Professional Documents
Culture Documents
Kalmar Reachstacker Manual
Kalmar Reachstacker Manual
Publ. no VDRF03.02GB
Workshop Manual in original WORKSHOP MANUAL
DRF 400-450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop
manual 2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
A Foreword
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About the machine version ................................................................................ 3
Copyright ........................................................................................................... 3
Reading instructions ................................................................................... 4
Warning information .......................................................................................... 4
Important information ........................................................................................ 4
Read the Operator’s Manual ............................................................................. 4
Read the Maintenance Manual ......................................................................... 4
Workshop manual contents ............................................................................... 5
Function group structure ................................................................................... 6
References between different information types ............................................... 7
Product alternatives and optional equipment .................................................... 8
Machine card ..................................................................................................... 8
Function descriptions ........................................................................................ 9
About the documentation ......................................................................... 12
Documentation sections .................................................................................. 12
Ordering of documentation .............................................................................. 12
Feedback .................................................................................................. 13
Form for copying ............................................................................................. 13
Foreword
mm mm mm mm mm mm
Conditions
page
–
Storage
page
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NOTE
The workshop manual should be accessible to service personnel.
D ANGER
External equipment must only be used if it is
approved by Cargotec.
Danger to life and property!
Copyright
page
–
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
Duplication by any means such as copying, printing, etc., is prohibited.
Reading instructions
Warning information
page
–
D ANGER
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WARN IN G
Situation that may result in serious personal injury if
the instruction is not followed.
C AUTION
Situation that may result in damage to the product if
the instruction is not followed.
Important information
page
–
NOTE
Information that is important without being safety related.
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s manual.
000262
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.
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 function are described under each subfunction.
Consequently, common components are described in several places, but in general
6 Suspension 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
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
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.
Product alternative
Product alternative describes options that are fitted instead of a spe-
cific piece of standard equipment (e.g. engine alternative).
Equivalent information for different product alternatives are described
consecutively in separate segments within the same function group.
To indicate that there are different alternatives, "Product alternative" is
added to the heading together with a simple description of the alterna-
tive, e.g. "(Product alternative Climate control system ECC)". In addi-
tion, the alternative that is an option is marked with the symbol for
optional equipment.
Optional equipment
000264
Machine card
page
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NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
The machine card indicates of which drawings the machine consists,
in many cases these can be associated options and product alterna-
tives. For more information about handling of product alternatives and
optional equipment, see Product alternatives and optional equipment
page 8. The machine card is delivered with the parts catalogue.
The machine card is divided into the same function groups as the
spare parts catalogue, maintenance manual and workshop manual.
For reasons of practicality, the machine card only uses the first and
second level of the function group register. The function groups are
written in groups of four characters, e.g. group 0107 refers to group 1.7
Cooling system in the manual.
For more information on how the machine card is used to order spare
parts, see the foreword of the spare parts catalogue.
If the information on the card machine does not help, contact
Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents. No notification is made regarding changes.
Function descriptions
page
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10
2
3
9
4
8
5
7
6
000520
Operator’s manual
The operator’s manual is supplied with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual.
• Supplier documentation for engine, transmission and drive axle.
Ordering of documentation
page
–
Feedback
Form for copying
page
–
From:
Company / Sender: ..........................................................................................................................................
Telephone:
..........................................................................................................................................................
E-mail:
.................................................................................................................................................................
Manual
information Name / Publication number: .............................................................................................................................
Sugges-
tions, ...........................................................................................................................................................................
views,
remarks,
etc. ...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
B Safety
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurising ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 9
Working under machine .................................................................................... 9
Lifting heavy components ............................................................................... 10
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 11
Solvents .......................................................................................................... 11
Fire and explosion risks ................................................................................... 12
Fluid or gas under pressure ............................................................................ 13
Coolant ............................................................................................................ 14
Refrigerant ...................................................................................................... 14
Air pollution ..................................................................................................... 15
Tensioned springs ........................................................................................... 16
Electric motors ................................................................................................. 16
Rotating components and tools ....................................................................... 17
Tyres and rims ................................................................................................. 18
Lifting equipment ............................................................................................. 18
Spare parts ...................................................................................................... 19
Non-ionised radiation ...................................................................................... 20
Environment ............................................................................................. 21
General ........................................................................................................... 21
Safety
mm mm mm mm mm mm
The safety information concerns everyone who works with the ma-
chine! Persons who do not follow the safety instructions given in this
manual must make absolutely sure that the work is performed without
risks of personal injury and without risk of damage to machine or ma-
chine property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully. 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.
That is why it is important that all who work with the machine, or repair
or service the machine, read and follow the information in the Work-
shop Manual and Operator’s Manual.
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic and brake systems, depressurising page 5
• Oils page 6
• Fuel system page 7
• Clothing, etc. page 8
• Several mechanics on the same machine page 9
• Working under machine page 9
• Lifting heavy components page 10
• Vibrations page 10
• Noise page 11
• Solvents page 11
• Fire and explosion risks page 12
• Fluid or gas under pressure page 13
• Coolant page 14
• Refrigerant page 14
• Air pollution page 15
• Tensioned springs page 16
• Electric motors page 16
• Rotating components and tools page 17
• Tyres and rims page 18
• Lifting equipment page 18
• Spare parts page 19
• Non-ionised radiation page 20
Service position
page
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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, parking brake applied.
• Boom fully retracted and lowered to horizontal position.
• Engine off.
• Main electric power off (with battery disconnector).
003603
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve top lift is closed before the
engine is started after the completion of work.
002269
NOTE
Keep the drain valve open as long as work is in progress.
NOTE
After work is finished, close drain valve and tighten the lock
ring.
Oils
page
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The following safety instructions shall be followed for work when han-
dling oils.
WARN IN G
Warm and pressurised oil.
I M P OR TA NT
Always clean the area around components and
connections before they are loosened. Dirt in oil
systems causes increased wear, resulting in
subsequent material damages.
Fuel system
page
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The following safety instructions shall be followed for work when han-
dling fuel.
D ANGER
Pay attention to the risk of fire when working on the
fuel system.
WARN IN G
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The
engine’s fuel system operates at very high pressure.
The pressure is so high that the jet can injure the skin,
resulting in severe injuries. Risk of personal injuries.
C AUTION
Always clean the area around components and
connections before they are loosened. Dirt in the fuel
may cause malfunctions and engine stop in
undesirable situations as well as increase wear,
resulting in subsequent material damages.
I M P OR TA NT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Clothing, etc.
page
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WARN IN G
If several mechanics are working on the same vehicle,
take extra care so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operator’s station, e.g., movement of
lifting equipment, may cause severe personal injuries.
Safety precautions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in another way.
• Move battery disconnector to position zero, remove the key.
• Be aware of the risks when several persons work around the
vehicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine's both sides at the
same time.
A Risks
Mechanical or hydraulic tools and lifting devices can fall over or acci-
001977
Locks on lift mast for securing the liftable cab in the Safety precautions
raised position.
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.
WARN IN G
Careless handling of heavy components can lead to
serious personal injury and material damage.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make un-
expected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilib-
rium is upset.
A component lifted using an overhead crane may start to swing back
and forth, which can cause severe crushing injuries or material
damage.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, especially
when there are such adapted for certain work. See workshop manual
for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
• Wear gloves. They're good protection against minor crushing in-
juries and cuts to fingers.
• Always use protective shoes.
Vibrations
page
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In case of long-term use of vibrating tools, for example, impact nut run-
ners or grinders, injuries may be sustained as vibrations can be trans-
mitted from tools to hands. Especially when fingers are cold.
Safety precautions
Use heavy gloves to protect against cold and somewhat against
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
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.
Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi-
ness, headaches and nausea. They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent ends up directly on the skin it may dry out and crack. Risk
of skin allergies increases. Solvents may also cause injury if they pen-
etrate through the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety precautions
Avoid inhaling 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 substances. It reduces the
risk of injury.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.
Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing 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, hot welding sparks can cause ignition and explosive fires.
When a battery is charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Today’s machines contain a lot of electronic equipment. When weld-
ing, the control units must be disconnected and the electric power
must be turned off with the battery disconnector. Powerful welding cur-
rents may otherwise short-circuit the electronics, destroy expensive
equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least 10
cm around the welding or cutting point). Use gloves, breathing protec-
tion and protective glasses. Also, welding work may not be done near
plastic or rubber materials without first protecting them from the heat.
Paints, plastics, and rubber develop a number of substances that may
be hazardous to health when heated. Be careful with machines that
have been exposed to intense heat or fire.
Safety precautions
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.
High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for exam-
ple, if it falls onto a hard surface. Gas can stream out through dam-
aged valves.
Risks
Risk of damage/injuries in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre repairs.
• Air conditioning.
Safety precautions
• Use safety glasses and protective gloves.
• Never work on a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
recommended by the manufacturer.
• A hydraulic hose that swells, for example, at a connection, is
about to rupture. Replace it as soon as possible! Check connec-
tions thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulator shall first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands directly to detect a leak. A fine high-pres-
sure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.
Coolant
page
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Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• Open the filler cap first, to release the excess pressure. Open
carefully. Hot steam and coolant can stream out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according
to the manual when working on the air conditioning system. Spe-
cial certification and authorisation is often required of the person
who may do the work. (Note national legislation and local
regulations!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
page
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Air pollution is the impurities in the air around us and which are regard-
ed as hazardous to health. Certain pollution is more prominent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon monoxide (fumes) is present in exhaust fumes. Odour-
less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanised or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases generated when grinding and heating
plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
• Isocyanates are present in certain paints, fillers, adhesives and
foam plastics used on machines.
Risks
Sulphuric acid mist is corrosive and injures the respiratory tracts.
(Generated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
generated.
• Use suitable protective gloves and breathing protection when
there is a risk of oil mist. Make sure that the protection is oil-proof.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.
Tensioned springs
page
–
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 uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety precautions
Always turn off the battery disconnector when working on electric
motors.
Always block the machine’s wheels and make sure that the parking
brake is activated and that the gear selector is in neutral position be-
fore starting any work on the machine.
Risks
Rotating components, for example, 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 precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
D ANGER
Tires shall be regarded as pressure reservoirs. If han-
dled incorrectly, they constitute a fatal danger
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating of wheels: Tires, rims or lock rings may be ejected.
Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings aren’t damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the machine’s lift-
ing equipment in particular, the greatest caution must be exercised
with respect to securing the boom and attachment.
For this reason, always be in the habit of having the boom fully lowered
and fully retracted during work on the machine.
Risks
Risk of crushing if the machine’s lifting equipment is not lowered or
secured.
Risk of crushing is extra high when depressurising the hydraulic sys-
tem, see Hydraulic and brake systems, depressurising page 5.
Safety precautions
• Do not start work until the boom is lowered and fully retracted if
possible.
Spare parts
page
–
WARN IN G
The following parts must, for safety reasons, only be
replaced with original spare parts:
• Brake valve
• Drive axle
• Steering axle
• Steering cylinder
• Rims
• Lift boom
• Lift cylinder
• Extension cylinder
• Tilt cylinder
• Emergency switch
• Frame
• Accumulator
Non-ionised radiation
page
–
WARN IN G
Extra equipment such as communication radio, RMI,
phone, etc. can emit non-ionised radiation.
NOTE
When there are no people with active or inactive products in the
vicinity the phone and communication radio in the cab may be
used.
Equipment should not be used during operation or load handling
as your concentration as operator is reduced.
Cargotec accepts no responsibility for equipment not installed by
Cargotec or with Cargotec approved installation.
Environment
General
page
–
Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to re-use materials in new products. Ac-
cording to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In cer-
tain models, there are lead castings as counterweight.
If the machine is equipped with air conditioning, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.
C Preventive maintenance
C Preventive maintenance
mm mm mm mm mm mm
Maintenance Manual
The information is found in the Maintenance Manual.
For information on how to order the Maintenance Manual, see the
section A Foreword.
0 Complete machine
Complete machine
mm mm mm mm mm mm
instructions
When troubleshooting, it is important that the work is structured and
logical. The point of the troubleshooting described in the maintenance
manual is to exclude components as error source so that the real error
source can be pin-pointed. A suggested structured work method is de-
scribed below.
When troubleshooting, it is important to understand how the machine
functions. Certain malfunctions can be pin-pointed directly using func-
tion descriptions. Sections 0–12 contain descriptions of the various
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 22–30 V.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• Engine oil
• Transmission oil
• Brake system fluid
• 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 error code, example page 5.
In the error code lists there are recommended actions for every
error code. Error code lists are found in section D Error codes.
5 If there is no error code or the problem persists, use the function
description for the function in question in section 0–12.
The function description contains information on which compo-
nents are involved in the function and how these components
work together. In some cases, there is information on what con-
ditions are required in order for it to be possible to activate the
function. Measurement points are marked with flags (C for meas-
uring outlet, D for diagnostic menu).
code, example
1 Choose suitable section 0–12 to find the function and sub-func-
tion that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the func-
tion in question to find where in the function chain that signal or
reaction is incorrect.
4 The fault is probably between the two units where the signal is
failing. Start by checking the component that should send the
signal.
5 If the component that is to send the signal seems to be correct,
check transmission of the signal (electric wiring or hydraulic
hoses).
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses,
see Troubleshooting hydraulic hoses page 8.
6 If the leads or hoses between the components seem in order,
then check the component that receives the signal.
example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It’s impor-
tant to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g., error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
Error code lists are found in section D Error codes.
For detailed instruction on reading out error code, see section D
Error codes.
3 Follow the instructions in the field “Action”.
4 Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control
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 includ-
ed components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.
NOTE
The main electric power shall be turned off with the battery
disconnector!
9 Disconnect the cable from the component in question.
10 Turn on the main electric power with the battery disconnector.
11 Turn the ignition key to the operating position.
12 Check that voltage reaches the component.
Connections
Diagnos- Function
Code Description Limitation Action and
tic menu group
components
34 Signal error from Parking brake Check cabling D791-1/K8:5 - HYD, 4.1.2 Parking
parking brake cannot be between the control S107, K8:13 - menu 5 brake control
switch, indicates re- released. unit and the S107
leased and applied component with
at same time or diagnostic menu.
nothing at all. Check component.
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
C AUTION
Wipe and re-grease the connectors.
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 for the component
in the connector at the control unit or component.
b. The resistance must correspond with the component. Other-
wise there may be an open circuit or short circuit in cable har-
ness and/or component.
5 Check if there is short circuit to frame:
a. Unplug the connector at both the control unit and the compo-
nent in question.
b. Measure the resistance of one lead at a time. Measure be-
tween the lead and a frame-connected part of the machine.
c. The multimeter should show endless resistance.
WARN IN G
Oil under high pressure!
Personal injury!
Always depressurise hydraulic and brake systems
before starting to work on the systems.
1 Engine
1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 23
1.1.1 Ignition switch ...................................................................................... 23
1.1.2 Accelerator pedal ................................................................................. 24
1.2 Fuel system .............................................................................................. 25
1.2.1 Fuel tank .............................................................................................. 25
1.2.2 Sensor, fuel level ................................................................................. 25
1.6 Air intake and exhaust outlet .................................................................... 26
1.6.1 Air cleaning system .............................................................................. 26
1.6.3 Exhaust system ................................................................................... 26
1.6.4 Intercooler ............................................................................................ 27
1.7 Cooling system ......................................................................................... 28
1.7.4 Radiator and expansion tank ............................................................... 29
1.7.5 Cooling fan ........................................................................................... 30
1.7.7 Coolant ................................................................................................ 32
1.7.10 Engine heater ...................................................................................... 35
1.9 Engine control system .............................................................................. 36
1.9.1 Control unit, engine .............................................................................. 36
1.11 Start/stop .................................................................................................. 37
1.11.1 Starter motor ........................................................................................ 37
1.11.2 Stopping device ................................................................................... 37
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
• Volvo TWD1240VE stage II as per Directive 97/68/EC
• Volvo TAD1250VE (stage III as per Directive 97/68/EC)
• Cummins QSM11 (stage III as per Directive 97/68/EC )
If there are differences between engine alternatives, this is written in
brackets after headings or under figures to clarify that which is shown.
Volvo engines have many similarities. Descriptions and instructions
that are the same for both engine alternatives are denominated "(en-
gine alternative Volvo)". If a description or set of instructions only ap-
plies to one engine alternative then the whole engine designation is
written out, for instance "(engine alternative Volvo TAD1250VE).
description
Condition Reference value Reference
Disconnected (when cable is in start lock-out is Engine heater, description page 35
Engine heater
activated)
˚C
0 . bar
P I
rpm
II kph
III D5
10 <˚ 1, 5
D10 D1
2, 11 6, 15 18, 21
D790-1 D790-2 D795
008223
9
2 Cab control unit (D790-1) sends ignition on Checked by control sys- Section 11 Common electrics, group
via the CAN bus. If the key is turned to the tem, error shown with 11.5.3.1 Cab control unit
preheating position, then preheating is error code.
also sent on the CAN bus.
3 If preheating is activated with the start key U = 24 V D3: Diagnostic menu, see section 8 Control
then Control unit, engine (D794) supplies system , group 8.4.6.5 ENGINE, menu 5
power to the preheating element.
4 The preheating coil warms the engine - D3: Diagnostic menu, see section 8 Control
intake air. system , group 8.4.6.5 ENGINE, menu 5
6 Control unit KIT (D790-2) transmits a start Checked by control Section 11 Common electrics, group
signal on the CAN bus. system, error shown 11.5.3.11 Control unit KIT
with error code.
7 The engine control unit (D794) supplies U = 24 V Starter motor, description (engine alterna-
power to the starter motor. tive Volvo) page 37
D7: Diagnostic menu, see section 8 Control
system , group 8.4.6.5 ENGINE, menu 5
8 The starter motor cranks the engine. - Starter motor, description (engine alterna-
tive Volvo) page 37
D7: Diagnostic menu, see section 8 Control
system , group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensors send signals to the Checked by control sys- Section 11 Common electrics, group
engine control unit (D794), which regulates tem, error shown with 11.5.3.10 Engine control unit
the injectors so that the engine starts. error code.
10 The accelerator pedal sends the cab con- U = 0.5–4.5 V Section 9 Frame, body, cab and accesso-
trol unit (D790-1) a voltage signal propor- Lower voltage than 0.5 ries, group 9.1 Controls and instruments
tional to the downward press of the pedal. V and higher voltage D10: Diagnostic menu, see section 8 Con-
than 4.5 V used to de- trol system , group 8.4.6.1 ENGINE,
tect malfunction in cable menu 1
harnesses and controls.
11 The cab control unit (D790-1) transmits a Checked by control sys- Section 11 Common electrics, group
message with the rpm request on the CAN tem, error shown with 11.5.3.1 Cab control unit
bus error code.
12 The engine control unit (D794) increases - Section 11 Common electrics, group
engine speed. 11.5.3.10 Engine control unit
13 The NO switch for coolant level sends a U = 24 V Cooling system, description page 28
voltage signal to Control unit, engine
(D794) if the coolant level in the expansion
tank is low.
14 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine data and warning messages on the tem, error shown with 11.5.3.10 Engine control unit
CAN bus. error code. D14: Diagnostic menu, see section 8 Con-
trol system , group 8.4.6.6 ENGINE,
menu 6 and 8.4.6.7 ENGINE, menu 7
15 The KID control unit (D795) shows engine - Section 11 Common electrics, group
data via display figures. 11.5.3.12 KID control unit
17 Control unit, frame rear (D797-R) transmits Checked by control sys- Section 11 Common electrics, group
fuel level on the CAN bus. tem, error shown with 11.5.3.3 Control unit, frame rear
error code.
18 The KID control unit (D795) displays the - Section 11 Common electrics, group
fuel level in the operating menu for engine. 11.5.3.12 KID control unit
19 The output shaft sensor (B758) sends the - D19: Diagnostic menu, see section 8
transmission control unit (D793) pulses Control system , group 8.4.7.6 TRANSM,
with frequency proportional to output shaft menu 6
rpm.
20 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group
transmits speed on the CAN bus. tem, error shown with 11.5.3.9 Control unit, transmission
error code.
21 The KID control unit (D795) shows the ma- - Section 11 Common electrics, group
chine’s speed. 11.5.3.12 KID control unit
22 If output shaft rpm is so high that it reaches Checked by control sys- Section 11 Common electrics, group
the limit for the machine’s speed limitation, tem, error shown with 11.5.3.1 Cab control unit
the cab control unit (D790-1) transmits a error code.
reduce engine rpm request on the CAN
bus.
23 Control unit engine (D794) restricts engine - Section 11 Common electrics, group
rpm. 11.5.3.10 Engine control unit
function description
(model year-2008)
Condition Reference value Reference
Disconnected (when cable is in start lock-out is Engine heater, description page 35
Engine heater
activated)
˚C
0 . bar
P I
rpm
II kph
III
1, 3
8 <˚
D8 D1 D3
2, 9 4, 13 16, 19
D790-1 D790-2 D795
008224
11 7
2 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group
Ignition on as a start message on the system, error shown 11.5.3.1 Cab control unit
CAN bus. with error code.
3 The ignition switch sends a voltage sig- U = 24 V Ignition switch, description page 23
nal to Control unit KIT (D790-2) when the D2: Diagnostic menu, see section 8 Control
start key is turned to the start position. system , group 8.4.6.4 ENGINE, menu 4
4 The KIT control unit (D790-2) transmits a Checked by control Section 11 Common electrics, group
start signal on the CAN bus. system, error shown 11.5.3.11 Control unit KIT
with error code.
6 The starter motor cranks the engine. - Starter motor, description (engine alternative
Cummins) page 37
7 The engine’s sensors send signals to the - Section 11 Common electrics, group
engine control unit (D794), which 11.5.3.10 Engine control unit
regulates the injectors so that the engine
starts.
8 The accelerator pedal sends the cab U = 0.5–4.5 V Section 9 Frame, body, cab and accessories,
control unit (D790-1) a voltage signal Lower voltage than 0.5 group 9.1 Controls and instruments
proportional to the downward press of V and higher voltage D8: Diagnostic menu, see section 8 Control
the pedal. than 4.5 V used to de- system , group 8.4.6.1 ENGINE, menu 1
tect malfunction in cable
harnesses and controls.
9 The cab control unit (D790-1) transmits a Checked by control Section 11 Common electrics, group
message with the rpm request on the system, error shown 11.5.3.1 Cab control unit
CAN bus with error code.
10 The engine control unit (D794) controls - Section 11 Common electrics, group
engine speed. 11.5.3.10 Engine control unit
11 The NO switch for coolant level sends a U = 24 V Cooling system, description page 28
voltage signal to Control unit, engine
(D794) if the coolant level in the expan-
sion tank is low.
12 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine data and warning messages on tem, error shown with 11.5.3.10 Engine control unit
the CAN bus. error code. D12: Diagnostic menu, see section 8 Control
system , group 8.4.6.6 ENGINE, menu 6 and
8.4.6.7 ENGINE, menu 7
13 The KID control unit (D795) shows en- - Section 11 Common electrics, group
gine data via display figures. 11.5.3.12 KID control unit
14 The fuel level sensor (B757) sends a U = 0.5–4.5 V Sensor, fuel level, description page 25
voltage signal to Control unit, frame rear Lower voltage than 0.5 D14: Diagnostic menu, see section 8 Control
(D797-R) proportional to the fuel level in V and higher voltage system , group 8.4.3.7 CAB, menu 7
the tank. than 4.5 V used to de-
tect malfunction in cable
harnesses and controls.
15 Control unit, frame rear (D797-R) Checked by control Section 11 Common electrics, group
transmits fuel level on the CAN bus. system, error shown 11.5.3.3 Control unit, frame rear
with error code.
16 The KID control unit (D795) displays the - Section 11 Common electrics, group
fuel level in the operating menu for 11.5.3.12 KID control unit
engine.
18 The transmission control unit (D793) Checked by control Section 11 Common electrics, group
transmits speed information on the CAN system, error shown 11.5.3.9 Control unit, transmission
bus. with error code.
19 The KID control unit (D795) shows the - Section 11 Common electrics, group
machine’s speed. 11.5.3.12 KID control unit
20 If the speed is at the machine’s speed Checked by control Section 11 Common electrics, group
limitation limit, the cab control unit system, error shown 11.5.3.1 Cab control unit
(D790-1) transmits an engine speed with error code.
reduction request on the CAN bus.
function description
(model year 2009-)
Condition Reference value Reference
Disconnected (when cable is in start lock-out is Engine heater, description page 35
Engine heater
activated)
0 . bar
P I
rpm
II kph
III
1, 3
8
D8 D1 D3
2, 9 4, 14 17, 20
D790-1 D790-2 D795
013025a
11
7
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
Ignition on as a start message on the tem, error shown with 11.5.3.1 Cab control unit
CAN bus. error code.
3 The ignition switch sends a voltage sig- U = 24 V Ignition switch, description page 23
nal to Control unit KIT (D790-2) when the D2: Diagnostic menu, see section 8 Control
start key is turned to the start position. system , group 8.4.6.4 ENGINE, menu 4
4 The KIT control unit (D790-2) transmits a Checked by control sys- Section 11 Common electrics, group
start signal on the CAN bus. tem, error shown with 11.5.3.11 Control unit KIT
error code.
6 The starter motor cranks the engine. - Starter motor, description (engine alternative
Cummins) page 37
7 The engine’s sensors send signals to the - Section 11 Common electrics, group
engine control unit (D794), which regu- 11.5.3.10 Engine control unit
lates the injectors so that the engine
starts.
8 The accelerator pedal sends the cab U = 0.5–4.5 V Section 9 Frame, body, cab and accessories,
control unit (D790-1) a voltage signal Lower voltage than 0.5 group 9.1 Controls and instruments
proportional to the downward press of V and higher voltage D8: Diagnostic menu, see section 8 Control
the pedal. than 4.5 V used to de- system , group 8.4.6.1 ENGINE, menu 1
tect malfunction in cable
harnesses and controls.
