5A
2:34 /9.4.B2 Ac compressor Digital Output 6A
2:35 /10.6.B1 Cooling fan hydraulic oil PWM 12A
2:36 /9.6_3.A1 Working light Boom, left Digital Output 6A
E 1:40 /9.10.B1 Cab Lower/REV valve PWM Output Group1 2:37 /4.8.A1 Cooling fan brake oil PWM 12A E
2:38 /9.6_3.C1 Working light Boom, right Digital Output 6A
24V
See pin C1:2

GND See pin C1:2
1:41 /9.10.C1 Cab Lift/FWD valve PWM Output Group1

1:42 /1.6.C7 Air intake filter low preasure Digital Out/In 1.5A
1:43 /1.11.A1 Engine starter Digital Output 3A
1:44 Digital Output 3A
1:45 /9.7.D1 Rotating beacon frame Digital Output 3A
1:46 /9.14.E1 Central lubrication chassi pump Digital Out/In 6A
F 1:47 /1.7.A1 Fan speed control valve PWM Output Group2 F
1:48 /5.2.C1 EHPS power supply PWM Output Group2
1:49 /1.11.B1 Ignition power Digital Out/In 6A
1:50 /5.2.B1 EHPS valve steering PWM Output Group2
E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 150625 A55031.1500 Kretsschema korsreferenser D7971 DRG100-1000 0.0_1
Name
R
Konstr/Design

Wiring diagram crossreferences D7971 A55039.1500 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7972
A A
1:1 Digital Output 1.5A 2:1 Digital Output 6A

1:2 /11.5_5.C5 Power Supply 2:5 Digital Output 6A
1:3 /11.6_1.E1 CAN 2:6 Digital Output 6A
1:4 See pin C1:3 2:7 Dig/Ana Input
1:5 Analog Input 2:8 Dig/Ana Input
1:6 See pin C1:3 2:9 Dig/Ana Input
1:7 See pin C1:3
1:8 5V Analogue Ref 2:10 Dig/Ana Input
1:9 0V Analogue Ref
1:10 /7.10.E8 Digital Output NPN
B B
1:11 Digital Output 1.5A 2:11 Dig/Ana Input
1:12 Digital Out/In 1.5A

1:13 Digital Out/In 1.5A 2:12 Dig/Ana/Freq Input
1:14 Support jacks up Digital Output 1.5A
1:15 Support jacks down Digital Output 1.5A 2:13 Dig/Ana Input
2:14 /7.10.B8 Support jacks left lower position Dig/Ana Input


1:18 Digital Output 1.5A 2:15 /7.10.C8 Support jacks right upper position Dig/Ana Input

1:19 Digital Out/In 1.5A 2:16 /7.10.C8 Support jacks right lower position Dig/Ana Input
C 1:21 Digital Output 1.5A C
1:22 Digital Output 1.5A 2:17 Dig/Ana Input
Digital Input D+
1:27 /7.10.E1 Support jacks up PWM Output Group1 2:19 Dig/Ana Input
1:28 /7.10.F1 Support jacks down PWM Output Group1 2:20 Dig/Ana/Freq Input
1:29 PWM Output Group1
1:30 Digital Output NPN

1:31 See pin C1:3 2:21 Dig/Ana/Freq Input

1:32 See pin C1:3 2:22 /7.10.A1 Digital Output 6A
1:33 PWM Output Group1 2:23 /7.10.A8 Support jacks left upper position Dig/Ana Input
1:34 /9.10.A1 PWM Output Group1 2:24 Ana/Temp/Rheo Input
1:35 /9.10.B1 PWM Output Group1 2:25 Ana/Temp/Rheo Input
D 1:36 PWM Output Group1 2:26 Digital Output 0.5A D
secuted.
1:37 PWM Output Group1 2:28 Dig/Ana/Freq Input

2:29 Ana/Temp/Rheo Input
2:35 PWM 12A
1:40 PWM Output Group1 2:37 PWM 12A
24V See pin C1:2
GND See pin C1:2
E E