9 The cab control unit (D790-1) transmits a Checked by control Section 11 Common electrics, group
message with the rpm request on the system, error shown 11.5.3.1 Cab control unit
CAN bus with error code.
10 The engine control unit (D794) controls - Section 11 Common electrics, group
engine speed. 11.5.3.10 Engine control unit
11 The NO switch for coolant level grounds Low coolant level: U Cooling system, description page 28
the control terminal of the coolant level K322:85 = 0 V
relay (K322) if the coolant level is low in
the expansion tank.
12 Coolant level relay (K322) breaks the cir- - Cooling system, description page 28
cuit to Control unit, engine (D794) if the
coolant level is low in the expansion
tank.
13 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine data and warning messages on tem, error shown with 11.5.3.10 Engine control unit
the CAN bus. error code. D13: Diagnostic menu, see section 8 Control
system , group 8.4.6.6 ENGINE, menu 6 and
8.4.6.7 ENGINE, menu 7
14 The KID control unit (D795) shows en- - Section 11 Common electrics, group
gine data via display figures. 11.5.3.12 KID control unit
15 The fuel level sensor (B757) sends a U = 0.5–4.5 V Sensor, fuel level, description page 25
voltage signal to Control unit, frame rear Lower voltage than 0.5 D15: Diagnostic menu, see section 8 Control
(D797-R) proportional to the fuel level in V and higher voltage system , group 8.4.3.7 CAB, menu 7
the tank. than 4.5 V used to de-
tect malfunction in cable
harnesses and controls.
17 The KID control unit (D795) displays the - Section 11 Common electrics, group
fuel level in the operating menu for 11.5.3.12 KID control unit
engine.
18 The output shaft sensor (B758) sends - D18: Diagnostic menu, see section 8 Control
the transmission control unit (D793) system , group 8.4.7.6 TRANSM, menu 6
pulses with frequency proportional to
output shaft rpm.
19 The transmission control unit (D793) Checked by control Section 11 Common electrics, group
transmits speed information on the CAN system, error shown 11.5.3.9 Control unit, transmission
bus. with error code.
20 The KID control unit (D795) shows the - Section 11 Common electrics, group
machine’s speed. 11.5.3.12 KID control unit
21 If the speed is at the machine’s speed Checked by control Section 11 Common electrics, group
limitation limit, the cab control unit system, error shown 11.5.3.1 Cab control unit
(D790-1) transmits an engine speed with error code.
reduction request on the CAN bus.
20
19
8
18 9
10
17 11
16
001641
15 14 13 12
8. Fuel connection (intake) 17. Oil pressure and oil temperature sensor
1 2 3 4 5 6
10
003160
17 16 15 14 13 12 11
Engine alternative, Volvo TWD1240VE, left side (in machine’s
direction of travel)
4 5
1 2 3 6
10
11
12
13
14
15
16
17
18
19
20
21
006446
Volvo TAD1250VE engine right side (in machine’s direction of travel)
006400
10 9 8
Volvo TAD1250VE engine, left side (in machine’s direction of travel)
component location
1 2 3
12
001643
11 10 9 8 7 6 5 4
Engine alternative, Cummins, right side (in machine’s direction of
travel)
1. Location for air conditioning compressor 7. Draining of condensation from fuel filter and water-in-fuel sensor
2. Fuel connection (outlet) 8. Fuel filter
3. Engine control unit (D794) 9. Sensor fuel pressure
4. Engine oil drain plug 10. Fuel pump
5. Starter motor 11. Oil pressure and oil temperature sensor
6. Fuel connection (intake) 12. Crankshaft position sensor
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15
16
25
17
24 18
003163
23 22 21 20 19
Engine alternative, Cummins, left side (in machine’s direction of travel)
NOTE
Drain and collect liquids before detaching hoses.
3 Attach hoisting equipment to the engine.
NOTE
Do not lift the engine or transmission.
Assembly
10 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.
11 Fit the engine or transmission brackets.
Tighten to a torque of 168 Nm.
12 Connect the engine to the transmission.
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.
NOTE
Drain and collect liquids before detaching hoses.
4 Use a jack to secure the transmission.
6 Rotate the engine for each bolt in the flex plate that has to be
removed.
7 Remove the screws of the flex plate through the hole under the
cover washer.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
9 Remove the bolts between engine and transmission.
10 Loosen the engine and transmission brackets.
11 Withdraw the engine rearwards to separate it from the
transmission.
Assembly
12 Rotate the engine so that the holes in the flywheel are just in front
of the attachment points on the flex plate.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
13 Fit the bolts to the engine and transmission brackets. Tighten to
a torque of 168 Nm.
14 Connect the engine to the transmission.
15 Fit the bolts between engine and transmission. Tighten to a
torque of 52 Nm.
16 Fit the flex plate’s attaching bolts. Tighten to a torque of 40 Nm.
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
17 Fit the plug in front of the flywheel.
18 Remove the hoisting equipment from the engine.
19 Remove the jack from underneath the transmission.
20 Connect the requisite hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.
P No function.
0 Stop position. Everything switched off; key can be removed.
I Operating position.
Voltage to all electrical functions. Engine and transmission con-
trol units are now ready for start.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.1.4 CAN/POWER, menu 4.
II Preheating position.
In the preheating position the engine’s intake air is heated by the
electric heater to a suitable temperature. The preheating lamp il-
luminates during preheating.
The signal can be checked from the diagnostic menu, see section
0 8 Control system , group 8.4.6.4 ENGINE, menu 4.
III Start position.
P I
Engagement of starter motor for engine start.
II NOTE
The machine is equipped with an electric restart interlock,
which prevents engagement of the starter motor when the
engine is rotating.
000317
III
Conditions for starter motor engagement are that
transmission is in neutral position and the engine is not
already running.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.6.4 ENGINE, menu 4.
1. Brake pedal
2. Accelerator pedal
The fuel system distributes fuel between the cylinders and thereby
controls the engine output power and rpm.
When the engine is started, the fuel pump sucks fuel from the tank
through the fuel filter and forces it to the unit injections. The unit injec-
tors spray in the fuel and atomises the fuel to the engine’s combustion
chamber.
The fuel tank is located on the left-hand side of the machine behind the
brake fluid reservoir.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.7 CAB, menu 7.
002289
1 2 3
1. Fuel filler orifice
2. Fuel tank
3. Sensor, fuel level (behind air filter)
001357
5
WARN IN G
001356
1.6.4 Intercooler
Intercooler, description
page
–
3
003215
The engine is water-cooled and has passages through which the cool-
ant from the radiator flows round a closed system.
Main parts of the cooling system:
• Coolant pump
• Expansion tank
• Thermostat
• Cooling fan
• Radiator
• Engine oil cooler
• Intercooler
• Coolant filter
How the engine cooling system works:
1. The coolant pump pumps coolant through the cylinder head, en-
gine block and oil cooler. On the engine alternative Volvo
TWD1240VE a separate coolant pump pumps coolant through the
intercooler.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening tempera-
ture it is pumped back to the engine.
When the coolant is warmer than the thermostat opening temper-
ature it is pumped through the radiator and then back to the cool-
ant pump.
4. The expansion tank allows the coolant to expand without escap-
ing from the engine.
Radiator for the engine is located in the cooling unit which is fitted be-
hind the engine.
The purpose of the cooler assembly is to cool:
1 • Engine coolant
• Transmission oil (cooled in the lower part of the cooling unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
• The charge air (engine alternative Volvo TAD1250VE and Cum-
mins QSM11) is cooled in the upper cooling unit), see also Inter-
cooler, description page 27.
Engine alternative Volvo TWD1240VE has water-air intercooler
mounted directly on the engine.
Also refer to Cooling system, description page 28.
For more information, see supplier documentation, engine.
4
1
3
003215
2
003214
1.7.7 Coolant
Coolant, changing (engine alternative Volvo)
page
–
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
C
004851
C AUTION
Different types of coolant cannot be mixed.
8 Open the bleed nipple to release the air and speed up the filling.
Close the bleed nipple when clean coolant without air bubbles is
flowing out.
9 Turn on the main electric power and start the engine.
10 Turn on max. heat in the cab.
11 Run the engine to operating temperature so the thermostat
opens and coolant is pumped around the whole system.
12 Check the level in the expansion tank, fill if required.
13 Check the coolant level again after 10 operating hours.
QSM11)
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety
C
004851
C AUTION
Different types of coolant cannot be mixed.
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo)
page
–
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the engine
control unit (D794).
For more information, see supplier documentation, engine.
Cummins)
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by Control unit,
frame rear (D797-R).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.6.5 ENGINE, menu 5.
For more information, see supplier documentation, engine.
NOTE
The battery disconnect switch must not be used for emergency
stop!
For more information, see supplier documentation, engine.
2 Transmission
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 21
2.1.1 Gear selector and multi-function lever ................................................. 21
2.2 Torque converter/Clutch system .............................................................. 22
2.2.1 Flex plates ........................................................................................... 22
2.6 Lubrication system ................................................................................... 26
2.6.3 Oil cooler .............................................................................................. 29
2.7 Cooling system ......................................................................................... 31
2.7.3 Oil cooler .............................................................................................. 31
2.8 Transmission control system .................................................................... 32
2.8.1 Control unit transmission ..................................................................... 32
2.8.2 Normally closed (NC) switch, disengagement ..................................... 32
2.8.3 Transmission cable harness ................................................................ 32
2 Transmission
mm mm mm mm mm mm
Transmission, general
page
–
F
R
1
D1
22 5
D22
D5
6, 23 2, 7 19
D790-1 D790-2 D795
D8 8 12 13 14 15 24
Pa
4 17
11
3
002212
Pos Explanation Signal description Reference
1 The gear selector sends a voltage sig- Forward, Conn. F: Section 9 Frame, body, cab and accessories,
nal to the KIT control unit (D790-2). U = 24 V group 9.1 Controls and instruments
Reverse, Conn. R: D1: Diagnostic menu, see section 8 Control
U = 24 V system , group 8.4.7.2 TRANSM, menu 2
2 The KIT control unit (D790-2) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.11
mits the selected direction of travel tem, error shown with KIT control unit
(forward or reverse) on the CAN bus. error code.
5 The accelerator pedal transmits a sig- U = 0.5-4.5 V Section 1 Engine, group 1.1.2
nal to the cab control unit (D790-1). Accelerator pedal
D5: Diagnostic menu, see section 8 Control
system , group 8.4.6.1 ENGINE, menu 1
7 The KIT control unit (D790-2) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.11
mits the selected shifting program on tem, error shown with KIT control unit
the CAN bus. error code.
8 The oil pressure sensor sends the Checked by Control unit D8: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error system , group 8.4.7.10 TRANSM, menu 10
voltage signal proportional to oil pres- shown with error code.
sure.
9 The engine speed and oil temperature Checked by Control unit D9: Diagnostic menu, See Section 8 Control
sensor (B758/766) sends the trans- transmission, error system , group 8.4.7.6 TRANSM, menu 6 and
mission control unit (D793) a pulse shown with error code. 8.4.7.10 TRANSM, menu 10
signal with frequency proportional to
engine speed and a voltage signal
proportional to the transmission oil
temperature.
10 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group 11.5.3.9
supplies voltage to valve block trans- transmission, error Transmission control unit
mission control to obtain desired func- shown with error code.
tion.
12 The turbine speed sensor (B751) Checked by Control unit D12: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error system , group 8.4.7.6 TRANS, menu 6
(D793) a pulse signal with frequency shown with error code.
proportional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit D13: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error system , group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- shown with error code.
tional to drum speed.
14 The output shaft speed sensor (B758) Checked by Control unit D14: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error system , group 8.4.7.6 TRANSM, menu 6
(D793) a pulse signal with frequency shown with error code.
proportional to output shaft speed.
15 The torque converter temperature Checked by Control unit D15: Diagnostic menu, see section 8 Control
switch (S221) sends the transmission transmission, error system , group 8.4.7.10 TRANSM, menu 10
control unit (D793) a voltage signal if shown with error code.
oil temperature in the torque converter
becomes too high.
17 The oil cooler cools the transmission - Oil cooler, description page 31
oil. A thermostat senses the oil’s tem-
perature and directs the oil back to the
transmission if the oil is cold.
18 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group 11.5.3.9
transmits temperature and speed data tem, error shown with Transmission control unit
on the CAN bus. error code.
19 The KID control unit (D795) shows Checked by control sys- Section 11 Common electrics, group 11.5.3.12
transmission information in operating tem, error shown with KID control unit
menus. error code.
20 If the signal from the output shaft - D15: Diagnostic menu, see section 8 Control
speed sensor (B758) indicates that system , group 8.4.7.6 TRANSM, menu 6
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine speed
reduction request on the CAN bus.
21 The engine control unit (D794) reduc- - Section 11 Common electrics, group 11.5.3.10
es engine speed. Engine control unit
22 If the clutch pedal (S220-1) is de- U = 24 V Section 9 Frame, body, cab and accessories,
pressed, it sends a voltage signal to group 9.1 Controls and instruments
the cab control unit (D790-1). D22: Diagnostic menu, see section 8 Control
system , group 8.4.7.1 TRANSM, menu 1
23 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits disengage drive on CAN bus. tem, error shown with Cab control unit
error code.
24 Normally closed (NC) switch, disen- Brake pressure above Normally closed (NC) switch, disengagement,
gagement (S220-2) sends the Control 0.2 MPa: description page 32
unit, frame front (D797-F) a voltage Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control
signal if brake pressure is high system , group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
enough to allow drive disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
25 Control unit, frame front (D797-F) Checked by control sys- Section 11 Common electrics, group 11.5.3.2
transmits disengagement approved tem, error shown with Control unit, frame front
on the CAN bus. error code.
26 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group 11.5.3.9
supplies voltage to valve block trans- transmission, error Transmission control unit
mission control so that drive is disen- shown with error code.
gaged.
F
R
1
D1
30 5 D1
D30 D5
6, 31 2, 7 27
D790-1 D790-2 D795
D13 D8 D10
8 9 10 20 21 22 D32
Pa
Pa Pa
23
D11 32
4 19
18 11
17
3 16
15 25
14
010494
13
2 The KIT control unit (D790-2) transmits Checked by control system, Section 11 Common electrics, group
the selected direction of travel (forward error shown with error code. 11.5.3.11 KIT control unit
or reverse) on the CAN bus. D1: Diagnostic menu, see section 8 Control
system , group 8.4.7.2 TRANSM, menu 2
5 The accelerator pedal transmits a sig- U = 0.5-4.5 V Section 1 Engine, group 1.1.2 Accelerator
nal to the cab control unit (D790-1). pedal
D5: Diagnostic menu, see section 8 Control
system , group 8.4.6.1 ENGINE, menu 1
7 The KIT control unit (D790-2) transmits Checked by control system, Section 11 Common electrics, group
the selected shifting program on the error shown with error code. 11.5.3.11 KIT control unit
CAN bus.
8 Pressure sensor gear 1/3 (B6067) Checked by Control unit D8: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error shown system , group 8.4.7.10 TRANSM,
(D793) a voltage signal proportional to with error code. menu 10
oil pressure.
9 Pressure sensor gear 2/4 (B6069) Checked by Control unit D8: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error shown system , group 8.4.7.10 TRANSM,
(D793) a voltage signal proportional to with error code. menu 10
oil pressure.
10 Sensor, engine speed (B7530) sends a Checked by Control unit D10: Diagnostic menu, see section 8 Con-
pulse signal with frequency proportion- transmission, error shown trol system , group 8.4.7.6 TRANSM,
al to the engine speed to Control unit, with error code. menu 6
transmission (D793).
11 The oil temperature sensor (B7660) Checked by Control unit D11: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system , group 8.4.7.10 TRANSM,
(D793) a voltage signal proportional to with error code. menu 10
transmission oil temperature.
12 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group
supplies voltage to the solenoid and transmission, error shown 11.5.3.9 Transmission control unit
servo valves to obtain the desired func- with error code.
tion.
13 Solenoid valve drive forward (Y6066F) Checked by Control unit D13: Diagnostic menu, See Section 8 Con-
14 or Solenoid valve drive reverse transmission, error shown trol system , group 8.4.7.7 TRANSM, menu
(Y6066R) and Servo valve gear for- with error code. 7 , 8.4.7.8 TRANSM, menu 8 and 8.4.7.9
15
ward/reverse (Y6300) are activated to TRANSM, menu 9
16 select the direction of travel.
17 Solenoid valve gear selection 1/3
18 (Y6075) and Servo valve gear 1/3
(Y6067) or Solenoid valve gear selec-
19
tion 2/4 (Y6074) and Servo valve gear
2/4 (Y6069) are activated to select gear
position.
The engine’s power is transferred to
the transmission’s output shaft.
20 The turbine speed sensor (B7510) Checked by Control unit D10: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system , group 8.4.7.6 TRANS, menu 6
(D793) a pulse signal with frequency with error code.
proportional to turbine speed.
22 The output shaft speed sensor (B7580) Checked by Control unit D10: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system , group 8.4.7.6 TRANSM,
(D793) a pulse signal with frequency with error code. menu 6
proportional to output shaft speed.
23 The torque converter temperature Checked by Control unit D11: Diagnostic menu, see section 8 Con-
switch (S2210) sends the transmission transmission, error shown trol system , group 8.4.7.10 TRANSM,
control unit (D793) a voltage signal if oil with error code. menu 10
temperature in the torque converter be-
comes too high.
24 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group
controls gear shifting according to se- transmission, error shown 11.5.3.9 Transmission control unit
lected shifting program. with error code.
25 The oil cooler cools the transmission - Oil cooler, description page 31
oil. A thermostat senses the oil’s tem-
perature and directs the oil back to the
transmission if the oil is cold.
26 The transmission control unit (D793) Checked by control system, Section 11 Common electrics, group
transmits temperature and speed data error shown with error code. 11.5.3.9 Transmission control unit
on the CAN bus.
27 The KID control unit (D795) shows Checked by control system, Section 11 Common electrics, group
transmission information in operating error shown with error code. 11.5.3.12 KID control unit
menus.
28 If the signal from the output shaft speed - D10: Diagnostic menu, see section 8 Con-
sensor (B7580) indicates that machine trol system , group 8.4.7.6 TRANSM,
speed exceeds the speed limitation, menu 6
the transmission control unit (D793)
transmits a engine speed reduction re-
quest on the CAN bus.
29 The engine control unit (D794) reduces - Section 11 Common electrics, group
engine speed. 11.5.3.10 Engine control unit
30 If the clutch pedal (S220-1) is de- U = 24 V Section 9 Frame, body, cab and accesso-
pressed, it sends a voltage signal to the ries, group 9.1 Controls and instruments
cab control unit (D790-1). D30: Diagnostic menu, see section 8 Con-
trol system , group 8.4.7.1 TRANSM,
menu 1
31 The cab control unit (D790-1) transmits Checked by control system, Section 11 Common electrics, group
disengage drive on CAN bus. error shown with error code. 11.5.3.1 Cab control unit
33 Control unit, frame front (D797-F) Checked by control system, Section 11 Common electrics, group
transmits disengagement approved on error shown with error code. 11.5.3.2 Control unit, frame front
the CAN bus.
34 The transmission control unit (D793) Checked by Control unit Section 11 Common electrics, group
supplies voltage to valve block trans- transmission, error shown 11.5.3.9 Transmission control unit
mission control so that drive is disen- with error code.
gaged.
description (transmission
alternative Dana)
Fwd 2/4 Rev 1/3
9 11 13 15
7
RSP
38 6
8
10 12 14 16
5
37 39
18
36 17
19 20 21 22
Rev Fwd VFS 2/4 VFS 1/3
34 35 3 4
23 24 25 26
1/3 2/4
33 2
Fwd 2:nd 4:th Rev 1:st 3:rd
1
27 28 29 30 31 32
008210
Pos Explanation Signal description Reference
1. Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2. The transmission’s oil pump 1 feeds the trans- 100.5 l/min at 1973 rpm -
mission with control pressure for control of the
transmission.
4. The bypass valve in the filter bracket leads the oil Opening pressure: 410-450 -
past the filter if the resistance through the filter kPa
becomes too high.
7. Solenoid valve neutral position (RSP) (Y6066) - Diagnostic menu, see section 8
controls Valve spool neutral position. Control system , group 8.4.7.7
TRANSM, menu 7
9. Solenoid valve drive forward (Y630) controls 0-600 kPa Diagnostic menu, see section 8
Pressure booster drive forward. Control system , group 8.4.7.8
TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
11. Solenoid valve gear 2/4 (Y6069) controls Pres- 0-600 kPa Diagnostic menu, see section 8
sure booster gear 2/4. Control system , group 8.4.7.8
TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
12. Pressure booster gear 2/4 increases the pres- 0-2000 kPa -
sure and feeds Valve slide gear selection 2/4 as
well as Valve slide gear 2/4 control.
13. Solenoid valve drive reverse controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster drive reverse. Control system , group 8.4.7.8
TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
15. Solenoid valve 1/3 (Y6067) controls Pressure 0-600 kPa Diagnostic menu, see section 8
booster gear 1/3. Control system , group 8.4.7.8
TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
16. Pressure booster gear 1/3 increases the pres- 0-2000 kPa -
sure and feeds Valve slide gear selection 1/3 as
well as Valve slide gear 1/3 control.
19. The valve spool for reverse drive control opens 0-2000 kPa
when the reverse drive clutch is pressurised and
leads a pressure signal to the drive control valve.
20. The valve spool for forward drive control opens 0-2000 kPa -
when the forward drive clutch is pressurised and
leads a pressure signal to the drive control valve.
21. Solenoid valve VFS 2/4 (Y6074) controls servo 1200 kPa Diagnostic menu, see section 8
pressure to Valve slide gear selection 2/4. Control system , group 8.4.7.7
TRANSM, menu 7
23. The valve slide for gear 1/3 control opens when 0-2000 kPa -
valve slide gear selection 1/3 is pressurised and
leads a pressure signal to the drive control valve.
24. The valve slide for gear 2/4 control opens when 0-2000 kPa -
valve slide gear selection 2/4 is pressurised and
leads a pressure signal to the drive control valve.
25. Valve slide gear selection 2/4 pressurises drive 0-2000 kPa -
clutch gear 2 or drive clutch gear 4.
26. Valve spool gear selection 1/3 pressurises Drive 0-2000 kPa -
clutch gear 1 or Drive clutch gear 3.
33. The transmission oil pump pumps oil through the 85.1 l/min at 1973 rpm -
cooler and supplies the torque converter with oil
pressure to run the machine.
35. The bypass valve in the filter bracket leads the oil - -
past the filter if the resistance through the filter
becomes too high.
39. The safety valve leads the oil back to the sump if Opening pressure: 900 kPa -
the pressure in the torque converter becomes
too high.
description (transmission
alternative Dana full flow)
30
28
5
6 11 17
16 22
27 Pa Pa
29
7 12 18
26 8 13 19
24 25 3 4
31
Rev Fwd 1st 3rd 2nd 4th
23 2
9 10 14 15 20 21
1
013040
Pos Explanation Signal description Reference
1 Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2 The transmission’s oil pump 1 feeds the trans- 30.4 l/min at 685 rpm -
mission with control pressure for control of the
transmission.
4 The bypass valve in the filter bracket leads the Opening pressure: 410-450 kPa -
oil past the filter if the resistance through the
filter becomes too high.
6 Servo valve front/rear (Y6300) controls pres- - Diagnostic menu, see section 8
sure to Valve travel direction, proportional to Control system , group 8.4.7.7
the desired traction. TRANSM, menu 7
7 Solenoid valve drive forward (Y6066F) or So- - Diagnostic menu, see section 8
lenoid valve drive reverse (Y6066R) controls Control system , group 8.4.7.8
Valve travel direction for drive forward or re- TRANSM, menu 8 and 8.4.7.9
verse. TRANSM, menu 9
Depending on the solenoid valve activated,
Valve travel direction controls pressure to
drive clutch forward or drive clutch reverse.
9 Drive clutch reverse locks the transmission in Drive reverse: 2200-2600 kPa -
reverse drive when the clutch is pressurised..
10 Drive clutch forward locks the transmission in Drive forward: 2200-2600 kPa -
forward drive when the clutch is pressurised.
11 Servo Valve 1/3 (Y6067) controls pressure to - Diagnostic menu, see section 8
Solenoid valve gear selection gear 1/3 Control system , group 8.4.7.8
(Y6075) proportional to the desired engage- TRANSM, menu 8 and 8.4.7.9
ment force. TRANSM, menu 9
12 Solenoid valve gear selection gear 1/3 - Diagnostic menu, see section 8
(Y6075) pressurises Drive clutch gear 1 or Control system , group 8.4.7.7
Drive clutch gear 3. TRANSM, menu 7
14 Drive clutch gear 1 locks the transmission in Gear selected: 2200-2600 kPa -
gear position 1 when the clutch is pressurised.
15 Drive clutch gear 3 locks the transmission in Gear selected: 2200-2600 kPa -
gear position 3 when the clutch is pressurised.
16 Pressure sensor gear 1/3 (B6067) sends the - Diagnostic menu, see section 8
transmission control unit (D793) a voltage sig- Control system , group 8.4.7.10
nal proportional to engagement pressure. TRANSM, menu 10
17 Servo Valve 2/4 (Y6069) controls pressure to - Diagnostic menu, see section 8
Solenoid valve gear selection gear 1/3 Control system , group 8.4.7.8
(Y6075) proportional to the desired engage- TRANSM, menu 8 and 8.4.7.9
ment force. TRANSM, menu 9
18 Solenoid valve gear selection gear 2/4 - Diagnostic menu, see section 8
(Y6074) pressurises Drive clutch gear 1 or Control system , group 8.4.7.7
Drive clutch gear 3. TRANSM, menu 7
20 Drive clutch gear 2 locks the transmission in Gear selected: 2200-2600 kPa -
gear position 2 when the clutch is pressurised.
21 Drive clutch gear 4 locks the transmission in Gear selected: 2200-2600 kPa -
gear position 4 when the clutch is pressurised.
22 Pressure sensor gear 2/4 (B6069) sends the - Diagnostic menu, see section 8
transmission control unit (D793) a voltage sig- Control system , group 8.4.7.10
nal proportional to engagement pressure. TRANSM, menu 10
23 The transmission oil pump pumps oil through 15.8 l/min at 685 rpm -
the cooler and supplies the torque converter
with oil pressure to run the machine.
29 The safety valve leads the oil back to the Opening pressure: 900 kPa -
sump if the pressure in the torque converter
becomes too high.
31 The oil temperature sensor (B7660) sends the - Diagnostic menu, see section 8
transmission control unit (D793) a voltage sig- Control system , group 8.4.7.10
nal proportional to oil temperature. TRANSM, menu 10
2
1
6
5
3 4
9
10
11 8
12
006768
15 14 13 7
1 2 3 4 5
11
6
10 7
006752
1. Accelerator pedal (B690) 7. Transmission control unit (D793)
2. Control unit KIT (D790-2) 8. Diagnostic socket, transmission
3. Control unit KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. NO switch, declutch (S220-2)
5. Control unit cab (D790-1) 11. Control unit frame front (D797-F)
6. Control unit frame rear (D797-R)
3 7
2 6
4 5
18
19
20
21
22 17 8
9
013433
25 23 10
24 16 15 14 13 12 11
1 2 3 4 5
11
6
10 7
006752
1. Accelerator pedal (B690) 7. Transmission control unit (D793)
2. Control unit KIT (D790-2) 8. Diagnostic socket, transmission
3. Control unit KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. NO switch, declutch (S220-2)
5. Control unit cab (D790-1) 11. Control unit frame front (D797-F)
6. Control unit frame rear (D797-R)
separation
Engine alternative Volvo: see section 1 Engine , group 1 Engine and
transmission separation (Engine alternative Volvo).
Engine alternative Cummins: see section 1 Engine , group 1 Engine
and transmission separation (Engine alternative Cummins).
The signal can be checked from the diagnostic menu, see section 8
R
Control system , group 8.4.7.2 TRANSM, menu 2.
4 Turn the engine for each bolt to be removed from the flex plate.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.
Cummins QSM11)
1 Machine in service position, see section B Safety.
2 Remove the cover plate.
3 Remove the bolts for the flex plate.
4 Turn the engine for each bolt to be removed from the flex plate.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be over filled!
1 Operate and warm up the transmission oil.
2 Machine in service position, see section B Safety.
3 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
A
013334
B C NOTE
Read the safety instructions for oil before working, see section B
Safety.
The transmission’s oil filler pipe and dipstick (position B) are located
under the service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 60-65 °C in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the dipstick before checking.
A NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if required (for volume and grade,
see section F Technical data).
013334
The transmission oil is cooled in the lower section of the cooling unit.
A temperature-controlled bypass valve, which only acts on the trans-
mission oil cooling circuit, is located in a pipe on the underside of the
1 cooler (engine side). The valve closes when the oil starts to reach
working temperature. This means that the oil reaches normal working
temperature more quickly.
For more detailed information, see supplier documentation, transmis-
sion.
3
003215
4
Cooling unit, engine alternative Cummins QSM11 and
Volvo TAD1250VE 3
1. Intercooler
2. Radiator, engine
3. Transmission oil cooler
4. Transmission oil thermostat
5. Condenser mounting (to AC)
2
003214
NOTE
Read the safety instructions for oil before working, see section B
Safety.
I M P OR TA NT
007447
6 Fill with transmission oil; see Oil and oil filter, changing page 26.
7 Start the engine and check for leaks.
8 Check the transmission oil level; see Oil level, check page 28.
description
The NC switch for disengagement detects if the wheel brakes are
1 pressurised. The NC switch is located on the distribution block for the
10
2 brake system, above the drive axle’s differential.
1
3 The sensor can be checked from the diagnostic menu, see section 8
3 Control system , group 8.4.7.1 TRANSM, menu 1.
4
5
5
9 6
8 7
000439
3 Driveline/axle
3 Driveline/axle .................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 3
3.3 Drive axle ................................................................................................... 4
3 Driveline/axle
mm mm mm mm mm mm
D ANGER
Drive axle and machine are very heavy.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
004501
2
1. Hydraulic hoses
2. Cables
6 Remove the casing (position 3) on the parking brake.
3
004505
5
NOTE
4 Plug all unions at once to protect the hydraulic system from
contamination.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose, parking brake
9 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
C AUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
Lifting the machine
13 Remove the bolts that secure the drive axle in the frame.
14 Lift away the drive axle.
C AUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
15 Transfer parts from the old drive axle to the new one.
Attaching bolts, drive axle
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
16 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the underside of the drive axle.
17 Remove the nuts for attaching the drive axle, blow clean and re-
install the nuts.
18 Transfer the guide pins from the old axle to the new axle.
19 Lift the drive axle into place under the frame.
C AUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
20 Lower the frame toward the drive axle. Check that the guide pins
fit in the frame.
21 Fit the new bolts that secure the drive axle in the frame. Tighten
the bolts to a torque of 2820 Nm.
22 Install the drive wheels on the new axle.
23 Rustproof the bolts with suitable paint.
4 Brakes
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 5
4.3.1 Brake fluid pump .................................................................................... 7
4.3.2 Brake fluid filter .................................................................................... 12
4.3.3 Accumulator charging valve ................................................................. 13
4.3.4 Accumulator ......................................................................................... 16
4.3.5 Brake valve .......................................................................................... 20
4.3.6 Drive axle block ................................................................................... 24
4.3.7 NC switch, brake fluid pressure ........................................................... 25
4.3.8 NO (normally open) switch, brake lights .............................................. 26
4.3.9 Wheel brake ......................................................................................... 28
4.3.10 Pipes and hoses .................................................................................. 30
4.5 Parking brake system ............................................................................... 31
4.5.1 Brake fluid pump .................................................................................. 32
4.5.2 Brake fluid filter .................................................................................... 32
4.5.3 M-valve parking brake ......................................................................... 33
4.5.4 Parking brake unit ................................................................................ 34
4.5.5 Parking brake NC switch ..................................................................... 37
4.5.6 Pipes and hoses .................................................................................. 37
4.8 Temperature control, cleaning and brake oil ............................................ 38
4.8.1 Brake fluid tank .................................................................................... 39
4.8.2 Tank heater .......................................................................................... 40
4.8.3 Brake fluid pump .................................................................................. 40
4.8.4 Accumulator charging valve ................................................................. 40
4.8.5 Drive axle block ................................................................................... 40
4.8.6 Wheel brake ......................................................................................... 40
4.8.7 Oil cooler .............................................................................................. 41
4.8.8 Cooling fan ........................................................................................... 42
4.8.9 Thermal bypass valve .......................................................................... 42
4.8.10 Sensor brake oil temperature .............................................................. 43
4.8.11 Breather filter ....................................................................................... 44
4.8.12 Brake fluid filter .................................................................................... 45
4.8.13 Pipes and hoses .................................................................................. 46
4.8.14 Brake system fluid ............................................................................... 46
4 Brakes
mm mm mm mm mm mm
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal moves easily.
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Turn off the engine and the main electrical power.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cab’s underside and remove the
brake valve attaching bolt.
NOTE
There is a variant available with adjustable steering wheel
shaft.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
15 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
description
13
D790-2 5
B
P
T
D10 D797-R D797-F
10 9, 12 8 C5
Pa
D11 D8
C3
4 11
Pa
7
B
ACC 6
C1
3
P
006401
Pos Explanation Signal description Reference
1 The brake fluid pump pumps fluid from P = 20.5 ±1.0 MPa Brake fluid tank, description page 39
the brake fluid tank. Brake fluid pump, description page 7
2 The brake oil filter cleans the oil. - Brake fluid filter, description page 45
4 The accumulators store oil pressure. See the pressure plate, Ac- Accumulator, description page 16
cumulator pressure brake
system, on the left-hand
frame member.
5 The brake valve directs pressure from - Brake valve, description page 20
the accumulators to the brake cylinders
proportional to pressing of the pedal.
7 The wheel brakes brake the machine. - Wheel brake, description page 28
8 The brake light NO switch (S216) closes Brake pressure above Switch normally open (NO), brake lights,
the circuit when the brake cylinders are 0.2 MPa: description page 26
pressurised. Conn 1, U = 24 V D8: Diagnostic menu, see section 8 Con-
Conn 2, U = 24 V trol system , group 8.4.5.4 HYD, menu 4
9 Control unit, frame front (D797-F) trans- Checked by control system, Section 11 Common electrics, group
mits the brake light request on the CAN error shown with error code. 11.5.3.2 Control unit, frame front
bus.
10 The brake lights are activated by Control U = 24 V Section 9 Frame, body, cab and accesso-
unit, frame rear (D797-R). ries, group 9.6.4 Brake lights
D10: Diagnostic menu, see section 8
Control system , group 8.4.2.11 LIGHTS,
menu 11
11 NC switch, brake oil pressure (S204) Brake pressure above NC switch, brake oil pressure, description
opens the circuit if the pressure in the 11.5 MPa: page 25
accumulators is low. Conn 1, U = 24 V D11: Diagnostic menu, see section
Conn 2, U = 24 V 8 Control system , group 8.4.5.4 HYD,
menu 4
Brake pressure below
11.5 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
12 Control unit, frame front (D797-F) trans- Checked by control system, Section 11 Common electrics, group
mits a warning about low brake pressure error shown with error code. 11.5.3.2 Control unit, frame front
on the CAN bus.
13 Control unit KIT (D790-2) activates Checked by control system, Section 11 Common electrics, group
Warning light brake pressure. error shown with error code. 11.5.3.11 Control unit KIT
The brake system has a gear pump with fixed displacement. The
brake oil pump is fitted at the front of the left-hand main pump. The
pump generates hydraulic power, which is stored in the accumulators
for brake force to the power-assisted brake and parking brake. It also
generates the oil flow used for cleaning and cooling. The switchover
between power generation and flow is regulated by the accumulator
charging valve, see Accumulator charging valve, description page 13.
The brake oil pump is driven by the main pump’s shaft from gearbox
power take-off. The brake oil pump’s speed is directly dependent on
engine speed. The pump flow rate increases with engine speed and
varies with the speed of the input shaft.
1
NOTE
2 It is very important that the clearance between the gears and be-
000006
tween the gear and the housing is correct. Clearance that is too
small creates wear damage. Clearance that is too large reduces
1. Brake fluid pump
the pump’s power output.
2. Pump cooling and filtering, working hydraulics
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
alternative Rexroth)
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake
system from impurities.
4 Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters and the contact to the new
pump.
6 Remove the spacer ring from the brake pump or hydraulic oil
pump.
Clean the O-rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as required. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the brake pump, see section F Technical data.
NOTE
Only use silicone on the side facing the brake pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
14 Check that the hose connections and seal between the hydraulic
oil pump and brake pump are fully sealed.
Check the feed pressure from the brake pump, see Brake fluid
pump, check page 7.
15 Check the oil level in the brake system, fill as necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the brake system as well.
alternative Sauer-Danfoss)
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
4 Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters and the contact to the new
pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
10 Turn on the main electric power and start the engine.
11 Check that the hose connections and seal between the hydraulic
oil pump and brake pump are fully sealed.
Check the feed pressure from the brake pump, see Brake fluid
pump, check page 7.
12 Check the oil level in the brake system, fill as necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the brake system as well.
The accumulator charging valve distributes oil from the hydraulic oil
1 2
13 pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is fitted on the beam in front of the gear-
12 3 box in the engine compartment.
The accumulator charging valve stores pressure by guiding the oil to
11 4
the accumulators. The wheel brakes are cooled by oil being guided to
the drive axle cooling circuit and then on to the brake system cooler.
10 5
The accumulator charging valve prioritises charging of the accumula-
6 tors above cooling. A restriction of the charging means that a small
9 quantity of oil also flows to cooling during accumulator charging. At
idling speed the flow from the pump is so small that all oil flows to pres-
8 sure storage.
The drain valve (position 11) is used to relieve the pressure in the ac-
7
cumulators to the tank. The valve opens a connection between the ac-
cumulators and the wheel brake’s cooling circuit. The oil is drained
through the wheel brake to the tank.
There is a measuring outlet for measuring the accumulator pressure
000431
NOTE
Read the safety instructions for oil before working, see section
B Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up hydraulic hoses and electric cables.
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator
charging valve.
Remove the parking brake valve (C) for easier access.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
NOTE
Check that the O-rings are intact and are fitted correctly.
10 Fit the parking brake valve and NC switch parking brake.
11 Connect the wiring to the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
Check that the hydraulic connections are sealed tightly.
14 Check the charging and changing function, see Accumulator
charging, checking and adjustment page 13.
4.3.4 Accumulator
Accumulator, description
page
–
Accumulator, checking
page
–
NOTE
Read the safety instructions for oil before working, see section
B Safety.
MPa
MPa
MPa
MPa
MPa MPa
001031
920643.0024
NOTE
Check that the seals are intact and are fitted correctly.
18 Turn on the main electric power and start the engine.
19 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
20 Check that the accumulators’ connections are sealed tightly.
21 When the accumulators are fully charged, shut 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 come
on.
Accumulator, replacement
page
–
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Turn off the engine and the main electrical power.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
NOTE
Check that the seal is intact and is fitted correctly.
8 Secure the accumulator’s clamp and tighten the bolt.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
10 Turn on the main electric power and start the engine.
11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking
page 16 steps 18-19.
The brake valve, which is located on the underside of the cab under-
neath the brake pedal, controls the hydraulic pressure to the brakes.
1 A lever transfers pedal force to the valve.
2 The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion to
3
brake pressure. This provides optimum pedal responsiveness and in-
creased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).
000013
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Operate and warm up the machine so that the brake fluid reaches
operating temperature, at least 50 °C.
2 Machine in service position, see section B Safety.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
9 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
MPa the pressure plate and must not decrease from this value for
15 seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
MPa
immediately. Otherwise the brake valve is not sealed and can
cause the brakes to remain applied and then overheat during
MPa
operation.
MPa MPa MPa
MPa Replace the brake valve if it is not sealed.
11 Depressurise the brake and hydraulic systems, see section
MPa
B Safety.
12 Remove the pressure gauge and fit the protective cap on the
MPa MPa measuring outlet.
008214
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Slide the cab forward slightly so that the brake valve is accessible
under the cab.
2 Machine in service position, see section B Safety.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
4 Mark up and detach the hydraulic hoses from the brake valve.
NOTE
Plug the connections immediately to protect the brake sys-
tem from impurities.
5 Secure the brake valve under the cab.
NOTE
Remember the spacer ring.
NOTE
Check that the O-rings are intact and are fitted correctly.
11 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 On machines with manual sliding cab. Secure the cab in the rear-
most position with the cab locks.
14 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
15 Test the brakes a couple of times.
16 Check that the brake valve's connections are sealed tightly.
17 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
A bleeding page 29.
000270
B C
A. Location, lock handle
B. Lock pin
C. Lock handle for securing cab
The drive axle block distributes oil flow and brake pressure to the right
1 and left-hand wheel brakes. The drive axle block is located on a brack-
10
2 et above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake’s cooling circuit.
4
The drive axle block has a bypass valve which guides oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance in
9 the axle becomes too great. This protects the wheel brake seals, e.g.
6 when the oil is cold.
8 7 The drive axle block houses two switches: brake light NO (normally
open) switch (S216), see Switch normally open (NO), brake lights, de-
scription page 26, and declutch NO switch (S220-2), see section 2
Transmission, group 2.8.2 Normally open (NO) switch, declutch.
000439
The brake oil pressure NC switch (S204) detects the pressure in the
accumulators. The NC switch is located on the accumulator charging
valve on the lifting beam in front of the gearbox in the engine
compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s opening
pressure is chosen so that there is pressure for another eight brake
applications without additional feed from the pump after the light has
gone off.
The brake oil pressure NC switch (S204) is supplied voltage by Control
unit, frame front (D797-F). When the pressure increases above the
cut-off pressure, the voltage signal to Control unit, frame front
(D797-F) is cut off.
The signal can be checked from the diagnostic menu, see tab
8 Control system , group 8.4.5.4 HYD, menu 4.
000435
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 °C.
2 Machine in service position, see section B Safety.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
accumulator pressure on the accumulator charging valve.
5 Close the drain valve on the accumulator charging valve.
6 Start the engine and fully charge the accumulators (the accumu-
lator charging valve changes to cooling).
7 Stop the engine and turn the starter key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
approx. 11.5 MPa.
10 If necessary, adjust the warning level by turning the adjusting
screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
13 Depressurise the brake and hydraulic systems, see section
B Safety.
14 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
15 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
The brake light NO switch controls brake light activation when the ma-
chine brakes. The switch is located on the drive axle block which sits
on a bracket above the drive axle differential.
The brake light NO switch (S216) is supplied voltage by and sends a
voltage signal to Control unit, frame front (D797-F). When the pres-
sure increases above the closing pressure, a voltage signal is sent to
Control unit, frame front (D797-F).
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system , group 8.4.5.4 HYD, menu 4.
000439
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Operate and warm up the machine until the brake fluid reaches
operating temperature, at least 50 °C.
2 Stop the engine and turn the starter key to position I.
3 Brake and check that the brake light comes on.
DECLUTCH PRESSURE X 9 Press down the brake pedal slowly until the brake light is activat-
ed or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status can be changed and the brake light should come on
when the pressure is approx. 0.2 MPa.
10 Stop the engine
11 Depressurise the brake and hydraulic systems, see section
B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
The wheel brakes brake the machine during operation and are located
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 effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
000015
The wheel brakes have two main sections - disc assembly and brake
1 2
cylinder. The disc assembly performs the braking. The brake cylinder
presses the discs in the disc assembly together during braking.
000016
NOTE
Read the safety instructions for oil before working, see section
B Safety.
I M P OR TA NT
Both the brake cylinder and disc brake must be bled
after work where the brake system is opened or after
work on the wheel brake.
Brake cylinder
1 Machine in service position, see section B Safety.
2 Place a ring spanner on the bleed nipple and connect a transpar-
ent hose to the bleed nipple.
Lead the other end of the hose down into a collection container.
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
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the air bleeder nipple when bleeding to
ensure that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub's inner short side (left-hand side).
6 Move the spanner and hose and repeat steps 1–4 on the other
side.
Disc brake
NOTE
Disc brake ventilation is vital to correct cooling of the discs.
1 Start the engine and allow it to idle. Wait until the brake accumu-
lators are fully loaded and the accumulating charging valve has
switched to brake cooling.
2 Remove the bleed screw of the disc brake and let oil flow out of
the hole until it is free of air bubbles. Refit the bleed screw.
3 Repeat steps 1-3 on the other wheel.
4 Check the oil level in the brake system, fill as necessary.
The disc assembly consists of several thin metal discs fixed alternately
to the wheel brake housing and to the hub reduction housing. The
discs are mounted on splines, which allows them to move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
Braking is effected by 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 assembly
Brake cylinder
D5
5
6 12
D790-1 D790-2
D797-F
7 11
D8
D10
C3 8
4
Pa 10 9
ACC
C1 3
H
P
2 T
006402
Pos Explanation Signal description Reference
1 The brake fluid pump pumps fluid from P = 19 ±0.5 MPa Brake fluid tank, description page 39
the brake fluid tank. Brake fluid pump, description page 7
2 The brake fluid filter cleans dirt from the - Brake fluid filter, description page 45
oil.
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 16
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
parking brake. Conn 1, U = 22–28 V ries, group 9.1 Controls and instruments
The switch uses two signals - one for ap- Conn 7, U = 0 V D5: Diagnostic menu, see section 8 Control
plied and one for released parking system , group 8.4.5.5 HYD, menu 5
Switch in home position:
brake. Both signals must be correct to
enable release of the parking brake. Conn 1, U = 0 V
Conn 7, U = 22–28 V
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
release or apply parking brake on the tem, error shown with 11.5.3.1 Cab control unit
CAN bus. error code.
8 Solenoid valve parking brake (Y642) af- Pump pressure. Solenoid valve parking brake, description
fects the valve slide which drains pres- page 33
sure in the parking brake calliper to tank. D8: Diagnostic menu, see section 8 Control
system , group 8.4.5.5 HYD, menu 5
9 The brake calliper is drained of pressure 0 MPa Parking brake unit, description page 34
and the spring applies the parking
brake.
10 The parking brake NC switch (S200) Applied parking brake: Parking brake NC switch, description page
closes the circuit when the pressure de- Conn 1: U = 24 V 37
creases. D10: Diagnostic menu, see section 8 Control
Conn 2: U = 0 V
system , group 8.4.5.5 HYD, menu 5
Released parking brake:
Conn 1: U = 24 V
Conn 2: U = 24 V
11 Control unit, frame front (D797-F) trans- Checked by control sys- Section 11 Common electrics, group
mits parking brake applied on the CAN tem, error shown with er- 11.5.3.2 Control unit, frame front
bus. ror code.
12 The KIT control unit (D790-2) activates Checked by control sys- Section 11 Common electrics, group
the parking brake indicator light (508). tem, error shown with er- 11.5.3.11 Control unit KIT
ror code.
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the gearbox in the engine com-
partment, see Accumulator charging valve, description page 13.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. In-
stead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by Control unit, frame front
(D797-F) on activation.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.5.5 HYD, menu 5.
000437
D ANGER
The machine may start to roll. Risk of crushing.
1 Start the engine and run the engine at idling speed until the warn-
ing lamp for brake pressure goes out and the accumulator charg-
ing valve changes to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake with switch parking brake and check
that the parking brake’s brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the parking brake switch and
check that the parking brake’s brake caliper is applied.
The parking brake unit keeps the machine stationary when parked.
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake calliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is ac-
tivated before the pressure drops so low that the parking brake is
applied. If the parking brake is applied while the machine is in mo-
tion, the brake disc and brake pads must be replaced.
005121
D ANGER
The machine may start to roll.
Risk of crushing.
1 Start the engine and run up hydraulic pressure until the accumu-
lators are fully charged and the accumulator charging valve
switches to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
11 Refit the cover to the caliper.
12 Test the operation of the parking brake.
The brake calliper has a spring section and a hydraulic section. The
1 2 3 4 5
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises.
000020
1. Brake pads
2. Release cylinder
3. Return spring
4. Slackening screw
5. Adjusting washer
The brake pads consist of a metal plate with friction material (lining).
D ANGER
The machine may start to roll.
Risk of crushing.
6 Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Install new parking brake pads.
10 Press the attaching bolt back.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment (drive axle alternative Kessler) page 34.
The brake disc is mounted on the drive axle input shaft. The drive ax-
le’s gear ratio amplifies the braking force.
NOTE
Gears cannot be engaged when the parking brake is applied.
000436
function description
11
D795
D797-F
9
D8 D10
C4
C1
3 4
P T
2
5
1
6 10
8 7
M
006403
˚C ˚C
2 The brake oil filter cleans the oil. - Brake fluid filter, description page 45
3 The accumulator charging valve directs Max. 0.1 MPa Accumulator charging valve, description
oil to charging of accumulators or page 13
through the brake system's cooling
circuit.
4 The oil cools the wheel brake. - Wheel brake, description page 28
5 The bypass valve in the distribution - Drive axle block, description page 24
block leads oil past the drive axle if the
back pressure through the wheel brake
is too high.
7 The thermo-bypass valve leads oil past approx. 50 °C Thermal bypass valve, description page 42
the cooler if the temperature is low.
8 The temperature sensor (B762) detects R = 25 kΩ at 20 °C Brake fluid temperature sensor, description
and oil temperature and sends Control page 43
unit, frame front (D797-F) a voltage sig- D8: Diagnostic menu, see section 8 Control
nal proportional to the oil temperature. system , group 8.4.5.2 HYD, menu 2
10 When the oil is hot, Control unit, frame U = 24 V with activated Cooling fan, description page 42
front (D797-F) activates the cooling fan fan D10: Diagnostic menu, see section 8 Control
(M674) and increases airflow through Activates at 65 °C system , group 8.4.5.2 HYD, menu 2
the cooler.
Deactivates at 55 °C
11 If temperature is high, the KID control Checked by control sys- Section 11 Common electrics, group
unit (D795) activates the high brake fluid tem, error shown with 11.5.3.12 KID control unit
temperature warning in the display. error code.
The brake fluid tank stores the brake system fluid and is located on the
left side of the machine in front of the fuel tank.
The brake system is separate from other hydraulics and has its own
tank and oil filter. This makes it possible to keep additives out of the
brake system fluid.
Brake fluid is filled directly to the tank. A drain plug is located at the
bottom of the tank. Hatches on top of the tank facilitate internal
cleaning.
The tank is equipped with a filtered breather that allows volume chang-
es in the tank, due to temperature variations and use. See Breather fil-
ter, description page 44.
The tank has a sight glass for checking oil level.
000012
C AUTION
High voltage.
The tank heater is connected to high voltage
(110 - 400 V).
The brake fluid tank can be equipped with a tank heater, which heats
the brake fluid in the tank and sits in a flange on the front short side of
the tank. The tank heater is designed for cold-climate usage.
The tank heater is operated with high voltage. Heater output is adapt-
ed through different connections and adaptation to different operating
voltage - 110, 230 or 400 V AC. Higher voltage generates higher heat-
er output.
The tank heater can be equipped with an adjustable thermostat which
001872
The oil cooler cools the brake system fluid in order to maintain brake
performance. The oil cooler is found inside the side panel on the left
side behind the front wing.
The brake system uses a flow-through cooler with electric cooling fan.
The brake system fluid is cooled when it passes the cooler. Openings
in the frame panel allow air to pass through the cooler.