1:45 Power supply sensors Options Support jacks Digital Output 3A

1:46 Digital Out/In 6A
1:49 Digital Out/In 6A
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 150625 A55031.1500 Kretsschema korsreferenser D7972 DRG100-1000 0.0_2
Name
R
Konstr/Design

Wiring diagram crossreferences D7972 A55039.1500 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
GND-CUBICLE
/11.5_4.B4
-X232m -X228f -X228m

1 23201 30 GN 0.75 8 8 22808 GN 0.75 30
A -X233m /1.0_A.C6 2 23202 YE 0.75 9 9 22809 YE 0.75

A
9937-201E06 BK 4 2 3 23203 WH 0.75 10 10 22810 WH 0.75
9958-RD-B2 9958-RD-B2 RD 4 1 -D7940 4
/11.5_3.A6
5 23205 30 GN 0.75 11 11 22811 GN 0.75 30
6 23206 YE 0.75 12 12 22812 YE 0.75
-X234f
4
3
5
6
1
B -X210m -XD7940 B
D7971-1:31/J1939_HI 1 21001 GN 0.75 30 1
/11.6_1.A6
D7971-1:32/J1939_LO 2 21002 YE 0.75 2
/11.6_1.A6
-X228f -X228m 3
9958-RD-A2 9958-RD-A2 RD 1.5 4 4 9958-RD-A2 RD 1.5 4
/11.5_3.A6
D7971-1:49 4 21004 WH 0.75 25102 WH 0.75 5
/1.11.B4
-X251m_BB -X251f
1 1 7
2 2 8
3 3
/1.0_A.A3
4 4
-X229f -X229m -X228f -X228m
-D7940
C 1 1 22803 WH 0.75 3 3 25103 WH 0.75
C
Diagnostic 3 3 9937-201E05 BK 0.75
connector 5 5 22801 GN 0.75 1 1 22905 GN 0.75 30
interface 2 2 22802 YE 0.75 2 2 22902 YE 0.75
-XG6600-D+
25104 -X228m -X228f
9937-201E04 BK 2.5 5 5 GND-CUBICLE
/11.5_4.A4
2
-G6600
GND-CUBICLE
+15 /11.5_4.B4
-X210m -XG6600-D+
D7971-1:25 3 21003 WH 0.75 1 D+ B-
/11.4.B5 G
-X9937-203 GND-CHASSIS
D B+ D
secuted.
-M6540
-XM6540-30-1 30 31 -XM6540-31-1
+24V RD 70 BK 70 GND-CHASSIS
/11.5_1.B2 M /11.5_4.B6
50
-Y6450
-X210m -X6450f
D7971-2:34 5 21005 WH 0.75 1 1 2
/9.4.B4
Magnetic clutch, compressor (opt)
E E
-X7590m -XB7590 -B7590 -XB7590

1 75901 WH 0.75 1 1 2 2
2 75902 WH 0.75
Circuit coolant level

F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 150625 A55031.1500 Kretsschema motor, Volvo D13 3B DRG450-1000 1.0_A
Name
R
Konstr/Design