The cooling fan is screwed onto the cooler. See Cooling fan, descrip-
tion page 42.
000010
NOTE
Read the safety instructions for oil before working, see section
B Safety.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
NOTE
2. Connector
Check that the O-rings are intact and fitted correctly.
3. Radiator
10 Fill the brake fluid tank; see Brake system fluid, changing page
46. The fluid level should be visible in the sight glass.
The cooling fan (M674) is a suctioning electronic fan. The fan suctions
air from the outside of the machine through the cooler and increases
airflow through the oil cooler as needed. The cooling fan is mounted
inside the cooler inside the side panel behind the left drive wheel.
The cooling fan (M674) is supplied voltage by Control unit, frame front
(D797-F). The cooling fan is activated when oil temperature is 65 °C
in the brake oil tank and the fan is deactivated when oil temperature is
55 °C.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.5.2 HYD, menu 2.
000009
When the oil is cold, the thermo-bypass value guides the oil past the
cooler directly to the tank. The thermo-bypass valve is found inside the
brake fluid tank at the hose connections to and from the cooler.
The thermo-bypass valve is a temperature-regulated bimetal valve
that is open at low temperatures and completely closed at 50 °C.
000023
NOTE
Read the safety instructions for oil before working, see section
B Safety.
NOTE
Note how the valve is fitted.
5 Fit in reverse order.
NOTE
Read the safety instructions for oil before working, see section
B Safety.
NOTE
Check that the O-rings are intact and fitted correctly.
5 Connect the cabling to the sensor.
6 Fill the brake fluid tank; see Brake system fluid, changing page
46. The fluid level should be visible in the sight glass.
The breather filter cleans the air that passes the tank’s breather upon
volume changes arising due to temperature variations and use. The
breather filter is located in a holder on the top of the brake fluid tank.
The breather filter is a paper insert filter. The filter removes moisture
and dust from the air passing through the tank’s breather.
000017
NOTE
Take care so as not to contaminate the tank.
5 Fit a new filter insert.
1. Brake system fluid filler orifice 6 Refit the cover on the filter holder.
2. Breather filter, brake fluid tank
The brake fluid filter eliminates contaminants from the fluid in the brake
system. The filter is secured on a mounting in front of the gearbox un-
der the lifting beam.
The brake system fluid filter is a high-pressure filter with removable fil-
ter insert. It is located between the pump and accumulator charging
valve. The fluid is cleaned when it is forced through the (glass-fibre)
material of the filter insert before reaching the accumulator charging
valve.
A bypass valve located between the intake and outlet protects the in-
sert. If resistance through the filter surface becomes too great, the by-
pass 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
cleaning. Therefore, it is very important to replace the filter at the
prescribed interval.
000018
NOTE
Read the safety instructions for oil before working, see section
B Safety.
I M P OR TA NT
The filter protects the brake system against contami-
nants. It is vital that new contaminants do not enter
the brake system during filter replacement.
NOTE
Leave the valves open during replacement.
NOTE
The filter holder is heavy. Detach it carefully.
5 Remove the filter insert.
NOTE
Note the location of the O-rings.
6 Clean the filter holder.
7 Fit the O-rings on the filter insert and filter holder. Lubricate the
O-rings with brake fluid.
8 Fit the new filter insert on the filter mounting.
9 Fit the filter holder and drain plug.
10 Close the valves opened for draining the pressure in the hydraulic
system.
11 Start the engine and check the filter holder for leaks.
000018
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic and brake systems; see section
B Safety.
3 Remove the filler cap and drain the brake fluid tank.
4 Remove the drain plug and allow the last of the fluid drain into a
receptacle.
5 Fit the drain plug, using a new gland washer.
6 Fill brake fluid until the fluid level is in the middle of the sight
glass. For volume and grade, see section F Technical data.
7 Fit the filler cap.
1. Brake system fluid filler orifice
2. Breather filter, brake fluid tank
5 Steering
5 Steering........................................................................................................... 3
5.1 Controls and instruments ........................................................................... 3
5.1.2 Mini-wheel .............................................................................................. 3
5.1.3 Joystick .................................................................................................. 4
5.2 Power assisted system ............................................................................... 6
5.2.1 Hydraulic oil pump ............................................................................... 13
5.2.2 Priority valve ........................................................................................ 14
5.2.3 Steering valve ...................................................................................... 20
5.2.4 Steering cylinder .................................................................................. 23
5.2.5 Steering axle cradle ............................................................................. 26
5.2.6 Link arm ............................................................................................... 27
5.2.7 Wheel spindle ...................................................................................... 27
5.2.8 Wheel hub ............................................................................................ 27
5.2.9 Shuttle valve ........................................................................................ 27
5.2.10 Control valve mini-wheel/joystick control ............................................. 28
5.2.11 Shuttle valve, mini-wheel/lever steering .............................................. 31
5.2.12 Steering angle sensor .......................................................................... 32
5.2.13 Pipes and hoses .................................................................................. 32
5 Steering
mm mm mm mm mm mm
3 4
On machines with mini-wheel, the machine is steered with an electric
2 control. A directional valve pressurises the steering cylinder.
The mini-wheel controls are integrated in the left armrest. The controls
1 consist of two rotary potentiometers and three switches to activate the
mini-wheel, select direction of travel and activate the horn.
NOTE
The mini-wheel is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds
below 3 km/h.
Mini-wheel
5 Rotary potentiometers transmit a 0-5 V signal for one revolution. The
potentiometers have phase displacement to determine the direction of
turning. The rotary potentiometers are supplied voltage by the cab
control unit (D790-1) and send it a voltage signal proportional to the
turn to indicate steering deflection.
The relationship between the deflection of the mini-wheel and that of
the wheels can be set to 31 different settings - from linear to extremely
progressive. It is also possible to set how steering deflection is to be
000583
Acoustic signal
The acoustic signal is used to activate the signal horn when the mini-
wheel is activated. The switch is supplied voltage by and sends a volt-
age signal to the cab control unit (D790-1).
The signals can be read from the diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING, menu 2.
5.1.3 Joystick
Joystick, description
page
–
3 4
On machines with joystick, the machine is steered with an electric con-
2
trol. A directional valve actuates the steering cylinder.
The joystick is integrated in the left armrest. The controls consist of a
1 sliding potentiometer and three switches to activate lever steering, se-
lect direction of travel and activate the horn.
NOTE
Lever steering is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds be-
low 3 km/h.
Joystick
5 The sliding potentiometer is supplied voltage by the cab control unit
(D790-1) and sends it a voltage signal proportional to movement to in-
dicate steering deflection.
The signals can be read from the diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING, menu 1.
The relationship between the deflection of the joystick and that of the
wheels can be set to 31 different settings - from linear to extremely
000900
Acoustic signal
The acoustic signal is used to activate the horn when the lever steering
is activated. The switch is supplied voltage by and sends a voltage sig-
nal to the cab control unit (D790-1).
The signals can be read from the diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING, menu 2.
2
PP P
C1
CF LS
5
P T
LS T L R
3
1 6
007428
Pos Explanation Signal description Reference
1 The hydraulic oil pumps pump oil to the See pressure plate on Section 10 Common hydraulics, group
priority valve. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
2 The priority valve prioritises pressure sup- Checked by control sys- Priority valve, description (hydraulic oil
ply to the steering valve over the working tem, error shown with pump alternative Rexroth) page 14
hydraulics. The priority valve also trans- error code.
mits a control signal to the hydraulic oil
pump 3 and 4.
3 The shuttle valve selects the strongest Checked by control sys- Section 10 Common hydraulics, group
load signal to the main pump if hydraulic tem, error shown with 10.5.3 Shuttle valve
functions are activated at the same time error code.
as the steering wheel is turned.
4 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments
5 The steering valve pumps pressurised oil - Steering valve, description page 20
to the steering cylinder and transmits a
load signal to the main pumps.
6 The steering cylinder turns the wheels. - Steering cylinder, description page 23
2
PP P
C1
CF LS
5
P T
LS T L R
3
1 6
007428
Pos Explanation Signal description Reference
1 The hydraulic oil pump 2 pumps oil to See pressure plate on left Section 10 Common hydraulics, group
the priority valve. frame beam. 10.4.2 Axial piston pump with variable
displacement
2 The priority valve prioritises pressure Checked by control sys- Priority valve, description (hydraulic oil
supply to the steering valve over the tem, error shown with pump alternative Rexroth) page 14
working hydraulics. The priority valve error code.
also transmits a control signal to the
hydraulic oil pump 2.
3 The shuttle valve selects the strongest Checked by control sys- Section 10 Common hydraulics, group
load signal to the main pump if hydraulic tem, error shown with 10.5.3 Shuttle valve
functions are activated at the same time error code.
as the steering wheel is turned.
4 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments
6 The steering cylinder turns the wheels. - Steering cylinder, description page 23
NOTE
The mini-wheel/lever steering is deactivated if the standard steer-
ing wheel is used.
Mini-wheel or lever steering can only be activated at speeds
below 3 km/h.
Steering wheel No signal from sensor steering Sensor, steering wheel movement, description page 32
stationary wheel movement.
Safety switch Not activated Section 11 Common electrics, group 11.2.3 Safety switch
1
D12 D1
11
13 2
D790-1
D790-2 D790-3
D797-O
12 3
D3 4 D4
C7 8
PP
P P
CF LS
P LS 5, 9
TP
LS T
T1
T L R A B
10
006404
Pos Explanation Signal description Reference
1 The joystick switch or mini-wheel switch Signal 1, U = 0.5 - 4.5 V Mini-wheel, description page 3 or Joystick,
sends a voltage signal to the cab control Signal 2, U = 0.5 - 4.5 V description page 4
unit (D790-1). (mini-wheel only) D1: Diagnostic menu, see section 8 Control
On machines with Combi attachment system , group 8.4.11.4 EL-STEERING,
the signal is sent to the cab control unit menu 1
option (D790-3).
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
the desired steering deflection on the tem; error indicated with 11.5.3.1 Cab control unit
CAN bus. error code.
On machines with Combi attachment
the cab control unit option (D790-3)
sends steering deflection on the CAN
bus.
3 Control unit, frame option (D797-O) sup- I = 350–550 mA Section 11 Common electrics, group
plies voltage to the solenoid valve for 11.5.3.4 Control unit, frame option
steering right (Y636R) or the solenoid D3: Diagnostic menu, see section 8 Control
valve for steering left (Y636L). system , group 8.4.11.4 EL-STEERING,
menu 4 and 5
5 The solenoid valve for lever control or - Control valve for lever steering or mini-
mini-wheel sends a load signal to shuttle wheel, description page 28
valve, steering.
6 The shuttle valve selects the strongest - Shuttle valve for mini-wheel or lever control,
load signal to hydraulic oil pump 3 and 4 description page 31
if hydraulic functions are activated at the
same time as the steering wheel is
turned.
7 Hydraulic oil pumps 3 and 4 pump oil See pressure plate on left Section 10 Common hydraulics, group
from the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
8 The priority valve prioritises pressure See pressure plate on left Priority valve page 14
supply to the steering valve over the frame beam.
working hydraulics. The priority valve
also transmits a control signal to the hy-
draulic oil pump 3 and 4.
9 The slide changes position and pressu- - Control valve for lever steering or mini-
rises the steering cylinder. wheel, description page 28
10 The steering cylinder turns the wheels. - Steering cylinder, description page 23
11 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments
12 Sensor steering axle sends a voltage U = 24 V Sensor, steering wheel movement, descrip-
signal to Control unit, cab (D790-1). tion page 32
D12: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING,
menu 3
13 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
the stop steering on the CAN bus. tem; error indicated with 11.5.3.1 Cab control unit
error code.
NOTE
The mini-wheel/lever steering is deactivated if the standard steer-
ing wheel is used.
Mini-wheel or lever steering can only be activated at speeds be-
low 3 km/h.
Steering wheel No signal from sensor steering Sensor, steering wheel movement, description page 32
stationary wheel movement.
Safety switch Not activated Section 11 Common electrics, group 11.2.3 Safety switch
1
D12 D1
11
13 2
D790-1
D790-2 D790-3
D797-O
12 3
D3 4 D4
C7 8
PP
P P
CF LS
P LS 5, 9
TP
LS T
T1
T L R A B
10
006404
Pos Explanation Signal description Reference
1 The joystick switch or mini-wheel switch Signal 1, U = 0.5 - 4.5 V Mini-wheel, description page 3 or Joystick,
sends a voltage signal to the cab control Signal 2, U = 0.5 - 4.5 V description page 4
unit (D790-1). (mini-wheel only) D1: Diagnostic menu, see section 8 Control
On machines with Combi attachment system , group 8.4.11.4 EL-STEERING,
the signal is sent to the cab control unit menu 1
option (D790-3).
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
the desired steering deflection on the tem; error indicated with 11.5.3.1 Cab control unit
CAN bus. error code.
On machines with Combi attachment
the cab control unit option (D790-3)
sends steering deflection on the CAN
bus.
3 Control unit, frame option (D797-O) sup- I = 350–550 mA Section 11 Common electrics, group
plies voltage to the solenoid valve for 11.5.3.4 Control unit, frame option
steering right (Y636R) or the solenoid D3: Diagnostic menu, see section 8 Control
valve for steering left (Y636L). system , group 8.4.11.4 EL-STEERING,
menu 4 and 5
5 The solenoid valve for lever control or - Control valve for lever steering or mini-
mini-wheel sends a load signal to shuttle wheel, description page 28
valve, steering.
6 The shuttle valve selects the strongest - Shuttle valve for mini-wheel or lever control,
load signal to hydraulic oil pump 2 if hy- description page 31
draulic functions are activated at the
same time as the steering wheel is
turned.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on left Section 10 Common hydraulics, group
hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
8 The priority valve prioritises pressure See pressure plate on left Priority valve page 14
supply to the steering valve over the frame beam.
working hydraulics. The priority valve
also transmits a control signal to the hy-
draulic oil pump 2.
9 The slide changes position and pressu- - Control valve for lever steering or mini-
rises the steering cylinder. wheel, description page 28
10 The steering cylinder turns the wheels. - Steering cylinder, description page 23
11 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments
12 Sensor steering axle sends a voltage U = 24 V Sensor, steering wheel movement, descrip-
signal to Control unit, cab (D790-1). tion page 32
D12: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.4 EL-STEERING,
menu 3
13 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
the stop steering on the CAN bus. tem; error indicated with 11.5.3.1 Cab control unit
error code.
alternative Rexroth)
Steering is supplied oil by the hydraulic oil pumps 3 and 4, see section
10 Common hydraulics , group 10.4 Pumps.
alternative Sauer-Danfoss)
Steering is supplied oil by the hydraulic oil pump 2, see section
10 Common hydraulics , group 10.4 Pumps.
alternative Rexroth)
The priority valve divides the oil flow from the main pump 3 and 4 so
that there is always oil to the steering valve. The residual flow goes to
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.
001016
alternative Rexroth)
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, 50 °C.
2 Machine in service position, see section B Safety.
˚C 3 Depressurising removed.
˚C
000475
MPa
MPa MPa
001033
920643.0024
alternative Sauer-Danfoss)
The priority valve divides the oil flow from the main pump 2 so that
there is always oil to the steering valve. The residual flow goes to
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
011345 pressure limiter maximises the load signal’s pressure.
alternative Sauer-Danfoss)
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, 50 °C.
2 Machine in service position, see section B Safety.
˚C 3 Depressurising removed.
˚C
000475
Operating menu, hydraulic oil temperature
4 Connect the pressure gauge to the measuring outlet for hydraulic
oil pump 2.
5 Start the engine and increase engine speed to approx. 1200 rpm.
MPa
A49195.0400
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Turn the start key to position 0 and turn off the main electric
power.
4 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
5 Remove the priority valve attaching bolts.
6 Release the priority valve from the collection block.
7 Remove the priority valve.
8 Transfer the connection adapters to the new priority valve.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to the collection block.
C AUTION
Do not tighten the hydraulic connection between pri-
ority valve and collection block before all other con-
nections and attaching bolts are fitted.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
16 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
17 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Remove the cover plates over the engine compartment.
2 Slide the cab forward so that the control valve is accessible from
below.
3 Stop the engine and turn the starter key to position I.
4 Depressurise the brake and hydraulic systems, see section
B Safety.
5 Turn the start key to position 0 and turn off the main electric
power.
1. Water valve
2. Steering valve
6 Detach the steering valve from the brake pedal.
Remove the steering valve attaching bolts and lower the steering
valve.
7 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
8 Remove the steering valve.
9 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one at a time so that the marking is not mixed up.
10 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
Check that the O-rings are intact and are fitted correctly.
11 Connect the new steering valve to the brake pedal.
Place the steering valve and check that the steering wheel shaft’s
splines enter straight in the steering valve’s slot. Install the at-
taching bolts.
000270
B C
A. Location, lock handle
B. Lock pin
C. Lock handle for securing cab
13 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 4 5 6 7 8 ing cylinder is a double-acting hydraulic cylinder.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Suspension
6. Steering cylinder
7. Rear mounting
8. Counterweight
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
2 Machine in service position, see section B Safety.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
4 Disconnect the link arms from the steering cylinder.
5 Mark up and disconnect the hydraulic hoses from the steering
cylinder.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
9 Fit and lubricate the steering cylinder attaching bolts. Tighten
them crosswise in steps until 680 Nm is achieved.
10 Transfer parts to the new steering cylinder.
Attaching bolts steering cylinder.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
010475
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
16 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The link arm transfers the lateral movement of the steering cylinder to
1 2 3 4 5 6 7 8 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,
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.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Suspension
6. Steering cylinder
7. Rear mounting
8. Counterweight
description
1
On machines with joystick control or mini-wheel, steering cylinder dis-
placement is regulated by the control valve for joystick control or mini-
6 2
wheel. The control valve is located on the inside of the right frame
member in front of the engine. The control valve is regulated by Con-
5 3 trol unit, frame option (D797-O).
The control valve is an electro-hydraulically controlled, proportional
4 and pressure-compensated directional valve. Electrically controlled
pressure reducing valves convert electrical current to servo pressure.
The servo pressure controls the spring-centred valve slides, which
control pressure and flow for the function in question. The valve slides
have flow limits so that several functions can be activated
simultaneously.
replacement
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
1
NOTE
6 2 Plug all connections immediately to protect the hydraulic
system from impurities.
5 3 4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
4
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
002205
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
15 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
description
4
002203
1
2
The steering angle sensor (B770) detects if the steering wheel is
turned and sends a signal to the KIT control unit (D790-2). This is used
to disengage joystick control or the mini-wheel. The sensor is located
by the steering axle inside the panels. The sensor is tripped by an in-
dicator ring on the steering axle with four lobes. The location of the
sensor and lobes’ spacing means that small steering wheel move-
ments can be detected.
The signals can be read from the diagnostic menu, see section 8 Con-
002628
trol system , group 8.4.11.4 EL-STEERING, menu 3.
1. Indicator ring
2. Sensor steering wheel movement (B770)
6 Suspension
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 3
6.2.1 Steering axle cradle ............................................................................... 5
6.2.2 Wheel spindle ........................................................................................ 7
6.2.3 Wheel hub ............................................................................................ 11
6.3 Tyres and rims .......................................................................................... 16
6.3.1 Tyres .................................................................................................... 18
6.3.2 Rims ..................................................................................................... 19
6.3.3 Nut, washer and clamp ........................................................................ 20
6 Suspension
mm mm mm mm mm mm
6.2 Suspension
Bushing steering axle mounting, changing
page
–
D ANGER
Steering axle and machine are very heavy.
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.
5 Connect lifting equipment to the rear of the machine and take up
the slack so that the steering axle’s mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
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 can be accessed.
NOTE
If needed, disconnect the cabling for the sensors on the
steering axle.
C AUTION
The bearing halves must be mounted horizontally.
14 Fit the washers that hold the bushing in place. Use locking fluid
and tighten the bolts to a torque of 45 Nm.
Parts of bushing steering axle 15 Move the steering axle into place under the frame.
1. Inner race
16 Grease and install the pins by the steering axle’s mounts.
2. Bearing halves
17 Remove the lifting equipment from the machine.
18 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front mounting
6. Steering cylinder
7. Rear mounting
8. Counterweight
D ANGER
Steering axle and machine are very heavy.
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 Detach the wiring from the overload sensor (applies only to ma-
chines with mechanical overload system).
10 Detach the hydraulic hoses from the steering cylinder.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
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.
C AUTION
The steering axle may start to roll.
Crushing injury!
14 Adjust the support so that the machine is secured in the new po-
sition.
15 Lift the steering axle into place underneath the frame.
16 Remove the support under the frame.
17 Lower the rear of the machine.
18 Fit the shafts at the steering axle mountings.
19 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact and that they are fitted cor-
rectly.
20 Attach the wiring to the overload sensor (applies only to ma-
chines with mechanical overload system).
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.
The wheel spindle is the link between steering axle and wheel hubs
1 2 3 4 5 6
which means that the wheels can be turned.
5
010483
1. Wheel spindle
2. Spindle bolt
3. Seal
4. Slide bearing washer
5. Cover
6. Spindle bolt bearing
7. Thrust bearing
8. Lock screw
004516
3
1. Shaft, link arm
2. Cover (upper)
3. Cover (lower)
8 Remove the spindle bolt’s upper and lower lock screw.
Remove the nut and the lock screw.
9 Adjust the lifting equipment to relieve the load on the wheel
spindle.
NOTE
The upper bearing bushing must protrude (4.5-4.8 mm) so
that it is level with the thrust bearing’s slotted washer.
004517
16 Fit new thrust washers on the steering axle. Only fit three bolts in
the manner illustrated. The fourth bolt cannot be fitted until the
wheel spindle is in place. Only tighten the bolts slightly (5-10 Nm)
so that the thrust bearings are secured in position.
Thoroughly coat the bearing bushings with grease. For grade,
see section F Technical data.
NOTE
Be sure to position the nuts as illustrated.
17 Fit new O-rings on the wheel spindle.
011152
Pull the O-ring toward the hub.
18 Lift the wheel spindle into place on the steering axle.
19 Coat the wear surface of the lower wear washer with lubricating
grease and align the bearing between the wheel spindle and the
lower thrust washer. Use a rubber mallet to get the bearing to the
right position. Check that the bearing is centred in the wheel spin-
dle by looking in the spindle from below.
20 Coat the wear surface of the upper wear washer with lubricating
grease and align the bearing between the wheel spindle and the
upper thrust washer. Use a rubber mallet to get the bearing to the
right position. Check that the bearing is centred in the wheel spin-
dle by looking in the spindle from above.
011163
NOTE
Check that the spindle bolt is turned so that the holes for the
guide screws align with the holes in the wheel spindle. It is
important that the spindle bolt is perfectly seated before the
lock screws are fitted. It is not possible to "tighten" the spin-
dle bolt into place.
22 Fit the lock screws and tighten with the lock nuts. Tighten to
250 Nm (oiled screw).
23 Coat the space between the wheel spindle and steering axle with
lubricating grease.
25 Fit the remaining bolts to the thrust bearings’ wear washer as il-
1
lustrated. Tighten to 25 Nm (oiled screw).
004517
3 32 Test-run the machine and test the steering. Check also that the
1. Cover (upper) machine feels stable when driving straight ahead.
2. Shaft, link arm
3. Cover (lower)
The wheel hub holds the wheel in place and allows the wheel to rotate.
1 2 3 4 5 6
001443
1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
2 Remove the steering wheel in question.
7 Bend up the lock washer’s tabs, remove the lock nut and the lock
washer.
8 Tension the lifting equipment so that the hub is unloaded.
9 Remove the hub nut.
NOTE
Fit the outer bearings with the larger diameter outward.
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the
seal does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.
17 Install the inner bearing’s inner race and rollers on the wheel
spindle. Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".
D ANGER
Always block the wheels on the side of the axle that is
not going to be worked on before positioning the jack.
Always secure the jack to prevent it from sliding out
of position.
Deflate the tyre before removal. Otherwise the conical
ring and locking clips can loosen and shoot out when
the pressure is changed. With double wheel fitting
both tyres must be deflated!
C AUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace
the spacer rings, with crushing injuries as a result.
6.3.1 Tyres
Tyres, description
page
–
The tyres are the point of contact between the machine and the
ground. These 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.
002027
Front wheels
002026
Rear wheels
Tyre replacement
page
–
D ANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
The wheel rims must be checked when tyres are changed. See Main-
tenance manual DRF 400–450 section 6 Suspension.
6.3.2 Rims
Rim, description
page
–
The rim is split to make it possible to fit a tyre, the rim consists of the
1 2 3 4 5 6 following parts.
• Rims
• Rim bead seat
• Rim flange
• Lock ring
• Lock lugs
• Hub plate
7
001444
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rims
6. Rim flange
7. Wheel nut
8. Wheel clamp
The rim is attached to the wheel hub with nuts and clamps.
1 2 3 4 5 6
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
7
001444
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rims
6. Rim flange
7. Wheel nut
8. Wheel clamp
7 Load handling
7 Load handling................................................................................................. 5
7.1 Controls and instruments ........................................................................... 7
7.1.1 Control lever .......................................................................................... 7
7.1.2 Switch, lock twistlocks ........................................................................... 9
7.1.3 Switch, automatic spreading ................................................................ 10
7.1.5 Switch, stop at 30' or 35' ...................................................................... 10
7.2 Lifting/lowering ......................................................................................... 11
7.2.1 Hydraulic oil pump ............................................................................... 15
7.2.2 Servo filter ............................................................................................ 16
7.2.3 Pressure reducer ................................................................................. 16
7.2.4 Accumulator servo circuit ..................................................................... 18
7.2.5 Control valve lift, lower and extension ................................................. 20
7.2.6 Shuttle valve ........................................................................................ 22
7.2.7 Valve block lift cylinder ........................................................................ 23
7.2.8 Lift cylinder ........................................................................................... 27
7.2.9 Sensor hydraulic pressure lift cylinder ................................................. 32
7.2.10 Lift boom .............................................................................................. 35
7.2.11 Sensor, boom angle ............................................................................. 35
7.2.12 Pipes and hoses .................................................................................. 35
7.2.16 Sensor, attachment damping ............................................................... 36
7.3 Extension .................................................................................................. 37
7.3.1 Hydraulic oil pump ............................................................................... 44
7.3.2 Servo filter ............................................................................................ 44
7.3.3 Pressure reducer ................................................................................. 44
7.3.4 Accumulator servo circuit ..................................................................... 45
7.3.5 Control valve lift, lower, extension ....................................................... 45
7.3.6 Shuttle valve ........................................................................................ 46
7.3.7 Valve block, extension cylinder ............................................................ 47
7.3.8 Extension cylinder ................................................................................ 47
7.3.9 Valve block, pump relief ....................................................................... 51
7.3.10 Lift boom .............................................................................................. 53
7.3.11 Sensor, boom length ............................................................................ 55
7.3.12 Pipes and hoses .................................................................................. 55
7.4 Side shift ................................................................................................... 56
7.4.1 Hydraulic oil pump ............................................................................... 57
7.4.2 Valve block, top lift hydraulics .............................................................. 58
7.4.3 Control valve attachment ..................................................................... 59
7.4.4 Shuttle valve ........................................................................................ 63
7.4.5 Side shift cylinder ................................................................................. 64
7.4.6 Side shift frame .................................................................................... 65
7.4.7 Main beam, attachment ....................................................................... 69
7.4.8 Relief valve, attachment ...................................................................... 69
7.4.9 Pipes and hoses .................................................................................. 70
7.5 Spreading ................................................................................................. 71
7 Load handling
mm mm mm mm mm mm
adjustment
1
2
4
3
3
5 6 7 8
9 12, 13 11
11
10
14
15
16
008212
C-C
4±1 mm
3 Check that the distance between the position sensor and
indicator is 4±1 mm. Adjust if necessary.
C-C
4±1 mm
I M P OR TA NT
It is very important that the bolt head on the steering
008209
4±1 mm axle sensor is in right front of the centre of the sensor
Adjusting position sensor - indicator and that the bolt head is turned so that the edge is
parallel with the top of the sensor.
The control lever (S815) is used to control the boom and attachment.
The lever sends a voltage signals to the cab control unit (D790-1).
1 2 The control lever has three or four potentiometer-controlled functions
3
and six on/off functions.
4
Lifting/lowering
5 Lifting/lowering is controlled by moving the control lever forward (lower
7 boom) or rearward (lift boom). See Lifting/lowering, function descrip-
6 tion page 11.
The signal can be checked from the diagnostic menu, see section 8
8 Control system , group 8.4.8.1 BOOM, menu 1.
Extension
Extension is controlled by moving the control lever right (boom out) or
000442
left (boom in). See Extension, function description (hydraulic oil pump
alternative Rexroth) page 37.
1. Tilt lock (S815-T3.1) The signal can be checked from the diagnostic menu, see section 8
2. Levelling lock (S815-T3.2) Control system , group 8.4.8.1 BOOM, menu 1.
3. Rotation (S815-P3)
4. Side shift right (S815-T1.2) Sideshift or spreading
5. Side shift left (S815-T1.1) When switch (position 4) is pressed down sideshift right is activated,
6. Opening of twistlocks (S815-T2) upon full contact and when switch (position 5) is pressed down sideshift left is activated.
See Side shift, function description page 56.
7. Tilt (S815-P4)
If the pistol trigger (position 8) is pressed in at the same time as side
8. Pistol trigger (S815-T4): Activates weighing ,
shift right (position 4), spreading out is activated. If the pistol trigger
changes function of side shift to spreading out
(position 8) is pressed in at the same time as side shift left (position 5),
(S815-T1.2) and spreading in (S815-T1.1) as well as
spreading in is activated. See Spreading, function description page
lift to synchronised lift 71.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.2 ATTACH, menu 2.
Rotation
When the potentiometer (position 3) is pressed down on the left side
rotation clockwise is activated, and when right side is pressed in rota-
tion anticlockwise is activated. See Rotation, function description page
95.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.1 ATTACH, menu 1.
Opening of twistlocks
When the switch (position 6) is activated, the twistlocks are opened if
the conditions for such are fulfilled. See Twistlocks, function descrip-
tion page 130.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.3 ATTACH, menu 3.
Tilt
Tilt lock
When the switch (position 1) is pressed down, the tilt lock is activated.
The light in the switch remains lit while the lock is active. See Tilt lock-
ing, function description page 112.
The signal can be checked from the diagnostic menu; see section 8
Control system , group 8.4.9.4 ATTACH, menu 4.
Levelling
Levelling lock
When the switch (position 2) is pressed down, the levelling lock is ac-
tivated. The indicator light in the switch remains lit while the lock is ac-
tive. See Levelling lock, function description page 125.
The signal can be checked from the diagnostic menu; see section 8
Control system , group 8.4.9.4 ATTACH, menu 4.
Pistol trigger
Twistlocks are opened with the switch on the control lever, see Control
lever, description page 7.
The switch is supplied voltage by and sends a voltage signal to the KIT
control unit (D790-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.3 ATTACH, menu 3.
WARN IN G
Risk of crushing and product damage!
Switch, stop at 30’ or 35’ (S1004) activates 30 and 35 foot stop. When
the switch is depressed the function for spreading is changed from
20’–40’ to stop at 30’.
35
30- The switch is supplied voltage by and sends a voltage signal to the KIT
control unit (D790-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.2 ATTACH, menu 2.
000447
7.2 Lifting/lowering
Lifting/lowering, function description
page
–
Twistlocks Locked or unlocked, not intermediate position Twistlocks, description page 137
Overload system Boom up: passive Section 8 Control system , group 8.2.1 Overload
Boom down: passive or bypass activated system
Bypassed or boom height lower than height Section 8 Control system, group 8.2.4 Height
Height limitation
limitation limitation
D1
1
2, 4 5 24 D23
D790-1 D794 D791-1
D797-F D797-R
3 13, 18 D22
D18
D3
D17
6 6 D13 14 19
11 C10 22 23
12
PSS PSL
10 PP C-M Pa 16, 21
A1 VA
C-
P B1 T
C+
LS D
8 Pa
7 C+M
17
C9 15, 20
9
010492
2 Control unit, cab (D790-1) transmits the Checked by control system, er- Section 11 Common electrics, group
request for Boom up or Boom down with ror shown with error code. 11.5.3.1 Cab control unit
the speed information on the CAN bus.
3 Control unit, frame front (D797-F) acti- I = 380–650 mA Section 11 Common electrics, group
vates Servo valve, lift (Y6005) or Servo 11.5.3.2 Control unit, frame front
valve, lower (Y6004). D3: Diagnostic menu, see section 8
Control system group 8.4.8.4 BOOM,
menu 4 and 8.4.8.5 BOOM, menu 5
4 The cab control unit (D790-1) transmits Checked by control system, er- Section 11 Common electrics, group
are request for increased engine speed ror shown with error code. 11.5.3.1 Cab control unit
on the CAN bus.
5 The engine control unit (D794) increases Checked by control system, er- Section 11 Common electrics, group
engine speed. ror shown with error code. 11.5.3.10 Engine control unit
6 Servo valve, lift (Y6005) or Servo valve, - Control valve lift, lower and extension
lower (Y6004) pressurises the control page 20
valve’s lift slide with servo pressure. D3: Diagnostic menu, see section 8
Control system group 8.4.8.4 BOOM,
menu 4 and 8.4.8.5 BOOM, menu 5
7 The control valve’s lift slide changes posi- - Control valve lift, lower and extension
tion and pressurises valve block, lift cylin- page 20
der and sends a load signal to the
hydraulic oil pumps.
9 The hydraulic oil pumps pump oil from the See pressure plate on left Section 10 Common hydraulics,
hydraulic oil tank. frame beam. group 10.4.2 Axial piston pump with
variable displacement
10 The pressure reducer reduces the oil See pressure plate on left Pressure reducer, description page
pressure from the hydraulic pumps to ser- frame beam. 16
vo pressure for the control valve.
12 The servo filter cleans the servo oil before - Servo filter, description page 16
the control valve.
13 With boom down Control unit, frame front U = 24 V Section 11 Common electrics, group
(D797-F) activates Servo valve, blocking 11.5.3.2 Control unit, frame front
right (Y6001) and Servo valves, blocking D13: Diagnostic menu, see section 8
left (Y6002). Control system, group 8.4.8.2
BOOM, menu 2
14 With boom down Servo valve, blocking - Lift cylinder valve block, description
right (Y6001) and Servo valve, blocking page 23
left (Y6002) act on the blocking valves in D13: Diagnostic menu, see section 8
the valve blocks for left and right lift cylin- Control system, group 8.4.8.2
der respectively. BOOM, menu 2
15 With boom up the blocking valves in the - Lift cylinder valve block, description
valve blocks are opened for left and right page 23
lift cylinder respectively by the hydraulic
pressure from the control valve.
With boom down the blocking valve opens
so that the pressure from the lift cylinder
can be released.
16 The lift cylinders’ piston side is pressu- - Lift cylinder, description page 27
rised and the boom is lifted.
18 Control unit, frame front (D797-F) acti- U = 24 V Section 11 Common electrics, group
vates solenoid valve, regeneration right 11.5.3.2 Control unit, frame front
(Y6051) and solenoid valve, regeneration D18: Diagnostic menu, see section 8
left (Y6052) if the pressure is sufficiently Control system, group 8.4.8.3
low for regeneration. BOOM, menu 3
19 The regeneration servo valve pressurised - Lift cylinder valve block, description
the regeneration valve. page 23
D ANGER
The lowering speed must correspond. If speed lower-
ing is too high there is a risk of rollover.
1 Operate the machine and hydraulics until the hydraulic oil reach-
es the operating temperature of 50 °C.
2 Lift a container weighing 35-45 tonnes.
3 Move the machine away to a level and a safe place.
NOTE
It is important that the ground is level and without gradient.
4 Retract the boom fully and lift to maximum.
5 Note the time for how long it takes to lower from the top position
until the container is about 20 cm from the ground.
Lowering should take 18-21 seconds.
6 If the time does not correspond then contact Cargotec for further
instructions.
The servo filter protects the control valve’s servo circuits against con-
taminants. The servo filter is located in the front edge of the lifting
beam on the right of the engine compartment, between the pressure
reducer and the control valve for lift, lower and extension.
The servo filter is a low-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter insert’s filter material.
The filter insert is pressed against the upper section of the filter hous-
ing by a spring. Rubber gaskets seal between the insert and filter
housing. If the back pressure through the filter is too great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
is viscous (cold or incorrect viscosity) or if the filter insert is clogged.
000534
The pressure reducer reduces the pressure from hydraulic oil pumps
to servo pressure for the control valve. The pressure reducer is located
1 to the right on the lifting beam in the engine compartment fitted togeth-
7 er with the accumulator for servo pressure.
3
000432
NOTE
Read the instructions for oil before working; see section B Safety.
˚C
000475
Operating menu, hydraulic oil temperature
3 Connect a pressure gauge (0–25 MPa) to the measuring outlet
on the pressure reducing valve.
4 Start the engine and check the servo pressure. Compare with the
pressure plate.
MPa Turn the steering wheel or activate a load handling function to ac-
tivate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
MPa
MPa
MPa
MPa MPa
001029
920643.0024
NOTE
If the servo pressure is too high, a load handling function
must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be
seen on the pressure gauge. Sometimes the engine has to
be shut off between the checks.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
6 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is lo-
cated 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 with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
001095
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Depressurise the brake and hydraulic systems, see section
B Safety.
2 Machine in service position, see section B Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
8 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
1. Connection, rod side, extension cylinder (B1) The speed of the function is controlled by means of the flow being reg-
2. Servo valve, boom out (Y6006) ulated in proportion to the lever movement.
3. Servo valve, lift (Y6005)
Lift slide
4. Connection, rod side, right lift cylinder (B2)
5. Connection, piston side, right lift cylinder (A2) The lift slide controls direction and flow of oil to the lift cylinder.
6. Servo valve, lower (Y6004)
7. Servo valve, boom in (Y6007) Servo valve, lift
8. Connection, feed from hydraulic oil pumps (P) The lift servo valve controls servo pressure to the lift slide so that it
9. Connection, piston side, extension cylinder (A1) controls oil pressure for lifting. The valve is controlled electrically with
the lift solenoid valve (Y6005), which is activated by Control unit, frame
front (D797-F).
The signals can be checked from the diagnostic menu, see section
8 Control system , group 8.4.8.4 BOOM, menu 4.
D ANGER
The lowering speed must correspond. If speed lower-
ing is too high there is a risk of rollover.
The machine must absolutely not be operated before
lowering speed is verified.
After replacing control valve lift, lower and extension or parts of the
valve, lowering speed must be checked. See Lowering speed, check-
ing page 15.
The lift cylinder valve block directs oil to the lift cylinder and is mounted
1
directly on the lower part of the lift cylinder. The valve block comprises
2 the blocking valve, regeneration valve, non-return valve and shock
valve.
3
Blocking valve
4 The blocking valve prevents unwanted lowering and angling of the lift
cylinders. The blocking valve holds the load by ensuring that the con-
5
nection to the lift cylinder’s piston side is closed. (The pressure passes
6 through a restriction as blocking pressure and holds the valve slide
closed.)
9
7 Servo valve blocking actuates the blocking valve. The servo valve is
controlled electrically with Solenoid valve, blocking left (Y6002) and
8
Solenoid valve, blocking right (Y6001), which are activated by Control
unit, frame front (D797-F).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.2 BOOM, menu 2.
Regeneration valve
The regeneration valve directs oil from the rod side of the cylinder back
to the piston side. This allows the oil to be re-used during lifting. For
000473
Non-return valve
The non-return valve prevents oil from going the wrong way during re-
generation.
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Turn the start key to position 0 and turn off the main electric
power.
4 Mark up and detach the wiring from the valve block.
5 Remove the wiring’s clamping at the valve block.
6 Mark up and detach the hydraulic hoses from the valve block.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Transfer one part at a time so that the marking is not mixed
up.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The lift cylinders lift and lower (angle) the lift boom. The lift cylinders
are located between boom and frame in the front edge of the machine,
one on the right and one on the left-hand side.
Each lift cylinder houses a valve block that controls pressurization and
regeneration of the lift cylinder.
The lift cylinder is equipped with guide bearings both in the cylinder
end and the piston rod mounting. The piston rod mounting is threaded
in the piston rod and locked with a lock nut.
The lift cylinders are connected in parallel and are supplied from the
lift, lower and extension control valve, see Control valve lift, lower and
extension page 20.
001096
D ANGER
Fatal danger, risk of crushing!
7 Mark up and detach the hydraulic hoses from the lift cylinder.
NOTE
The bearings are only lubricated during replacement.
15 Lift the new lift cylinder into place.
16 Fit the shafts for the lift cylinder.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the functions carefully and operate at the
lowest possible speed a couple of times to avoid cav-
itation.
23 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
If the machine is equipped with the fixed scale option then an extra
pressure sensor is used, on the piston side for the right lift cylinder.
2 1
If the machine is equipped with the electrical dynamic scale option
then two pressure sensors are used, one for the rod side and one for
the piston side on right and left-hand lift cylinders respectively (a total
of four pressure sensors).
The sensors are supplied with power by, and send a voltage signal
proportional to the hydraulic oil pressure, to Control unit, frame front
(D797-F).
The signals can be checked from the diagnostic menu, see section
001097
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Detach the cable harness from the lift cylinder hydraulic pressure
sensor.
4 Remove the lift cylinder hydraulic pressure sensor.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
NOTE
Check that the O-rings are intact and fitted correctly.
6 Connect the cable harness to the hydraulic pressure sensor.
7 Clamp the cable harness as before.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
C AUTION
Overfilling of oil, leakage, and environmental damage.
14 Check the function of the sensor from the diagnostic menu. See
DIAG OP 3(x) section 8 Control system, group 8.4.10.3 OP, menu 3.
PRESENT INPUT SIGNAL
LIFT CYL LE RI Raise the boom and check that the sensor is sending values. The
C- X.XXV X.XXV value should be approximately the same as from the sensor on
C+ X.XXV X.XXV the second lift cylinder (RI/LE).
C-
C+
008213
The lift boom lifts the load. The rear section of the boom is secured into
the frame with two bearing-mounted shafts. In the front edge is the lift
attachment and in the centre on each side of the boom are lift cylinders
which are secured with bearing-mounted shafts. The lift cylinders an-
gle the boom and raise the front section of the boom in this way. The
lift boom is available in several versions depending on reach and load
capacity.
The boom consists of outer boom and inner boom manufactured in
high-strength steel with a minimum number of welds to provide maxi-
mum strength.
The inner boom runs in the outer boom and can be extended longitu-
dinally with the extension cylinder. There are slide plates between in-
ner boom and outer boom which reduce the friction between them.
The slide plates are located in the front edge of the outer boom and
the rear edge of the inner boom.
Running along the left-hand side is a cable chain for hydraulic hoses
and cables between outer and inner boom.
1 2
001239
9 8 7 8 6 5 4 3
010491
7.3 Extension
Extension, function description (hydraulic oil
page
–
Overload system Boom out: passive Section 8 Control system , group 8.2.1 Overload system
Bypassed or the attachment Section 8 Control system, group 8.2.3 Load centre limitation
is within the limit for the load
Load centre limitation centre limitation.
Bypassed or boom height Section 8 Control system, group 8.2.4 Height limitation
lower than height limitation
Height limitation
1
D1
2, 4 5
D790-1 D794
Pa 18
D797-F D797-R
3,19 14, 20 D18 D24
D20
6 6 D6 D14 15 21 m
12
C11 13
7 PS PL 24
11 PP A1 VA
16, 22
A1 VA
C- 17, 23
P B1 VB C+
LS D
8
D3
9
C10
10
006406
2 Control unit, cab (D790-1) transmits the Checked by control system, Section 11 Common electrics, group
request for boom out or boom in with the error shown with error code. 11.5.3.1 Cab control unit
speed information on the CAN bus.
3 Control unit, frame front (D797-F) acti- I = 380-650 mA Control valve lift, lower and extension
vates Servo valve, boom out (Y6006) or page 20
Servo valve, boom in (Y6007). D3: Diagnostic menu, see section 8
During retraction of the boom Control Control system group 8.4.8.6 BOOM,
unit, frame rear (D797-R) activates So- menu 6 and 8.4.8.7 BOOM, menu 7 and
lenoid valve pump relief (Y6062). 8.4.8.2 BOOM, menu 2
4 The cab control unit (D790-1) transmits Checked by control system, Section 11 Common electrics, group
are request for increased engine speed error shown with error code. 11.5.3.1 Cab control unit
on the CAN bus.
5 The engine control unit (D794) increas- Checked by control system, Section 11 Common electrics, group
es engine speed. error shown with error code. 11.5.3.10 Engine control unit
6 Servo valve, boom out (Y6006) or Servo - Control valve lift, lower and extension
valve, boom in (Y6007) pressurises the page 20
control valve’s extension slide with ser- D6: Diagnostic menu, see section 8
vo pressure. Control system group 8.4.8.6 BOOM,
menu 6 and 8.4.8.7 BOOM, menu 7
7 The control valve’s extension slide - Control valve lift, lower and extension
changes position and pressurises valve page 20
block, extension cylinder and sends a
load signal to the hydraulic oil pumps.
8 When the boom is retracted the valve - Valve block, pump relief, description (hy-
block, pump relief load signal, drains to draulic oil pump alternative Rexroth)
two of the hydraulic oil pumps to the tank page 51
so that only two pumps generate pres-
sure.
9 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group
load signal if several functions are acti- 10.5.3 Shuttle valve
vated simultaneously.
11 The pressure reducer reduces pressure See pressure plate on left Pressure reducer, description page 16
from the hydraulic oil pumps to servo frame beam.
pressure.
12 Servo pressure is stored in the accumu- See pressure plate on left Accumulator servo circuit, description
lator. The non-return valve in the pres- frame beam. page 18
sure reducer makes it possible to store
the pressure when the engine is shut off.
13 The servo filter filters the oil before the - Servo filter, description page 16
control valve.
14 For boom in Control unit, frame rear U = 24 V Valve block extension cylinder, descrip-
(D797-R) activates Servo valve, block- tion page 47
ing extension (Y6050). D14: Diagnostic menu, see section 8
Control system, group 8.4.8.2 BOOM,
menu 2
15 For boom in Servo valve, blocking ex- - Valve block extension cylinder, descrip-
tension (Y6050) actuates the blocking tion page 47
slide in valve block, extension cylinder.
16 For boom out the blocking slide is - Valve block extension cylinder, descrip-
opened in valve block, extension cylin- tion page 47
der by the hydraulic pressure from the
control valve.
For boom in the blocking valve opens
and releases pressure from the exten-
sion cylinder.
19 Control unit, frame front (D797-F) sends Checked by control system, Section 11 Common electrics, group
information about the pressure in the lift error shown with error code. 11.5.3.2 Control unit, frame front
cylinders.
20 Control unit, frame rear (D797-R) acti- U = 24 V Valve block extension cylinder, descrip-
vates Servo valve, regeneration tion page 47
(Y6046), if the pressure is low enough D20: Diagnostic menu, see section 8
for regeneration. Control system, group 8.4.8.3 BOOM,
menu 3
22 The regeneration valve changes posi- - Valve block extension cylinder, descrip-
tion and directs oil from the rod side of tion page 47
the lift cylinder to the piston side.
Overload system Boom out: passive Section 8 Control system , group 8.2.1 Overload system
Bypassed or the attachment Section 8 Control system, group 8.2.3 Load centre limitation
is within the limit for the load
Load centre limitation centre limitation.
Bypassed or boom height Section 8 Control system, group 8.2.4 Height limitation
lower than height limitation
Height limitation
1
D1
2, 4 5
D790-1 D794
Pa 18
D797-F D797-R
3,19 14, 20 D18 D24
D20
6 6 D6 D14 15 21 m
12
C11 13
7 PS PL 24
11 PP A1 VA
16, 22
A1 VA
C- 17, 23
P B1 VB C+
LS D
8
D3
9
C10
10
006406
2 Control unit, cab (D790-1) transmits Checked by control system, Section 11 Common electrics, group
the request for boom out or boom in error shown with error code. 11.5.3.1 Cab control unit
with the speed information on the
CAN bus.
3 Control unit, frame front (D797-F) ac- I = 380-650 mA Control valve lift, lower and extension page
tivates Servo valve, boom out 20
(Y6006) or Servo valve, boom in D3: Diagnostic menu, see section 8 Control
(Y6007). system, group 8.4.8.6 BOOM, menu 6,
During retraction of the boom Control 8.4.8.7 BOOM, menu 7 and 8.4.8.2
unit, frame rear (D797-R) activates BOOM, menu 2
Solenoid valve pump relief (Y6062).
4 The cab control unit (D790-1) trans- Checked by control system, Section 11 Common electrics, group
mits are request for increased engine error shown with error code. 11.5.3.1 Cab control unit
speed on the CAN bus.
5 The engine control unit (D794) in- Checked by control system, Section 11 Common electrics, group
creases engine speed. error shown with error code. 11.5.3.10 Engine control unit
6 Servo valve, boom out (Y6006) or - Control valve lift, lower and extension page
Servo valve, boom in (Y6007) pressu- 20
rises the control valve’s extension D6: Diagnostic menu, see section 8 Control
slide with servo pressure. system, group 8.4.8.6 BOOM, menu 6 and
8.4.8.7 BOOM, menu 7
7 The control valve’s extension slide - Control valve lift, lower and extension page
changes position and pressurises 20
valve block, extension cylinder and
sends a load signal to the hydraulic oil
pumps.
8 When the boom is retracted the valve - Valve block, pump relief, description (hy-
block, pump relief load signal, drains draulic oil pump alternative Sauer-Danfoss]
to one of the hydraulic oil pumps to page 52
the tank so that only one pump gener-
ates pressure.
10 The hydraulic oil pumps pump oil See pressure plate on left Section 10 Common hydraulics, group
from the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
11 The pressure reducer reduces pres- See pressure plate on left Pressure reducer, description page 16
sure from the hydraulic oil pumps to frame beam.
servo pressure.
12 Servo pressure is stored in the accu- See pressure plate on left Accumulator servo circuit, description page
mulator. The non-return valve in the frame beam. 18
pressure reducer makes it possible to
store the pressure when the engine is
shut off.
13 The servo filter filters the oil before - Servo filter, description page 16
the control valve.
14 For boom in Control unit, frame rear U = 24 V Valve block extension cylinder, description
(D797-R) activates Servo valve, page 47
blocking extension (Y6050). D14: Diagnostic menu, see section 8 Con-
trol system, group 8.4.8.2 BOOM, menu 2
15 For boom in Servo valve, blocking ex- - Valve block extension cylinder, description
tension (Y6050) actuates the block- page 47
ing slide in valve block, extension
cylinder.
16 For boom out the blocking slide is - Valve block extension cylinder, description
opened in valve block, extension cyl- page 47
inder by the hydraulic pressure from
the control valve.
For boom in the blocking valve opens
and releases pressure from the ex-
tension cylinder.
19 Control unit, frame front (D797-F) Checked by control system, Section 11 Common electrics, group
sends information about the pressure error shown with error code. 11.5.3.2 Control unit, frame front
in the lift cylinders.
22 The regeneration valve changes po- - Valve block extension cylinder, description
sition and directs oil from the rod side page 47
of the lift cylinder to the piston side.
8 3 Extension slide
The extension slide controls direction (in or out) and oil flow to valve
7 4 block extension cylinder.