Wiring diagram engine, Volvo D13 3B A55039.1500 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-D7940-1
9958-RD-A2
/1.0_F1.A1 -X7940-1m
-X228f -X228m 1/50
A 9958-RD-A2 9958-RD-A2 RD 2.5 4 4 22804 WH 1.5 2/50 A
/11.5_3.A6
-X228f 3/50
9958-RD-A2 9958-RD-A2 RD 1.5 4 4/50
/11.5_3.A6 9958-RD-B2
/1.0_F1.A1 -X286m_BB -X286f 5/50
-X228f -X228m 1 1 -XD7940-1f 6/50
9958-RD-B2 9958-RD-B2 RD 1.5 6 6 22806 WH 1.5 2 2 2822 WH 0.75 7 7/50
/11.5_3.A6
3 3 2823 WH 0.75 8 8/50
4 4 2824 WH 0.75 9/50
10/50
-X210m 11/50
D7971-1:31/J1939_HI 1 30 GN 0.75 21001
/11.6_1.A6 12/50
21002
-X248m_BB -X248f 13/50
1 1 30 1
B 14/50 B
2 2 21002 24802 GN 0.75 30
15/50
6 6 30 24806 GN 0.75 24804
-XR8200-3f -XR8200-3m 16/50
2 30 24805 A A -X287m_BB -X287f -XD7940-1f
/11.6_1.A6
D7971-1:32/J1939_LO YE 0.75 21002 120 ohm 1 1 17 17/50
21001 3 3 30 B B Termination 2 2 2832 WH 0.75 18 18/50
4 4 21001 24804 YE 0.75 30
3 3 2833 WH 0.75 19/50
5 5 30 28405 YE 0.75 24802
4 20/50
24806
21/50
22/50
D7971-1:49 4 21004 WH 0.75 23/50
/1.11.B4
24/50
/1.0_F1.C1
-X228f -X228m 25/50
C GND-CUBICLE 9937-201E04 BK 2.5 5 5 22805 BK 1.5 26/50 C
/11.5_4.A4
-X288m_BB -X288f -XD7940-1f 27/50
1 1 28 28/50
2 2 2842 BK 0.75 29 29/50
3 3 2843 BK 0.75 30 30/50
4 4 2844 BK 0.75 31/50
5 5 2845 BK 0.75 32/50
6 6 33/50
2846 BK 0.75

34/50
-K3600 35/50
-X210m
D7971-1:43 6 21006 WH 1.5 86 85 -XD7940-1f 36/50
/1.11.A4
30 37 37/50
30 87
24802 38 38/50
D D
Relay, starting solenoid 39 39/50
secuted.
40 40/50
-G6600
-XG6600-D+ W 41/50
-X210m
D7971-1:25 3 21003 WH 1.5 D+ B- -XG6600-B- BK 16 42/50
/11.4.B5 G
43/50
150A
-XG6600-B+ B+ 44/50
-XG6600-B+
-XF9952-3:3 -F9952-3:2 -XF9952-3:4 -XD7940-1f 45/50
9952-304 RD 16
1 2 30 46 46/50
200A RD RD 16 24804 47/50
48/50
-XM6540:30-2 49/50
-XD7940-1f
-M6540 -XM6540:31-2 BK 50 50/50
E 6540-302 RD 16
-XM6540:30-2 E
-XM6540:31-1
-XM6540:30-1 30 31 BK 70 GND-CHASSIS
M /11.5_4.B6
+24V RD 70
/11.5_1.B2 -XM6540:31-3
-XM6540:30-3 50
-XM6540:31-5 6540-315 BK 16
-XM6540:30-4
6540-3004 RD 16
-XM6450:50 ELECTRONIC CONTROL UNIT, ENGINE
-K3120
-XF9952-3:1 -F9952-3:1 -XF9952-3:2 -XK3120:30 -XK3120:87 -XE8000:1 -E8000 -XE8000:2
9952-302 RD 16 30 87 3120-87 WH 16 1 2
1 2 -Y6450
125A /1.0_B1.D5 90A/2160W
F -X210m -X6450f -X6450f
D7971-2:34 5 21005 WH 1.5 1 1 2 2 645002 BK 1.5
F
/9.4.B4
Magnetic clutch, compressor
E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 150625 A55031.1500 Kretsschema motor Cummins, QSM11 3A 150 DRG450-1000 1.0_B
Name
R
Konstr/Design

Wiring diagram engine, Cummins QSM11 3A A55039.1500 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
-X7940-2m -X7940-2f
5/31 5 7940205 WH 0.75 -X7590
WH 0.75 A
C 6/31 6 7940206 WH 0.75 WH 0.75 B C
WH 0.75 C
7/31 7 7940207 WH 0.75 WH 0.75 D
19/31 19 7940219 WH 0.75
-K3120
-XK3120 -XK3120
10/31 10 1 2
7940210 WH 0.75 86 85