The signal can be checked from the diagnostic menu, see section
1. Connection, rod side, extension cylinder (B1) 8 Control system , group 8.4.8.7 BOOM, menu 7.
2. Servo valve, boom out (Y6006)
Servo valve, boom in
3. Servo valve, lift (Y6005)
4. Connection, rod side, right lift cylinder (B2) Servo valve boom in, controls servo pressure to the extension slide so
5. Connection, piston side, right lift cylinder (A2) that it controls oil pressure for boom retraction.
6. Servo valve, lower (Y6004) Servo valve boom in is controlled electrically with Solenoid valve boom
7. Servo valve, boom in (Y6007) in (Y6007) which is activated by Control unit, frame front (D797-F).
8. Connection, feed from hydraulic oil pumps (P)
The signal can be checked from the diagnostic menu, see section
9. Connection, piston side, extension cylinder (A1)
8 Control system , group 8.4.8.6 BOOM, menu 6.
Regeneration valve
000474
The regeneration valve directs oil from the rod side back to the piston
side. This allows the oil to be re-used during extension. For more in-
1. Connection, rod side, (C-) formation on regeneration see Extension, function description (hy-
2. Draining (D) draulic oil pump alternative Rexroth) page 37 or Extension, function
3. Solenoid valve regeneration (Y6046) description (hydraulic oil pump alternative Sauer-Danfoss) page 41.
4. Connection control valve (VB) The regeneration valve is regulated by the regeneration servo valve.
5. Connection control valve (VA)
Solenoid valve, extension (Y6046) pressurises the regeneration valve.
6. Connection control valve (VA)
7. Solenoid valve blocking (Y6050) Solenoid valve, extension (Y6046) is activated by Control unit, frame
rear (D797-R).
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.8.3 BOOM, menu 3.
The extension cylinder forces out and pulls in the inner boom. The ex-
tension cylinder is located in the lift boom. The rear section is secured
in the outer boom, the front section is secured in the inner boom. On
the extension cylinder is a valve block which controls pressurising of
the cylinder and regeneration for boom out.
The extension cylinder piston rod end is designed as a lug with a
flange which is secured on the piston rod with hexagonal bolts.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Removal
1 Machine in service position, see section B Safety.
2 Operate the boom out until the inspection holes in the side of the
inner boom become accessible.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
4 Remove the lock rings and press out the shaft for the front cylin-
der mounting in the inner boom.
NOTE
Plug all hydraulic connections immediately.
7 Mark up and detach the wiring from the valve block on the exten-
sion cylinder.
8 Remove the valve block from the extension cylinder.
NOTE
Plug all hydraulic connections immediately.
9 Remove the lock rings and press out the outer shafts for the rear
cylinder mountings in the outer boom.
10 Connect lifting equipment to the rear extension cylinder
mounting.
11 Tighten the extension cylinder carefully. When the cylinder has
come out slightly connect a second lifting device that is moved
forward on the lift cylinder during the entire disassembly in order
to stabilise the lifting.
12 Place the cylinder on wooden blocks.
Outer shafts extension cylinder
13 Transfer parts to the new extension cylinder.
Installation
14 Clean and lubricate all bearing surfaces with lubricating grease.
15 Measure how far the old extension cylinder is extended and ex-
tend the new cylinder to the same length.
NOTE
If this is not carried out then the front cylinder mounting will
not reach far enough forward.
16 Lift the extension cylinder into place.
C AUTION
Use the dual lifting devices to achieve balance during
the lifting. The front should be positioned behind the
support at the front edge of the cylinder so that it can
be slid into the boom.
17 Fit the shaft at the front cylinder mounting in the inner boom.
NOTE
Lubricate the shaft with lubricating grease before
installation.
18 Fit the lock rings on the shaft.
NOTE
Lubricate the shaft with lubricating grease before
installation.
20 Fit the lock rings on the shafts.
21 Fit the valve block on the extension cylinder.
NOTE
Check that the O-rings are intact and fitted correctly.
22 Connect the hydraulic hoses and the wiring to the extension
cylinder.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The hydraulic oil level is checked with the boom com-
pletely lowered and retracted.
28 Calibrate the sensor for boom length, see section 8 Control sys-
tem, group 8.5.2.1 Calibrate SCALE steps 9 - 12.
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom and that the
inner boom is centred in the outer boom.
Front slide plates
1 Move the boom to the lowest position with the inner boom extend-
ed approx. 50 cm.
2 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slid plate.
3 Fit in the reverse order.
4 Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with spacer plates as required.
NOTE
1. Side-mounted slide plates Inner boom must be centred in the outer boom.
2. Lower slide plates 5 Remove the lock screws and the slide plates’ brackets, and pull
out the upper slide plates and the spacer plates.
6 Unload the lower slide plates, lift the inner boom at the front edge
and use wooden shims.
WARN IN G
Risk of pinch injury!
Secure the inner boom relative to the outer boom with
wooden blocks.
7 Remove the lock screws, slide plates’ brackets and pull out the
lower slide plates.
8 Transfer the nuts for the lock screws for the lower slide plates to
the new slide plates.
9 Fit the new lower slide plates, lock screws and brackets.
10 Remove the wooden blocks and ease down the inner boom so
that it rests on the lower slide plates.
11 Transfer the nuts for the lock screws for the upper slide plates to
the new slide plates.
12 Fit the new slide plates, spacer plates, lock screws and brackets.
13 Check the clearance between the boom and stop at the front
edge/top edge of the boom, the clearance must be max. 2 mm,
adjust the slide plates with spacer plates if necessary.
Check attachment levelling
14 Park the machine on level ground.
15 Lower the boom fully and centre the attachment.
16 Measure the distance between the extension beam and the
ground on the right and left-hand sides of the attachment.
The difference between the dimensions for right (A) and left (B)
sides must not be more than 50 mm at 20' position, or 100 mm
for 40' position.
Check both the dimensions with the boom fully retracted and fully
A B extended.
008217
23 Remove the cover plates, spacer plates and the lower slide
plates.
24 Fit new slide plates, spacer plates and cover plate.
25 Unload the upper slide plates, use wooden shims.
WARN IN G
Risk of pinch injury!
26 Remove the lock screws, the slide plates’ brackets and pull out
the upper slide plates and the spacer plates.
27 Transfer the nuts for the lock screws for the upper slide plates to
the new slide plates.
28 Fit the new slide plates, spacer plates, lock screws and brackets.
29 Check the clearance between the outer and inner boom, the
clearance should be max. 2 mm, adjust the slide plates with
spacer plates as required.
Lubrication
004874
Sliding surfaces, boom
30 Operate the inner boom outwards completely and lubricate the
sliding surfaces inside the outer boom and on the inner boom with
white lubricating paste.
31 Operate the boom in and out about 10 times and stop with the
boom fully out.
32 Wipe away excess lubricating paste at the slide plates and on
sliding surfaces.
1
D1
2
D790-1
D797-R D791-1
3 7 D7
D3 8
C6
P1 A
10
9
4
T1 B
5
C6
6
006407
Pos Explanation Signal description Reference
1 The control lever (S815-T1.1) sends a Left: US815-T1.1 = 24 V Control lever, description page 7
voltage signal to the cab control unit D1: Diagnostic menu, see section 8 Control
Right: US815-T1.2 = 24 V
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits side shift left or right on the CAN tem, error shown with er- Cab control unit
bus. ror code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group 11.5.3.3
vates the solenoid valve, engagement Control unit, frame rear
of hydraulics for top lift (Y6003). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description
draulics for top lift (Y6003) opens and page 58
pressurises valve block lift cylinder and D3: Diagnostic menu, see section 8 Control
sends a load signal to hydraulic oil system, group 8.4.5.6 HYD, menu 6
pump 2.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. frame beam. Axial piston pump with variable displacement
7 Control unit, attachment (D791-1) acti- U = 24 V Section 11 Common electrics, group 11.5.3.5
vates the servo valve for side shift left Control unit, attachment
(Y6020) or servo valve for side shift D7: Diagnostic menu, see section 8 Control
right (Y6021). system, group 8.4.9.8 ATTACH, menu 8
8 The servo valve for side shift left - Attachment control valve, description page
(Y6020) or servo valve for side shift 59
right (Y6021) pressurises the side shift D7: Diagnostic menu, see section 8 Control
slide in the attachment control valve. system, group 8.4.9.8 ATTACH, menu 8
9 The control valve’s side shift slide - Attachment control valve, description page
changes position and pressurizes the 59
side shift cylinders.
10 The side shift cylinders push the main - Side shift cylinder, description page 64
beam in sideways in relation to the
side shift frame.
The valve block for top lift hydraulics is an electrically controlled valve.
1 2 3 4
It leads an unloaded constant pressure as the load signal to the hy-
draulic oil pumps when attachment functions are activated. The valve
block is positioned horizontally on the bracket for the oil filling point be-
5 tween the engine and transmission.
When the solenoid valve is activated, pressure is routed from the top
10 6 hydraulics’ supply through a shuttle valve to the hydraulic oil pumps for
steering. A restriction before the valve block ensures that pressure for
7 control of the hydraulic oil pumps does not become too high. When the
9 solenoid valve is not activated, the load signal is drained to the tank
8 and the inlet from the top hydraulics’ supply is closed.
The valve is controlled electrically with Solenoid valve, engagement
hydraulic pressure (Y6003) which is activated by Control unit, frame
rear (D797-R).
003623
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.5.6 HYD, menu 6.
1. Solenoid valve, engagement of hydraulic pressure
(Y6003)
2. Pressure signal to hydraulic oil pump 2
3. Valve block, top lift hydraulics
4. Tank drain
5. Pressure signal in, from shuttle valve
6. Valve block, pump relief
7. Pressure signal to hydraulic oil pump 2
8. Solenoid valve, pump relief (Y6062)
9. Tank drain
10. Pressure signal in, from shuttle valve 1
1 2 3 4 5 6 7 8 9 10
11
28
27 12
26
13
25
24
001098
23 22 21 20 19 18 17 16 15 14
14. Connection to spreader motor 28. Solenoid valve, levelling left (Y6036)
15. Connection to spreader motor
• Controllable tilt
• Hydraulic levelling
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer the connection adapters to the new control valve.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Transfer one adapter at a time so that the marking is not
mixed up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
Lift the valve into place and fit the attaching bolts.
9 Connect the wiring to the control valve in accordance with the
marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
16 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
pressure
NOTE
Read the instructions for oil before working; see section B Safety.
˚C
Operating menu, hydraulic oil temperature 000475
Function Pressure
15.0 MPa
Tilt control
Measuring outlet, control valve, attachment 15.5 MPa
Levelling
10.0 MPa
Overheight jacks, lowering
10.0 MPa
Lifting jacks, knee in/out
13.0 MPa
Lifting jacks, jack up/down
13.0 MPa
Lifting jacks, clamping
5 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
The side shift cylinders are two cross connected hydraulic cylinders
1 which extend the attachment’s main beam laterally in relation to the
sideshift frame. The side shift cylinders are located along the front and
10 rear of the attachment and are used to centre the load’s centre of
gravity.
9
8 2
3
4 001500
7 6 5
The attachment is secured in the boom with the rotation yoke. The side
1 2 3 4 5 6 shift frame is located under the rotation yoke. The attachment’s main
beam is located in the side shift frame. The main beam can be extend-
ed laterally in relation to the side shift frame with two hydraulic cylin-
ders. Inside the main beam are two spreader beams which can be
extended in and out with a hydraulic motor.
The position of the attachment can be adjusted laterally by moving the
main beam in relation to the side shift frame. The main beam runs on
slide pates in the sides and in the bottom. The side shift cylinders se-
cure the lateral position.
The side shift frame is available in two versions:
• Standard top lift. The side shift frame allows the main beam to be
000526
1 Undo the cover plate’s attaching bolt and remove the cover plate.
2 Remove the spacer plates and slide plate.
3 Repeat steps 1 - 3 on the other slide plates.
4 Measure the distance between the edge of the cover plate and
the attachment’s main beam slide surface on all slide plates.
5 Centre the boom so that the distance between the attachment’s
main beam and edge is the same on all slide plates.
Lubrication
004875
Sliding surfaces, attachment
11 Lubricate the sliding surfaces of the attachment with white lubri-
cating paste.
12 Operate full side shift from right to left approx. 10 times.
13 Wipe away excess lubricating paste at the slide plates and on
sliding surfaces.
D ANGER
Risk of pinch injury!
Lubrication
004875
The main beam attachment is located in the side shift frame. The main
1 2 3 4 5 6 beam contains equipment for spreading (spreader beams, hydraulic
motor, chains, slide plates and sensors). On the attachment’s main
beam are also the control valves for the attachment’s hydraulic
functions.
000526
1. Main beam
2. Ring gear
3. Rotation motor unit
4. Rotation yoke
5. Control valve attachment
6. Side shift frame
The attachment relief valve opens the connection between the attach-
ment’s pressure supply and the tank. This is used to drain the pressure
in the attachment hoses prior to work on the hydraulic system. The re-
lief valve is located at the rear of the lifting beam in front of the
transmission.
002269
7.5 Spreading
Spreading, function description
page
–
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
1 D1
+
2
D790-1
D797-R D791-1
3 7, 13 D12
D3 D7
8, 14
C6
12
P1 A
4
11, 16
T1 B
9, 15 10
5
C6
6
006408
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group
mits a signal on the CAN bus. tem, error shown with error 11.5.3.1 Cab control unit
code.
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description
draulics for top lift (Y6003) opens and page 58
sends a load signal to the hydraulic oil D3: Diagnostic menu, see section 8 Control
pumps. system, group 8.4.5.6 HYD, menu 6
5 The shuttle valve forwards the strong- - Section 10 Common hydraulics, group
est load signal to the hydraulic oil 10.5.3 Shuttle valve
pumps if several functions are activat-
ed simultaneously.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Section 10 Common hydraulics, group
the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
7 The attachment control unit (D791-1) I = 350–600 mA Section 11 Common electrics, group
activates the servo valve for spreading 11.5.3.5 Control unit, attachment
out (Y6018) or spreading in (Y6019). D7: Diagnostic menu, see section 8 Control
system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
8 The servo valve for spreading out - Attachment control valve, description page
(Y6018) or spreading in (Y6019) pres- 59
surizes the spreader slide in the at- D7: Diagnostic menu, see section 8 Control
tachment’s control valve. system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
9 The control valve’s spreader slide - Attachment control valve, description page
changes position and directs pressure 59
to the spreader motor.
10 The motor valve block directs the pres- - Spreader motor valve block, description
sure to the motor and prevents the mo- page 79
tor from pumping (rotating faster than
supplied pressure).
11 The motor drives the chains that ex- - Spreader motor, description page 79
tend or retract the spreader beams.
12 The sensor for end position 20’-40’ Sensor directly opposite in- Position sensor spreading, description
(B769) sends a voltage signal to the at- dicator plate: U > 24 V page 93
tachment control unit (D791-1). D12: Diagnostic menu, see section 8 Con-
trol system, group 8.4.9.5 ATTACH, menu 5
15 The control valve’s spreader slide - Attachment control valve, description page
changes position and reduces pres- 78
sure to the spreader motor.
16 The speed of the spreader motor is re- - Spreader motor, description page 79
duced.
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
2
1
35
D2
30-
D1 3
D790-1
D791-1 D5 D7
6, 8
D8
5 7
006409
2 The control lever (S815-T1.2 and Spreading: US815-T4 = 24 V Control lever, description page 7
S815-T4) sends a voltage signal to the D2: Diagnostic menu, see section 8 Control
Out: US815-T1.2 = 24 V
cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 2
In: US815-T1.1 = 24 V
3 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
spreading 30’ on the CAN bus. tem, error shown with error 11.5.3.1 Cab control unit
code.
7 When spreading is in the 30’ position, Sensor directly opposite in- Position sensor spreading, description
the 20’-40’ end position sensor (Y769) dicator plate: U = 24 V page 93
sends a voltage signal. D7: Diagnostic menu, see section 8 Control
system, group 8.4.9.5 ATTACH, menu 5
8 Spreading is interrupted by the attach- U=0V Attachment control valve, description page
ment control unit (D791-1) cutting of 78
current to the servo valve for spreading D8: Diagnostic menu, see section 8 Control
out (Y6018) or spreading in (Y6019). system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
description
Overload system Passive Section 8 Control system, group 8.2.1.1 Mechanical overload system
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
2 D2
1
+
3 9
D1 D790-1 D795
D791-1
4, 5, 8, 11 D10 D7
D5
D4 10 7
6
006884
2. The switch for automatic spread- Switch in ON position: Switch automatic spreading, description page
ing 20’-40’ (S199-2) sends a volt- US199-2/2 = 0 V 10
age signal to the cab control unit D2: Diagnostic menu, see section 8 Control sys-
(D790-1). US199-2/5 = 24 V
tem, group 8.4.9.4 ATTACH, menu 4
Switch in OFF position:
US199-2/2 = 24 V
US199-2/5 = 24 V
3. The cab control unit (D790-1) Checked by control sys- Section 11 Common electrics, group 11.5.3.1
transmits "automatic spreading tem, error shown with error Cab control unit
out" or "automatic spreading in" on code.
the CAN bus.
5. The attachment control unit Buzzer active: U = 24 V Buzzer for automatic spreading 20’-40’, descrip-
(D791-1) activates the automatic tion page 94
spreading buzzer (H9003). D5: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.9.15 ATTACH, menu 15
6. The automatic spreading buzzer Buzzer active: U = 24 V Buzzer for automatic spreading 20’-40’, descrip-
(H9003) generates an acoustic tion page 94
warning signal. D5: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.9.15 ATTACH, menu 15
7. When spreading approaches the Sensor directly opposite in- Position sensor spreading, description page 93
30' position, the end position 30’ dicator plate: U = 24 V D7: Diagnostic menu, see section 8 Control sys-
sensor (B777-3) sends a voltage tem, group 8.4.9.5 ATTACH, menu 5
signal to the attachment control
unit (D791-1).
10. When spreading is at the 20' posi- Sensor directly opposite in- Position sensor spreading, description page 93
tion, 30' position or 40' position, dicator plate: U = 24 V D10: Diagnostic menu, see section 8 Control
the 20’-40’ end position sensor system, group 8.4.9.5 ATTACH, menu 5
(B769) sends a voltage signal to
the attachment control unit
(D791-1).
11. The attachment control unit I = 0 mA Attachment control valve, description page 78
(D791-1) cuts off control current to D4: Diagnostic menu, see section 8 Control sys-
the servo valve for spreading out tem, group 8.4.9.13 ATTACH, menu 13 and
(Y6018) or spreading in (Y6019). 8.4.9.14 ATTACH, menu 14
Spreader slide
The valve slide controls the direction and speed of spreading. The
valve slide is controlled by a servo valve for spreading out and a servo
valve for spreading in.
The spreader motor valve block regulates the oil’s direction to the
spreader motor. The valve block sits on the spreader motor all the way
out out to the left on the front side of the attachment’s main beam.
The valve block maintains a balance between supply and spreading
speed. Balance means that the valve block prevents the motor from
pumping oil, i.e. rotates faster than the supply of oil allows. The
spreading valve block contains overcentre valves that block the outlet
if pressure on the outlet side is higher than pressure on the inlet side.
I II
001004
Via two chains, the spreader motor moves the spreader beams in and
1 out in the attachment’s main beam. The spreader motor sits all the way
out out to the left on the front side of the attachment’s main beam.
10
The hydraulic motor is integrated with a planetary gear that reduces
speed and makes the motor more powerful. A valve block with two
9
overcentre valves is located on the hydraulic connections and pre-
vents the motor from rotating faster than the supplied hydraulic
8 2 pressure.
3
4
001500
7 6 5
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Remove the cover on the left side of the attachment’s main beam.
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
4 Stop the engine and turn the starter key to position I.
5 Depressurise the brake and hydraulic systems, see section
B Safety.
6 Turn the start key to position 0 and turn off the main electric
power.
7 Measure and note the chain tensioners’ length to attain the cor-
rect chain tension when refitting.
8 Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
10 Mark up and detach the hydraulic hoses from the valve block of
the spreader motor.
NOTE
Check that the O-rings are intact and fitted correctly.
13 Clean the contact surfaces between the planetary gear and the
attachment’s main beam.
14 Fit the motor unit. Tighten the bolts crosswise in steps until
117 Nm is achieved.
15 Attach the hydraulic hoses to the valve block.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
26 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The spreader chains move the extension beams in and out of the at-
tachment’s main beam. The force from the spreading motor is trans-
ferred to extension beams via two chains. The chains run inside the
attachment between the extension beams.
The chains are fastened crosswise with one end at the bottom of one
M extension beam and the other end along the side of the other exten-
sion beam.
Openings in the sides of the extension beams and the attachment’s
main beam make it possible to access the chains for maintenance
purposes.
000472
20-foot position
2 Start the engine, run spreading in to the 20-foot position and
switch off the engine.
3 Check that both spreader beams are against the 20-foot stop and
that the distance between the spreader beam and spreader mo-
tor mounting is at least 3 mm.
4 Check the C-C measurement between the twistlocks.
C-C 20 feet: 5853±3 mm.
If the 20-foot setting is correct proceed to step 8.
NOTE
Note the distance the stop was adjusted.
Run spreading out a little to make it possible to move the
washers.
C AUTION
20-foot stop
Incorrect chain tension.
NOTE
Check the vertical position of the chain tensioner so that the
chain runs straight to the sprocket.
005105
40-foot position
8 Start the engine, run spreading out to the 40-foot position and
switch off the engine.
9 Check the C-C measurement between the twistlocks.
C-C 40 feet: 11985±3 mm.
If the 40-foot setting is correct proceed to step 11.
10 Adjust the 40-foot stop if necessary.
Chain tension
11 Start the engine and run spreading out to the 40-foot position.
12 Wait 2 minutes and then check the tension of the chains.
005106
40-foot stop
13 Use suspension scales and measure how far the chain moves
100 N
815 mm when pulled outward with a force of 100 N at 815 mm from the
main beam’s internal reinforcement collar as illustrated.
Standard attachment: X = 8-13 mm.
Overheight attachment: X = 5-6 mm.
815mm
100 N
0N
010486
100 N
X
NOTE
Adjust max. 2 mm on the chain tightener at a time.
15 Repeat steps 11–14 until the chains have the correct tension.
16
If the machine is equipped with a 30 or 35-foot stop, start the en-
gine, run spreading out to the 30 or 35-foot position, switch off the
engine and check the C-C measurement between the twistlocks.
C-C 30 feet: 8918±3 mm
C-C 35 feet: 10488±3 mm
I M P OR TA NT
Check the distance at stop from both 20’ and 40’.
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
4 Turn off the engine and the main electrical power.
005105
NOTE
Measure and note the chain tensioners’ length to attain the
correct chain tension when refitting.
005105
NOTE
Note the location of the spacer ring.
If the sprocket on the engine side must be removed, fist remove
the spreader motor. See Spreader motor, replacement page 80.
7 Pull the chain out through the sprocket hole so that the chain runs
along the spreader beam.
8 Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.
NOTE
Support the spreader beam to minimise breaks. If neces-
sary, remove the upper slide plates to reduce resistance.
12 Detach the cable rack from the attachment’s main beam. Support
the cable rack so that it is not damaged.
13 Pull out the spreader beam until the chain mounting becomes
accessible.
14 Detach the chain from the spreader beam and cable rack.
15 Connect the new chain to the spreader beam.
16 Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
17 Grease the chain with lubricating grease.
23 Detach the chain from the cable rack and insert it through the
sprocket hole.
24 Fit the sprocket. The spacer ring should sit on the underside of
the sprocket.
If the rotation motor has been removed, refit it. See Spreader mo-
tor, replacement page 80.
NOTE
Check that the chain runs straight in the sprockets.
NOTE
Use a new split pin.
005105
The spreader beams are the part of the attachment that grip the con-
1 tainer. Two spreader beams run along the main beam. The spreader
beams are slid in and out via the spreader motor and spreader chains.
10
The spreader beam houses twistlocks. See Twistlocks, description
page 137.
9
8 2
3
4
001500
7 6 5
Lubrication
004875
With the 30-foot stop option, there is an extra sensor - position sensor
(B779) - and two indicator plates. The sensor is used to activate the
30-foot stop.
The sensors are supplied power by and send a 24 V signal to the at-
tachment control unit (D791-1) when the indicator plates pass the sen-
sor. Indicator plates on the spreader units are mounted so that the
sensors generate a signal when the spreader unit passes the sensor.
The indicator plates and the position of the sensors are designed so
that the distance between the spreaders becomes 20’ (30’) and 40’.
The signals can be checked from the diagnostic menu, see section
8 Control system , group 8.4.9.5 ATTACH, menu 5.
003165
7.6 Rotation
Rotation, function description
page
–
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
D1
1
2
D790-1
D797-R D791-1
3 7
D8
D4
8
C6
P1 A
11, 12
4 T1 B
9 10
C6 5
006410
2 Control unit, cab (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
clockwise rotation or anticlockwise tem, error shown with er- Cab control unit
rotation on the CAN bus. ror code.
3 Control unit, frame rear (D797-R) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the solenoid valve, en- Control unit, frame rear
gagement of hydraulics for top lift D4: Diagnostic menu, see section 8 Control
(Y6003). system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description page
draulics for top lift (Y6003) opens 58
and pressurises valve block lift cyl- D4: Diagnostic menu, see section 8 Control sys-
inder and sends a load signal to the tem, group 8.4.5.6 HYD, menu 6
hydraulic oil pumps.
5 The shuttle valve forwards the - Section 10 Common hydraulics, group 10.5.3
strongest load signal to hydraulic oil Shuttle valve
pump 2 if several functions are acti-
vated simultaneously.
6 Hydraulic oil pump 2 pumps oil from See pressure plate on left Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. frame beam. Axial piston pump with variable displacement
7 Control unit, attachment (D791-1) I = 435–650 mA Section 11 Common electrics, group 11.5.3.5
activates servo valve, rotation Control unit, attachment
clockwise or servo valve, rotation D8: Diagnostic menu, see section 8 Control sys-
anticlockwise. tem, group 8.4.9.11 ATTACH, menu 11 and
8.4.9.12 ATTACH, menu 12
8 Servo valve, rotation clockwise - Attachment control valve, description page 100
(Y6008) or servo valve, rotation an- D8: Diagnostic menu, see section 8 Control sys-
ticlockwise (Y6009) pressurise the tem, group 8.4.9.11 ATTACH, menu 11 and
rotation slide in the attachment con- 8.4.9.12 ATTACH, menu 12
trol valve.
10 The hydraulic motor valve block - Valve block rotation motor, description page 101
controls the pressure to both
motors.
11 The hydraulic motors’ disc brakes - Rotation motor unit, description page 102
are disengaged.
12 The hydraulic motors rotate the - Rotation motor unit, description page 102
attachment.
Rotation stop is used to avoid rotating the attachment into the boom in
the raised position.
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
1 D1
2
3 7
D2 D790-1 D795
D791-1 D5
6
D6
006411
5
US1014/5 U = 24 V
2 Control lever (S815-P3) sends Anticlockwise: US815/P3 = 0.5–2.0 V Section 9 Frame, body, cab and accesso-
the cab control unit (D790-1) a ries, group 9.1 Controls and instruments
Zero position: US815/P3 = 2.0–3.0 V
voltage signal proportional to D2: Diagnostic menu, see section 8 Control
lever movement. Clockwise: US815/P3 = 3.0–4.5 V
system, group 8.4.9.1 ATTACH, menu 1
0.5 V is the minimum rotation speed
and 4.5 V is the maximum rotation
speed. Lower voltages than 0.5 V
and higher voltages than 4.5 V are
used to detect malfunctions in ca-
bling and controls.
5 Sensor rotation stop (B7225) Sensor directly opposite indicator Sensor rotation stop, description page 110
sends a voltage signal to the plate: U = 24 V D5: Diagnostic menu, see section 8 Control
attachment control unit system, group 8.4.9.21 ATTACH, menu 21
(D791-1).
Rotation slide
The valve slide controls the direction and speed of rotation. The valve
slide is controlled by servo valve, rotation clockwise and servo valve,
rotation anticlockwise.
1
1
2
2
3 3
4 4
6 5
7
000530
The rotation motors rotate the attachment in relation to the boom. The
motors are located along the front pf the attachment’s rotation yoke.
The motors work against the ring gear between the rotation yoke and
the side shift frame. The rotation motor unit consists of hydraulic mo-
tor, disc brake and planetary gear which are built together into one
unit.
The hydraulic motor is located on the disc brake housing. Between the
motor and the discs is a gear wheel.
The disc brake prevents accidental rotation. The disc brake is applied
1 with springs and is disengaged when the hydraulic pressure is built up
1
to rotate the yoke.
2
2 The planetary gear reinforces the output in the motor and disc brake.
3 The planetary gear changes the motor speed down so that motor pow-
3
er is greater.
4 4
6 5
7
000530
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up and detach the hydraulic hoses from the motor.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Remove the hydraulic motor’s attaching bolts.
5 Lift away the rotation motor unit. Position the motor unit so that
the pinion and planetary gear are not damaged.
6 Clean the contact surfaces on the motor unit and rotation yoke.
7 Lift the new motor unit into place.
8 Fit the motor unit. Tighten the bolts crosswise in steps until
117 Nm is achieved.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
15 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The rotation yoke is a part of the attachment which connects the at-
1 2 3 4 5 6 tachment to the boom. The rotation yoke is secured on the inner boom
with two shafts which run in bearing equipped attaching lugs. In the
bottom of the rotation yoke is the ring gear with lead-through bolts.
Using the rotation motors which act on the ring gear the remaining
parts of the attachment can be rotated in relation to the lift boom.
The rotation yoke’s mounting in the lift boom facilitates longitudinal
motion (so-called tilt). The oscillating motion is dampened by two hy-
draulic cylinders which are secured between the upper yoke and the
upper edge on the inner boom.
000526
1. Main beam
2. Ring gear
3. Rotation motor unit
4. Rotation yoke
5. Control valve attachment
6. Side shift frame
NOTE
Align the position against that of the ring gear so that the lu-
brication lines can be fitted.
13 Grease the rotation yoke’s mounting shafts with lubricating
grease and fit them in the rotation yoke.
NOTE
If necessary, rotate the rotation yoke so that the rotation mo-
tor’s gear wheel aligns against the ring gear.
19 Connect the attachment to the boom.
20 Start the motor and check that the rotation is working.
21 Clean the attachment.
22 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
C AUTION
Overfilling of oil.
The ring gear is the joint between the rotation yoke and the side shift
frame. The ring gear consists of gear wheel, bearings and mounting
parts. The unit is bolted into the rotation yoke and side shift frame.
1
1
2
2
3 3
4 4
6 5
7
000530
NOTE
Note down the locations of the lubricating pipes to facilitate
fitting.
The illustration shows removed rotation yoke and ring 3 Remove the attaching bolts between the ring gear and the side
gear. shift frame.
4 Lift away the ring gear.
5 Clean the contact surfaces on the side shift frame and ring gear.
6 Lift the new ring gear into place.
NOTE
Rotate it so that the connections for the lubricating pipes are
in the same positions as before.
7 Lubricate the inner attaching bolts with lubricating grease and fit
them. Tighten the bolts crosswise in turns to a torque of 331 Nm.
8 Fit the rotation yoke, see Rotation yoke, replacement page 106.
9 Fit the lubricating pipes to the ring gear.
10 Lubricate the ring gear with lubricating grease.
11 Start the motor and check the function of the rotation.
C AUTION
Overfilling of oil.
Sensor rotation stop (B7225) indicates when rotation is 25° from the
centre position and is used to activate rotation stop. The sensor is lo-
cated on a bracket on the left side of the rotation yoke and detects 25°
towards the rotation yoke’s mechanical stop.
The sensors are supplied with voltage and send 24 V signal to the at-
tachment control unit (D791-1) when the raised parts pass the sensor.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.9.21 ATTACH, menu 21.
7.7 Tilt
Tilt damping, function description
page
–
2
C1-
A C2+
C
B C1+
C2- 3
1
000461
Pos Explanation Signal description Reference
1 Hydraulic oil pump 2 pumps oil. See pressure plate on Section 10 Common hydraulics, group
left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
2 The tilt damping block distributes oil to the - Damping block tilt, description page 117
tilt cylinders.
3 The tilt cylinders suppress the attachment’s - Tilt cylinder, description page 121
movements.
1 D1
2 11
D790-1 D795
D797-R D791-1
3 7
D3 8 D7
C1-
A C2+
10
4
B C1+
C2-
5 9
C6
6
006412
Pos Explanation Signal description Reference
1 The control lever (S815-T3.1) sends a US815-T3.1 = 24 V Section 9 Frame, body, cab and accessories,
voltage signal to the cab control unit group 9.1 Controls and instruments
(D790-1). D1: Diagnostic menu, see section 8 Control
system, group 8.4.9.4 ATTACH, menu 4
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
tilt locking on the CAN bus. tem, error shown with Cab control unit
error code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Valve block, top lift hydraulics, description
vates the solenoid valve, engagement of page 58
hydraulics for top lift (Y6003). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and pres- page 58
surises valve block lift cylinder and D3: Diagnostic menu, see section 8 Control
sends a load signal to the hydraulic oil system, group 8.4.5.6 HYD, menu 6
pumps.
5 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group 10.5.3
load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simulta-
neously.
7 The attachment control unit (D791-1) ac- Float position: U = 24 V Section 11 Common electrics, group 11.5.3.5
tivates the servo valve, tilt lock (Y6012). Lock position: U = 0 V Control unit, attachment
D7: Diagnostic menu, see section 8 Control
system, group 8.4.9.15 ATTACH, menu 15
8 Servo valve, tilt lock (Y6012) pressuris- - Lock valve tilt, description page 119
es the lock valve in the attachment con- D7: Diagnostic menu, see section 8 Control
trol valve. system, group 8.4.9.15 ATTACH, menu 15
9 The lock valve changes position and - Lock valve tilt, description page 119
blocks the connections to the tilt cylin-
ders.
10 The tilt cylinders lock the attachment’s - Tilt cylinder, description page 121
inclination.
11 When tilt locking is activated, the KID - Section 11 Common electrics, group
control unit (D795) shows the tilt locking 11.5.3.12 KID control unit
event menu.
When tilt locking is activated, the ma-
chine’s speed is limited to max. 5 km/h.
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
D1
1
2
D790-1
13
4
T1 B B C1+
C2-
C6 9 12
5
6
013027
Pos Explanation Signal description Reference
1 Control lever (S815-P4) sends the Tilt out: US815/P4 = 0.5–2.0 V Section 9 Frame, body, cab and accessories,
cab control unit (D790-1) a voltage group 9.1 Controls and instruments
Zero position: US815/P4 =
signal proportional to lever move- D1: Diagnostic menu, see section 8 Control
2.0-3.0 V
ment. system, group 8.4.9.1 ATTACH, menu 1
Tilt in: US815/P4 = 3.0–4.5 V
2 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics, group 11.5.3.1
transmits tilt in or tilt out on the error shown with error code. Cab control unit
CAN bus.
3 Control unit, frame rear (D797-R) U = 24 V Section 11 Common electrics, group 11.5.3.3
activates the solenoid valve, en- Control unit, frame rear
gagement of hydraulics for top lift D3: Diagnostic menu, see section 8 Control
(Y6003). system, group 8.4.5.6 HYD, menu 6
5 The shuttle valve forwards the - Section 10 Common hydraulics, group 10.5.3
strongest load signal to the hy- Shuttle valve
draulic oil pumps if several func-
tions are activated simultaneously.
6 Hydraulic oil pump 2 pumps oil See pressure plate on left Section 10 Common hydraulics, group 10.4.2
from the hydraulic oil tank. frame beam. Axial piston pump with variable displacement
7 The attachment control unit option I = 400–650 mA Section 11 Common electrics, group 11.5.3.6
(D791-2) activates servo valve, tilt Control unit, attachment option or section 11
out (6010) or servo valve, tilt in Common electrics, group 11.5.3.8 Control
(Y6011). unit, attachment right jack pair
D7: Diagnostic menu, see section 8 Control
Machine with lifting jacks
system, group 8.4.9.16 ATTACH, menu 16
The attachment control unit right and 8.4.9.17 ATTACH, menu 17
jack pair (D791-4) activates servo
valve, tilt out (6010) or servo
valve, tilt in (Y6011).
8 The servo valve for tilt out (Y6010) - Attachment control valve, description page
or tilt in (Y6011) pressurises the tilt 120
slide in the attachment’s control D7: Diagnostic menu, see section 8 Control
valve. system, group 8.4.9.16 ATTACH, menu 16
and 8.4.9.17 ATTACH, menu 17
9 The control valve’s tilt slide chang- - Attachment control valve, description page
es position and pressurises the 120
damping block.
10 The attachment control unit Float position: U = 24 V Section 11 Common electrics, group 11.5.3.5
(D791-1) activates the servo Lock position: U = 0 V Control unit, attachment
valve, tilt lock (Y6012). D10: Diagnostic menu, see section 8 Control
system, group 8.4.9.15 ATTACH, menu 15
11 Servo valve, tilt lock (Y6012) pres- - Lock valve tilt, description page 119
surises the lock valve in the at- D10: Diagnostic menu, see section 8 Control
tachment control valve. system, group 8.4.9.15 ATTACH, menu 15
12 The lock valve changes position - Damping block tilt, description page 117
and directs oil crosswise to the tilt
cylinders.
13 The tilt cylinders change the at- - Tilt cylinder, description page 121
tachment’s inclination.
Hydraulic diagram, top lift, tilt lock and controllable tilt and hydraulic
levelling
NOTE
Read the safety instructions for oil before working, see section
B Safety.
NOTE
Tilt damping may need to be adjusted after running-in due to me-
chanical tolerances.
1 Engine at idling speed.
2 Raise the boom without a load and check that the attachment is
suspended horizontally throughout the lifting movement.
3 Adjust tilt damping as required by adjusting the screws on the
damping block. Adjust both screws by the same amount.
1 Clockwise: increase damping.
Anticlockwise: decrease damping.
4 Lift a loaded container, test drive, and brake, check that the con-
tainer does not swing uncontrollably. If necessary, adjust the
damping in accordance with Step 3.
5 Start the machine and check that the function is working
satisfactorily.
005350
1. Adjusting screws
1. Damping block
2. Tilt cylinder
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section
B Safety.
3 Mark up and detach the hydraulic hoses from the valve block.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Remove the valve block from the boom.
NOTE
Check that the O-rings are intact and fitted correctly.
6 Fit a new valve block to the boom nose.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Overfilling of oil, leakage, and environmental damage.
On machines with tilt lock, there are two solenoid valves on the damp-
ing block’s return lines. When the solenoid valves are activated the
connection between the cylinders is blocked and locks the tilt position.
The lock valves are located on the damping block.
Solenoid valve tilt (Y6012) is supplied with voltage by Control unit, at-
tachment option (D791-2) when tilt lock is not activated.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.9.15 ATTACH, menu 15.
Tilt slide
The valve slide controls the direction and speed of attachment tilting.
The valve slide is controlled by servo valve, tilt in and servo valve, tilt
out.
The tilt cylinders are located between the inner boom’s front edge and
1
the rotation yoke’s upper section. The two cylinders are positioned di-
agonally and can therefore effectively dampen or control tilt motion.
The piston rod bracket is welded to the piston rod, which is threaded
in the piston head and locked with a lock screw. The cylinder head is
threaded in the cylinder pipe.
2 2
000535
1. Damping block
2. Tilt cylinder
7.8 Levelling
Hydraulic levelling, function description
page
–
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
D1
1
2
+ D790-1
D791-2
D797-R D791-3
3 7 9
D8
D9
D4
10 8
C6 14
P1 A
4 T1 B
11 12 13
5
C6
6
006888
3 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group 11.5.3.3
vates the solenoid valve, engagement Control unit, frame rear
of hydraulics for top lift (Y6003). D4: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens the con- page 58
nection between the pumps and the D4: Diagnostic menu, see section 8 Control
attachment’s control valve. system, group 8.4.5.6 HYD, menu 6
5 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group 10.5.3
load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simulta-
neously.
6 Hydraulic oil pump 2 pumps oil from the See pressure plate on Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
8 The levelling control valve opens a con- - Levelling cylinders’ valve block, description
nection to the levelling cylinders in the page 128
levelling cylinders’ valve block.
9 Control unit, attachment option I = 400–650 mA Section 11 Common electrics, group 11.5.3.6
(D791-2) or control unit attachment, left Control unit, attachment option or section 11
jack pair (D791-3) activates servo valve, Common electrics, group 11.5.3.7 Control
levelling right (Y6035) or servo valve unit, attachment left jack pair
levelling left (Y6036). D9: Diagnostic menu, see section 8 Control
system, group 8.4.9.19 ATTACH, menu 19
and 8.4.9.20 ATTACH, menu 20
10 The servo valve for levelling right - Attachment control valve, description page
(Y6035) or levelling left (Y6036) is actu- 127
ates the levelling slide in the attachment D9: Diagnostic menu, see section 8 Control
control valve. system, group 8.4.9.19 ATTACH, menu 19
and 8.4.9.20 ATTACH, menu 20
11 The control valve’s levelling slide - Attachment control valve, description page
changes position and pressurises the 127
levelling overcentre valve.
13 The levelling cylinders’ valve block di- - Levelling cylinders’ valve block, description
rects pressure on to the levelling cylin- page 128
ders.
14 The levelling cylinders lock the attach- - Levelling cylinders, description page 129
ment’s inclination.
D1
1 2 10
D790-1 D795
D791-2
D797-F
3 D791-3 7 D8
D4
8
C6
P1 A
9
4 T1 B
5
C6
1 The control lever (S815-T3.1) sends a US815-T3.1 = 24 V Section 9 Frame, body, cab and accessories,
voltage signal to the cab control unit group 9.1 Controls and instruments
(D790-1). D1: Diagnostic menu, see section 8 Control
system, group 8.4.9.4 ATTACH, menu 4
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
levelling lock on the CAN bus. tem, error shown with Cab control unit
error code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Valve block, top lift hydraulics, description
vates the solenoid valve, engagement of page 58
hydraulics for top lift (Y6003). D4: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
5 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group 10.5.3
load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simulta-
neously.
6 The hydraulic oil pumps pump oil from See pressure plate on Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
7 Control unit, attachment option (D791-2) U=0V Levelling cylinders’ valve block, description
stops activation solenoid valve, levelling page 128
(Y6034). D8: Diagnostic menu, see section 8 Control
system, group 8.4.9.18 ATTACH, menu 18
Machine with combi attachment.
Control unit, attachment left jack pair
(D791-3) stops activation solenoid
valve, levelling (Y6034).
8 The levelling control valve (Y6034) - Levelling cylinders’ valve block, description
blocks the connections to the levelling page 128
cylinders in the levelling cylinders’ valve D8: Diagnostic menu, see section 8 Control
block. system, group 8.4.9.18 ATTACH, menu 18
9 The levelling cylinders change the at- - Levelling cylinders, description page 129
tachment’s inclination.
10 When tilt lock is activated, event menu - Section 11 Common electrics, group
shows tilt lock. 11.5.3.12 KID control unit
When levelling lock is activated, the ma-
chine’s speed is limited to max. 5 km/h.
Levelling slide
The valve slide controls the direction and speed of attachment level-
ling.
The valve slide is controlled by the servo valve for levelling right
(Y6035) and levelling left (Y6034).
Passive levelling
The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left-hand side levelling cylinders, from
piston sides to rod sides, in accordance with inclination.
Active levelling
Levelling is monitored by the sequence valves in the valve block lev-
elling cylinder, which close when the feed pressure is high enough to
set all cylinders in bottom position. Following which, hydraulic oil is fed
to the rod sides on one side’s cylinders and the side lifts. When level-
ling, the other side will thus always be in its lowest position. This al-
ways gives maximal levelling travel.
The overcentre valve ensures that the levelling cylinders are com-
pletely extended. The valve is located to the right of the attachment
control valve on the rear edge of the side shift frame under the levelling
cylinders’ valve block.
Passive levelling
The over-centre valves allow flow of hydraulic oil between right and left
levelling cylinders, from piston sides to rod sides, in accordance with
inclination.
Active levelling
The over-centre valves close when the feed pressure is high enough
to put all levelling cylinders in bottom position. Then, hydraulic oil is
supplied through the levelling cylinder valve block to the rod sides on
one side’s (right or left) cylinders and the side lifts. When levelling, the
other side will thus always be in its lowest position. This always gives
maximal levelling travel.
001062
The levelling cylinders’ valve block directs pressure from the attach-
ment control valve to the levelling cylinders. The valve block compris-
es lock valves that block the levelling when the levelling lock is
activated or if the machine is without power. The valve sits to the right
of the attachment control valve on the rear edge of the side shift frame
above the overcentre valve for levelling.
Lock valve
The lock valve is opened by Solenoid valve levelling (Y6034). When
the lock valve is closed the oil is blocked to and from the levelling cyl-
inders, and levelling is blocked. Solenoid valve levelling (Y6034) is
supplied with voltage by Control unit, attachment option (D791-2) or
Control unit, attachment right jack pair (D791-4).
The signal can be checked from the diagnostic menu; see section
8 Control system , group 8.4.9.18 ATTACH, menu 18.
001061
001860
The sideshift frame is available in two different versions, see Side shift
1 2 3 4
frame, description page 65.
Mechanical levelling
The sideshift frame is larger than the attachment’s main beam. The
main beam can move freely between the slide plates. This allows ap-
prox. 5° levelling.
001932
5 Hydraulic levelling
1. Main beam, attachment The sideshift frame is split in two. There are four levelling cylinders be-
2. Side shift frame upper section tween the two sections, see Levelling cylinders, description page 129.
3. Levelling cylinder The outer section is secured in the rotation yoke via the ring gear. The
4. Side shift frame lower section inner part holds the attachment’s main beam. The main beam slides
5. Side shift cylinder on slide plates. The hydraulic cylinders’ stroke makes levelling of the
main beam possible, approx. 5°. With hydraulically controlled levelling,
the angle of the main beam attachment can be controlled with the con-
trol lever.
Contact Full contact or bypass Section 9 Frame, body, cab and accessories, group 9.1 Controls and in-
activated struments
Section 8 Control system, group 8.2.2 Bypassing
Overload system Passive Section 8 Control system , group 8.2.1 Overload system
D1
2 1
D18
8 7, 20
5, 21
D790-1 D790-2 D795
D2
D797-R D791-1
4, 6, 13,18, 19
9
D13
D8 D3
14 3
17
C12
D17
P1 A
10 16
T1 B
C12 15
11
12
006890
3 The sensor for front left alignment Sensor directly opposite Sensor alignment, description page 140
(7202L), sensor for front right alignment indicator plate: U = 24 V D3: Diagnostic menu, see section 8 Control
(7202R), sensor for rear left alignment system, group 8.4.9.6 ATTACH, menu 6
(Y7203L) and sensor for rear right align-
ment (Y7203R) send a voltage signal to
the attachment control unit (D791).
4 The attachment control unit (D791) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. tem, error shown with Control unit, attachment
error code.
5 The KID control unit (D795) activates - Section 11 Common electrics, group
the alignment event menu. 11.5.3.12 KID control unit
6 The attachment control module (D791) U = 24 V D18: Diagnostic menu, see section 8 Control
activates the alignment indicator light on system group 8.4.9.10 ATTACH, menu 10
the boom’s light panel.
7 The KIT control module (D790-2) acti- - Section 11 Common electrics, group
vates the alignment indicator light on the 11.5.3.11 Control unit KIT
cab light panel.
8 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group 11.5.3.1
"open twistlocks" or "lock twistlocks" on tem, error shown with Cab control unit
the CAN bus. error code.
9 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group 11.5.3.3
vates the solenoid valve, engagement of Control unit, frame rear
hydraulics for top lift (Y6003). D8: Diagnostic menu, see section 8 Control
system , group 8.4.5.6 HYD, menu 6
10 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and pres- page 58
surises valve block lift cylinder and D8: Diagnostic menu, see section 8 Control
sends a load signal to hydraulic oil system , group 8.4.5.6 HYD, menu 6
pump 2.
11 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group 10.5.3
load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simulta-
neously.
12 Hydraulic oil pump 2 pumps oil from the See pressure plate on Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
14 The "open twistlocks" servo valve - Attachment control valve, description page
(Y6039) or "lock twistlocks" servo valve 135
(Y6040) pressurises the twistlocks slide D12: Diagnostic menu, see section 8 Control
with servo pressure. system, group 8.4.9.9 ATTACH, menu 9
15 The control valve’s twistlocks slide - Attachment control valve, description page
changes position and pressurises the 135
locks cylinders.
16 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 136
17 The "unlocked twistlocks" sensor Sensor directly opposite Sensor twistlocks, description page 141
(B7204) or the "locked twistlocks" sen- indicator plate: U = 24 V D16: Diagnostic menu, see section 8 Control
sor (B7205) sends a signal to the attach- system, group 8.4.9.7 ATTACH, menu 7
ment control unit (D791).
18 The attachment control unit (D791) sup- U = 24 V D18: Diagnostic menu, see section 8 Control
plies voltage to the "unlocked twistlocks" system group 8.4.9.10 ATTACH, menu 10
indicator light (H562) or the "locked
twistlocks" indicator light (H563) on the
boom’s light panel.
19 The attachment control unit (D791) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits "twistlocks unlocked" or "twist- tem, error shown with Control unit, attachment
locks locked" on the CAN bus. error code.
20 The KIT control unit (D790-2) supplies - Section 11 Common electrics, group
voltage to the "unlocked twistlocks" indi- 11.5.3.11 Control unit KIT
cator light or the "locked twistlocks" indi-
cator light on the cab light panel.
21 The KID control unit (D795) activates - Section 11 Common electrics, group
the twistlocks event menu. 11.5.3.12 KID control unit
Overload system Passive Section 8 Control system, group 8.2.1.1 Mechanical overload system
13
1
2
D790-1
D797-R D791-2 7
3
8 12
D3
C6
P1
A
4 B 11
T1
10
9
C6 5
6
008218
2. Control unit cab (D790-1) sends a message Checked by control Section 11 Common electrics, group
to lower overheight jacks on the CAN bus. system, error shown 11.5.3.1 Cab control unit
with error code.
3. Control unit, frame rear (D797-R) activates U = 24 V Valve block, top lift hydraulics, description
the solenoid valve, engagement of hydrau- page 58
lics for top lift (Y6003). D3: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.6 HYD, menu 6
5. The shuttle valve forwards the strongest - Section 10 Common hydraulics, group
load signal to the hydraulic oil pump 2 if sev- 10.5.3 Shuttle valve
eral functions are activated simultaneously.
6. Hydraulic oil pump 2 pumps oil from the hy- See pressure plate on Section 10 Common hydraulics, group
draulic oil tank. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
7. Control unit, attachment option (D791-2) ac- U = 24 V Attachment control valve, description page
tivates the servo valve overheight jacks up 135
(Y6070) or servo valve overheight jacks
down (Y6071).
8. Servo valve overheight jacks up (Y6070) or U = 24 V Attachment control valve, description page
servo valve overheight jack down (Y6071) 135
pressurises the overcentre valve for over-
height jacks.
9. Overcentre valve opens and pressurises hy- - Overcentre valve (product alternative over-
draulic cylinder overheight jacks. height jacks) page 142
10. Hydraulic cylinder overheight jacks lowers - Hydraulic cylinder, overheight jacks page
the overheight jacks. 142
11. Sensor overheight jacks up left (B7231-L) or Sensor directly oppo- Sensor, overheight-jacks page 143
sensor overheight jacks up right (B7231-R) site indicator plate: U =
sends a voltage signal to Control unit, at- 24 V
tachment option (D791-2).