/1.0_B.F3
Intake air heater
11/31 11 7940211 WH 0.75
D D
secuted.
-D7940-2
ELECTRONIC CONTROL UNIT, ENGINE
E E
F F

E³ DRAWING
Sign.
Ruta
Sq.
No. Design change Change No. Date Ritad/Drawn MLG 150625 A55031.1500 Kretsschema motor Cummins, QSM11 3A 150 DRG450-1000 1.0_B1
Name
R
Konstr/Design

Wiring diagram engine, Cummins QSM11 3A A55039.1500 07
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X311m
GND-CUBICLE 2 9937-201G06
/11.5_4.D4
-X228m -X233f -X233m /1.0_D.C6
9958-RD-A2 4 9958-RD-A2 BK 4 1 1
/11.5_3.A7
-D7940
ACM
A -X311m RD 2.5 3 3 A
9958-RD-B2 1 9958-RD-B2 RD 4 4 4
/11.5_3.A7
-X210m
D7971-1:31/J1939_HI 1 21001 GN 0.75 30
/11.6_1.A6
D7971-1:32/J1939_LO 2 21002 YE 0.75 -X227m_BB -X227f
/11.6_1.A6
1 1
2 2
6 6
-X227m_BB -X227f
B 3 3 B

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Empty container handler 8-10

9 Frame, body, cab and accessories

G Terminology and index

Workshop Manual DCU80–100 VDU01.01GB

VDU01.01GB Workshop Manual DCU80–100

Cargotec will not accept any responsibility for modifications performed

About the machine version

Cargotec reserves the right to change specifications and equipment

Duplication by any means such as copying, printing, etc., is prohibited.

Workshop Manual DCU80–100 VDU01.01GB

Read operator's manual

Read the operator's manual

Read maintenance manual

refers to important information in the maintenance manual.

Read the maintenance manual

VDU01.01GB Workshop Manual DCU80–100

The workshop manual's contents

The workshop manual is divided into the following sections.

Workshop Manual DCU80–100 VDU01.01GB

Function group structure

The maintenance manual and workshop manual contain different

References are indicated by either section and group numbers, e.g.

References between Maintenance manual and Workshop manual are

VDU01.01GB Workshop Manual DCU80–100

References between different information types

The basic rule of searching for information is to use the function

Function descriptions Hydraulic diagrams

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop Manual DCU80–100 VDU01.01GB

Product alternatives and optional equipment

Special equipment is not described in the manual. If you're uncertain

Equivalent information for different product alternatives is described

Optional equipment refers to options that can be added to standard

Information for optional equipment is described in separate sections

VDU01.01GB Workshop Manual DCU80–100

The machine card indicates which drawings the machine is

If the information on the machine card is inadequate, contact Cargotec.

Workshop Manual DCU80–100 VDU01.01GB

The function descriptions describe the function in a logical flow from

The function descriptions use symbols to illustrate components such as

Example of function description

VDU01.01GB Workshop Manual DCU80–100

Symbol explanation function descriptions

Symbol explanation function descriptions

Pa Pa 23. Temperature sensor

Workshop Manual DCU80–100 VDU01.01GB

About the documentation

Always specify publication number when ordering.

For publication number, see the machine card.

Your feedback is important to be able to improve the information.

VDU01.01GB Workshop Manual DCU80–100

Workshop Manual DCU80–100 VDU01.01GB

VDU01.01GB Workshop Manual DCU80–100

Cargotec has in this publication documented and warned for situations

A near accident is a warning!

Workshop Manual DCU80–100 VDU01.01GB

VDU01.01GB Workshop Manual DCU80–100

Service position means:

Machine with lifting carriage and attachment in

Workshop Manual DCU80–100 VDU01.01GB

Hydraulic system, depressurising

Before the hydraulic system is opened