12. Control unit, attachment option (D791-2) ac- Overheight jacks up: U Section 11 Common electrics, group
tivates the indicator lamp for overheight = 24 V 11.5.3.6 Control unit, attachment option
jacks up (H5001). Overheight jacks
down: U = 0 V
13 Indicator light, overheight jacks up (H5001) Overheight jacks up: U Section 9 Frame, body, cab and accesso-
illuminates when the jacks are completely = 24 V ries, group 9.1 Controls and instruments
raised. Overheight jacks
down: U = 0 V
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders - one in the right and one in the left spread-
er beam - pull the lock mechanism. The lock cylinders are located in
the centre of the spreader beam’s longitudinal section.
000539
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism runs
along the longitudinal section of the spreader beam between the twist-
locks.
The lock mechanism consists of a rod with two spherical plain bear-
ings in the end. The rod is fastened in levers that rotate the twistlocks.
A retaining lug for the lock cylinder sits in the centre of the rod.
001863
7.9.1.7 Twistlocks
Twistlocks, description
page
–
1
WARN IN G
Dropped load.
2 Fatal danger!
Twistlocks hold the load during load handling and
5 therefore it is very important that twistlocks are
checked according to instructions and are replaced at
the slightest sign of damage or wear.
4 3 Twistlocks secure the load and are located in the corners of the
spreader beam’s longitudinal part.
Twistlocks are manufactured from high-strength steel according to in-
ternational standards. The lift pins are marked with serial numbers.
Twistlocks are connected in pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachment’s
control valve. Inductive sensors send signals when the twistlocks are
000536
1. Lock mechanism
2. Sensor alignment
3. Contact pin
4. Lift pin
5. Lock guide
Twistlock, replacement
page
–
WARN IN G
Dropped component.
NOTE
Do not forget the washer between the extension beam and
guide pin.
WARN IN G
Dropped component.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlock can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlock and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlock is working.
009958
The alignment sensors detect when the attachment has contact with
the container. Four inductive sensors - one at each twistlock at the far
corner of the longitudinal section of the spreader beam - are used to
indicate alignment.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located above the pin. The position of the sensor can be adjusted so
that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied voltage by and send a 24 V signal to the at-
tachment control unit (D791) when the indicator pin is pressed in.
The signal can be checked from the diagnostic menu, see section 8
001451
goes out).
Event menu, alignment 7 Check more must indicator pin movement is required to detect
contact. The movement must be 3–4 mm.
8 Adjust sensor position if necessary. See Position sensor, check-
ing and adjustment page 5.
001452
twistlocks, the other sensor sends a signal to the attachment control
unit (D791). No signals are sent if the lock mechanism stops midway.
The sensors are supplied voltage by and send a 24 V signal to the at-
tachment control unit (D791) when the indicator plate is in front of the
sensor.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.7 ATTACH, menu 7.
1
The overcentre valve prevents the overheight jacks lowering under
2 their own weight.
008219
1
The hydraulic cylinder lowers the overheight jacks. The hydraulic cyl-
2 inder is controlled by a separate section in the attachment control
valve, see Attachment control valve, description page 78.
3
008219
1
Sensor, overheight jacks up, detects when the jacks are completely
2 raised.
Sensor, overheight jacks up left (B7231-L) detects the position of the
3 left jack pair and sends a voltage signal to Control unit, attachment op-
tion (D791-2) when the jack pair is fully folded up.
Sensor, overheight jacks up right (B7231-R) detects the position of the
left jack pair and sends a voltage signal to Control unit, attachment op-
tion (D791-2) when the jack pair is fully folded up.
008219
description
20
25
1, 29 D1 21, 22
D21
26, 27
A B A B A B A B A B
T1 D26
P1
19 24
2
D28 3, 18, 23
D790-1 D791-4 D18 D23
P1
T1
A B A B A B A B A B
D16
D4
D11 16, 17
5
15
6 11, 12
C7
7 10
013028
2 Control unit cab (D790-1) sends front Checked by control sys- Section 11 Common electrics, group
lifting jacks down or up on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit
ror code.
3 Control unit, attachment left jack pair Checked by control sys- Section 11 Common electrics, group
(D791-3) and Control unit, attachment tem, error shown with er- 11.5.3.7 Control unit, attachment left jack
right jack pair (D791-4) send activate ror code. pair and section 11 Common electrics,
top hydraulics on the CAN bus. group 11.5.3.8 Control unit, attachment right
jack pair
4 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group
vates the solenoid valve, engagement of 11.5.3.3 Control unit, frame rear
hydraulics for top lift (Y6003). D4: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
5 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and pres- page 58
surises valve block lift cylinder and D4: Diagnostic menu, see section 8 Control
sends a load signal to hydraulic oil pump system, group 8.4.5.6 HYD, menu 6
2.
6 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group
load signal to the hydraulic oil pumps if 10.5.3 Shuttle valve
several functions are activated simulta-
neously.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on left Section 10 Common hydraulics, group
hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable dis-
placement
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve front 11.5.3.7 Control unit, attachment left jack
knee out left (Y6056L). pair
D8: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 10
9 Solenoid valve front knee out left - Control valve, lifting jacks, description page
(Y6056L) pressurises hydraulic cylinder 160
knee left front. D8: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 10
10 Hydraulic cylinder knee left front lowers - Hydraulic cylinder knee/clamp, description
knee left front. page 165
11 Sensor front knee left (B7217L) sends a U = 24 V Sensor knee, description page 166
voltage signal to Control unit, attach- D11: Diagnostic menu, see section 8 Control
ment left jack pair (D791-3) when the system , group 8.4.11.1 COMBI, menu 4
knee is lowered.
13 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve front 11.5.3.7 Control unit, attachment left jack
jack down left (Y6013L) when sensor pair
front knee left (B7217L) stops sending a D13: Diagnostic menu, see section 8 Control
signal. system , group 8.4.11.1 COMBI, menu 10
14 Solenoid valve front jack down left - Control valve, lifting jacks, description page
(Y6013L) pressurises Hydraulic cylinder 160
jack left front. D13: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 10
15 Hydraulic cylinder jack left front lowers - Hydraulic cylinder, jack, description page
jack left front. 168
16 Sensor front jack left (B7219L) sends a U = 24 V Sensor, lifting jacks, description page 168
signal to Control unit, attachment left D16: Diagnostic menu, see section 8 Control
jack pair (D791-3) when the jack is low- system , group 8.4.11.1 COMBI, menu 4
ered.
17 Sensor front jack left (B7219L) stops U=0V Sensor, lifting jacks, description page 168
sending a signal to Control unit, attach- D16: Diagnostic menu, see section 8 Control
ment left jack pair (D791-3). system , group 8.4.11.1 COMBI, menu 4
18 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group
(D791-4) activates solenoid valve front 11.5.3.8 Control unit, attachment right jack
knee out right (Y6056R) when sensor pair
front jack left (B7219L) stops sending a D18: Diagnostic menu, see section 8 Control
signal. system , group 8.4.11.1 COMBI, menu 10
19 Solenoid valve front knee out right - Control valve, lifting jacks, description page
(Y6056R) pressurises hydraulic cylinder 160
knee right front. D18: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 10
20 Hydraulic cylinder knee right front low- - Hydraulic cylinder knee/clamp, description
ers knee right front. page 165
21 Sensor front knee right (B7217R) sends U = 24 V Sensor knee, description page 166
a voltage signal to Control unit, attach- D21: Diagnostic menu, see section 8 Control
ment right jack pair (D791-4) when the system , group 8.4.11.1 COMBI, menu 4
knee is lowered.
22 Sensor front knee right (B7217R) stops U=0V Sensor knee, description page 166
sending a signal to Control unit, attach- D21: Diagnostic menu, see section 8 Control
ment right jack pair (D791-4). system , group 8.4.11.1 COMBI, menu 4
24 Solenoid valve front jack down right - Control valve, lifting jacks, description page
(Y6013R) pressurises Hydraulic cylin- 160
der jack right front.
25 Hydraulic cylinder jack right front lowers - Hydraulic cylinder, jack, description page
jack right front. 168
26 Sensor front jack right (B7219R) sends U = 24 V Sensor, lifting jacks, description page 168
a signal to Control unit, attachment right D26: Diagnostic menu, see section 8 Control
jack pair (D791-4) when the jack is low- system , group 8.4.11.1 COMBI, menu 4
ered.
27 Sensor front jack right (B7219R) stops U=0V Sensor, lifting jacks, description page 168
sending a signal to Control unit, attach- D26: Diagnostic menu, see section 8 Control
ment right jack pair (D791-4) when the system , group 8.4.11.1 COMBI, menu 4
jack has reached the end position.
28 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group
(D791-4) activates indicator lamp front 11.5.3.8 Control unit, attachment right jack
jack down (H580). pair
D28: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 9
29 When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is re-
leased when the lifting jack is in an intermediate position.
description
D32 32
20
31
21
1, 33 D1 D21 22
D26 25
26 30 D30
27
A B A B A B A B A B
P1
T1
D23
24 19 29
2
3, 18, 23, 28 D18
D790-1 D791-4
D29
D797-R D791-3 3, 8, 13, 28 D8
4
D5 14 9 29
D13
P1
T1 A B A B A B A B A B
5 D16 16
17 30
15
C 6
11
D11 12
7 31
10 32
D32
013029
2 Control unit cab (D790-1) sends rear lift- Checked by control sys- Section 11 Common electrics, group
ing jacks down or up on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit
error code.
3 Control unit, attachment left jack pair Checked by control sys- Section 11 Common electrics, group
(D791-3) and Control unit, attachment tem, error shown with 11.5.3.7 Control unit, attachment left jack
right jack pair (D791-4) send activate top error code. pair and section 11 Common electrics,
hydraulics on the CAN bus. group 11.5.3.8 Control unit, attachment right
jack pair
4 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group
vates the solenoid valve, engagement of 11.5.3.3 Control unit, frame rear
hydraulics for top lift (Y6003). D5: Diagnostic menu, see section 8 Control
system , group 8.4.5.6 HYD, menu 6
5 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and pressu- page 58
rises valve block lift cylinder and sends a D5: Diagnostic menu, see section 8 Control
load signal to hydraulic oil pump 2. system , group 8.4.5.6 HYD, menu 6
6 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group
load signal to the hydraulic oil pumps if 10.5.3 Shuttle valve
several functions are activated simultane-
ously.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on Section 10 Common hydraulics, group
hydraulic oil tank. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve rear 11.5.3.7 Control unit, attachment left jack
knee out left (Y6058L). pair
D8: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 12
9 Solenoid valve rear knee out left - Control valve, lifting jacks, description page
(Y6058L) pressurises hydraulic cylinder 160
knee left rear. D8: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 12
10 Hydraulic cylinder knee left rear lowers - Hydraulic cylinder knee/clamp, description
knee left rear. page 165
11 Sensor rear knee left (B7218L) sends a U = 24 V Sensor knee, description page 166
voltage signal to Control unit, attachment D11: Diagnostic menu, see section 8 Con-
left jack pair (D791-3) when the knee is trol system , group 8.4.11.1 COMBI, menu 5
lowered.
13 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve rear 11.5.3.7 Control unit, attachment left jack
jack down left (Y6014L), sensor rear knee pair
left (B7218L) stops sending a signal. D13: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI, menu
12
14 Solenoid valve rear jack down left - Control valve, lifting jacks, description page
(Y6014L) pressurises Hydraulic cylinder 160
jack left rear. D13: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI,
menu 12
15 Hydraulic cylinder jack left rear lowers - Hydraulic cylinder, jack, description page
jack left rear. 168
16 Sensor rear jack left (B7220L) sends a U = 24 V Sensor, lifting jacks, description page 168
signal to Control unit, attachment left jack D16: Diagnostic menu, see section 8 Con-
pair (D791-3) when the jack is lowered. trol system , group 8.4.11.1 COMBI, menu 5
17 Sensor rear jack left (B7220L) stops U=0V Sensor, lifting jacks, description page 168
sending a signal to Control unit, attach- D16: Diagnostic menu, see section 8 Con-
ment left jack pair (D791-3) when sensor trol system , group 8.4.11.1 COMBI, menu 5
rear jack left (B7220L) stops sending a
signal.
18 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group
(D791-4) activates solenoid valve rear 11.5.3.8 Control unit, attachment right jack
knee out right (Y6058R). pair
D18: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI, menu
12
19 Solenoid valve rear knee out right - Control valve, lifting jacks, description page
(Y6058R) pressurises hydraulic cylinder 160
knee right rear. D18: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI, menu
12
21 Sensor rear knee right (B7218R) sends a U = 24 V Sensor knee, description page 166
voltage signal to Control unit, attachment D21: Diagnostic menu, see section 8 Con-
right jack pair (D791-4) when the knee is trol system , group 8.4.11.1 COMBI, menu 5
lowered.
23 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group
(D791-4) activates solenoid valve rear 11.5.3.8 Control unit, attachment right jack
jack down right (Y6014R) when sensor pair
rear knee right (B7218R) stops sending a D23: Diagnostic menu, see section 8 Con-
signal. trol system , group 8.4.11.1 COMBI, menu
12
24 Solenoid valve rear jack down right - Control valve, lifting jacks, description page
(Y6014R) pressurises Hydraulic cylinder 160
jack right rear. D23: Diagnostic menu, see section 8 Con-
trol system , group 8.4.11.1 COMBI, menu
12
25 Hydraulic cylinder jack right rear lowers - Hydraulic cylinder, jack, description page
jack right rear. 168
26 Sensor rear jack right (B7220R) sends a U = 24 V Sensor, lifting jacks, description page 168
signal to Control unit, attachment right D26: Diagnostic menu, see section 8 Con-
jack pair (D791-4) when the jack is low- trol system , group 8.4.11.1 COMBI, menu 5
ered.
27 Sensor rear jack right (B7220R) stops U=0V Sensor, lifting jacks, description page 168
sending a signal to Control unit, attach- D26: Diagnostic menu, see section 8 Con-
ment right jack pair (D791-4). trol system , group 8.4.11.1 COMBI, menu 5
28 When both rear lifting jacks are complete- U = 24 V Section 11 Common electrics, group
ly lowered Control unit, attachment left 11.5.3.7 Control unit, attachment left jack
jack pair (D791-3) activates solenoid pair and section 11 Common electrics,
valve operating position left (Y6053L) and group 11.5.3.8 Control unit, attachment right
solenoid valve clamping left (Y6054L). jack pair
At the same time Control unit, attachment D29: Diagnostic menu, see section 8 Con-
right jack pair (D791-4) activates Solenoid trol system group 8.4.11.1 COMBI, menu
valve operating position right (Y6053R) 15 and 8.4.11.1 COMBI, menu 16
and Solenoid valve clamping right
(Y6054R).
29 Solenoid valve operating position left - Control valve, lifting jacks, description page
(Y6053L) closes the connection between 160
control valve and hydraulic cylinder D29: Diagnostic menu, see section 8 Con-
clamping left front. trol system group 8.4.11.1 COMBI, menu
Solenoid valve operating position right 15 and 8.4.11.1 COMBI, menu 16
(Y6053R) closes the connection between
control valve and hydraulic cylinder
clamping right front.
32 Sensor operating position left (B7212L) Sensor directly opposite Sensor operating position, description page
sends a voltage signal to Control unit, at- indicator plate: U = 24 V 165
tachment left jack pair (D791-3) and sen- D32: Diagnostic menu, see section 8 Con-
sor operating position right (B7212R) trol system , group 8.4.11.1 COMBI, menu 6
sends a voltage signal to Control unit at-
tachment right jack pair (D791-4) when
the jack pair is in the operating position.
33 When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is re-
leased when a lifting jack is in an intermediate position.
Lifting jacks Lowered Raising/lowering of front lifting jacks, function description page 144
Raising/lowering of rear lifting jacks, function description page 148
22 20 15 14
17 22
D1
1
D22 D20 D17
P1 B A B A B A B A B A
D22
T1
D21
D12
13
2, 25 3, 12, 18, 21
D790-1 D791-4
T1
A B A B A B A B A B
D22
5
D22 D16
D19
6
7 22 19 16 22
006894
11 10
2 The cab control unit (D790-1) sends Checked by control Section 11 Common electrics, group 11.5.3.1
clamp or release jacks on the CAN bus. system, error shown Cab control unit
with error code.
4 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics, group 11.5.3.3
vates the solenoid valve, engagement of Control unit, frame rear
hydraulics for top lift (Y6003). D4: Diagnostic menu, see section 8 Control
system , group 8.4.5.6 HYD, menu 6
5 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and pressu- page 58
rises valve block lift cylinder and sends a D4: Diagnostic menu, see section 8 Control
load signal to hydraulic oil pump 2. system , group 8.4.5.6 HYD, menu 6
6 The shuttle valve forwards the strongest - Section 10 Common hydraulics, group 10.5.3
load signal to the hydraulic oil pumps if Shuttle valve
several functions are activated simultane-
ously.
7 Hydraulic oil pump 2 pumps oil from the See pressure plate on Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. left frame beam. Axial piston pump with variable displacement
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group 11.5.3.7
(D791-3) activates solenoid valve clamp Control unit, attachment left jack pair
left (Y6054L) or solenoid valve clamp re- D8: Diagnostic menu, see section 8 Control
lease left (Y6055L). system , group 8.4.11.1 COMBI, menu 15
9 Solenoid valve clamp left (Y6054L) or so- - Control valve, lifting jacks, description page
lenoid valve clamp release left (Y6055L) 160
pressurises hydraulic cylinder clamp left D8: Diagnostic menu, see section 8 Control
front and hydraulic cylinder clamp left system , group 8.4.11.1 COMBI, menu 15
rear.
10 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lifting page 165
jacks clamp or release.
11 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lifting page 165
jacks clamp or release.
12 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group 11.5.3.8
(D791-4) activates solenoid valve clamp Control unit, attachment right jack pair
right (Y6054R) or solenoid valve clamp D12: Diagnostic menu, see section 8 Control
release right (Y6055R). system , group 8.4.11.1 COMBI, menu 15
13 Solenoid valve clamp left (Y6054L) or so- - Control valve, lifting jacks, description page
lenoid valve clamp release left (Y6055L) 160
pressurises hydraulic cylinder clamp left D12: Diagnostic menu, see section 8 Control
front and hydraulic cylinder clamp left system , group 8.4.11.1 COMBI, menu 15
rear.
15 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lifting page 165
jacks clamp or release.
16 Sensor clamping position front jack left U = 24 V Sensor, clamping position, description page
(B7215L) sends a voltage signal to Con- 171
trol unit, attachment left jack pair D16: Diagnostic menu, see section 8 Control
(D791-3). system , group 8.4.11.1 COMBI, menu 2
17 Sensor clamping position front jack right U = 24 V Sensor, clamping position, description page
(B7215R) sends a voltage signal to Con- 171
trol unit, attachment right jack pair D17: Diagnostic menu, see section 8 Control
(D791-4). system , group 8.4.11.1 COMBI, menu 2
18 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group 11.5.3.8
(D791-4) activates indicator light clamp- Control unit, attachment right jack pair
ing position front jack (H578). D21: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 8
19 Sensor clamping position rear jack left U = 24 V Sensor, clamping position, description page
(B7216L) sends a voltage signal to Con- 171
trol unit, attachment left jack pair D19: Diagnostic menu, see section 8 Control
(D791-3). system , group 8.4.11.1 COMBI, menu 2
20 Sensor clamping position rear jack right U = 24 V Sensor, clamping position, description page
(B7216R) sends a voltage signal to Con- 171
trol unit, attachment right jack pair D20: Diagnostic menu, see section 8 Control
(D791-4). system , group 8.4.11.1 COMBI, menu 2
21 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group 11.5.3.8
(D791-4) activates indicator light clamp- Control unit, attachment right jack pair
ing position rear jack (H579). D21: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 8
22 When lifting is started, Sensor alignment U = 24 V Section 9 Frame, body, cab and accessories,
front jack left (B7213L) and Sensor align- group 9.1 Controls and instruments
ment rear jack left (B7214L) send a signal D22: Diagnostic menu, see section 8 Control
to Control unit, attachment left jack pair system , group 8.4.11.1 COMBI, menu 3
(D791-3). Sensor alignment front jack
right (B7213R) and Sensor alignment rear
jack right (B7214R) send a signal to Con-
trol unit, attachment right jack pair
(D791-4).
If it takes longer than 4 seconds between
the first sensor’s signal until all sensors
send signals, the lift function is blocked.
24 The KID control unit (D795) activates the - Section 11 Common electrics, group
event menu for alignment bottom lift. 11.5.3.12 KID control unit
25 When more than two sensors indicate Checked by control Section 8 Control system, group 8.2.5 Speed
alignment or clamping position, speed system, error shown limitation
limitation is activated. with error code.
NOTE
Loosen the lock nuts on the piston head before adjustment.
8 Check the c-c measurement between right and left lifting jacks,
90˚ 90˚ the measurement should be approximately 4876 mm at the bot-
tom of the jacks.
c-c = 4876 mm
008205
NOTE
Loosen the lock screws in the piston head before adjust-
8,0˚ 8,0˚ ment.
007458
9,0˚ 1,5˚
007459
15 Press the top of the rear lowering button, the rear lifting jacks
should move to operating position. (Operate clamping position
apart to return to end position in order to test the operating posi-
tion again.)
16 Check that the lifting jacks stop at 1.0° inwards (forward).
1,0˚
007460
19 Press in the contact surfaces on the front and rear lifting jacks
and check that the indicator light for clamping position alignment
for the respective jack pair is working.
When both contact surfaces are pressed in the indicator light for
clamping position front and rear should illuminate.
If the light does not illuminate when the contact surfaces are
pressed in, check the lamp and clamping position sensor, see
Sensor, clamping position, description page 171.
008201
Indicator lights, clamping position
20 Check that the indicator light for front jacks lowered is illuminated
when the front lifting jacks are lowered.
008202
The lifting jacks are controlled by two control valves: one for the left
1 2 3 4 5 6 7 8 9 10 jack pair and one for the right jack pair. The control valves are control-
led by separate control units: Control unit, attachment left jack pair
23 (D791-3) and Control unit, attachment right jack pair (D791-4). The
11 control valves are fitted crosswise (left front and right rear, respective-
22
ly) on the bracket for the knee on the attachment’s main beam.
12
21 The control valves are identical and have five sections each:
The valve for operating position cuts off the pressure to the front hy-
draulic cylinder for clamping. The valve is located on the attachment’s
main beam by the hydraulic cylinder knee and clamp.
When the valve is activated, it cuts the hydraulic connection between
Control valve, attachment lifting jacks and hydraulic cylinder knee and
clamp front. This results in only the rear lifting jack being angled for-
ward.
Solenoid valve operating position (Y6053L/R) is activated by Control
unit, attachment left jack pair (D791-3) or Control unit, attachment right
jack pair (D791-4), depending on if it is the right or left jack.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.11.1 COMBI, menu 16.
001849
The brackets for knee and hydraulic cylinder knee and clamp are lo-
cated on the attachment’s main beam.
7.9.2.7 Knee
Knee, description
page
–
The knee is located between the attachment’s main beam and lifting
jack. There are four knees, one at each lifting jack. The knee enables
folding in and clamping with the jacks. The knee is controlled by hy-
draulic cylinder knee and clamp.
Located on the knee joint is an indicator ring which is turned with the
lifting jack. The indicator ring is used together with Sensor, knee, to de-
termine whether the jack is raised, in intermediate position or lowered.
001851
Hydraulic cylinder knee and clamp has two pistons in separate cylin-
1 2
ders. There are four hydraulic cylinders, one at each lifting jack. The
hydraulic cylinder is located between attachment and knee. One of the
hydraulic cylinder’s pistons folds the knee joint out. The other piston
clamps with the lifting jacks by angling the knee joint further.
001852
1. Hydraulic cylinder, clamp
2. Hydraulic cylinder, knee
The sensor for operating position senses the position of the rear lifting
jacks’ hydraulic cylinder for knee and clamp. This is used to indicate
operating position for the rear lifting jacks. There are two sensors, one
on each side (right and left).
Sensor, operating position left (B7212L/R) provides a voltage signal
when the rear hydraulic cylinder lowering knee/clamp is in its inner end
position. The signal is used to stop activation of the solenoid valve for
operating position when the rear lifting jack is lowered.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.11.1 COMBI, menu 6.
001856
Sensor knee senses the position of the knee joint, this is used to con-
trol lowering of the jacks. There are four sensors, one by each knee.
Sensor front knee (B7217) and Sensor rear knee (B7218) give voltage
signals when the knee is between either end-position. The signal goes
to 0 V when end-position is reached. This applies both when retracting
and extending. The signal is used to activate the next step in the se-
quence. If the signal does not go to 0 V, the jack is not lowered.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.11.1 COMBI, menu 4 5.
001853
The lifting jacks grip around/under the load. In the lower end of the
jacks there are lifting shoes. The lifting jacks are raised and lowered
with the hydraulic cylinder for lifting jacks.
Located on the lifting jack’s joint is an indicator ring which is turned
with the lifting jack. The indicator ring is used together with Sensor,
jack, to determine whether the jack is raised, in intermediate position
or lowered.
001866
Hydraulic cylinder lifting jack is located between knee and lifting jack.
The hydraulic cylinder raises and lowers the lifting jacks.
001855
Sensor, lifting jacks, senses the position of the lifting jacks, this is used
to control lowering of the jacks. There are four sensors, one by each
lifting jack.
Sensor front jack (B7219) and Sensor rear lifting jack (B7220) give
voltage signals when the lifting jacks are between either end-position.
The signal goes down to 0 V when end-position is reached. This ap-
plies both when raising and lowering. The signal is used to activate the
next step in the sequence. If the signal does not go to 0 V, the knees
are not lowered.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.11.1 COMBI, menu 4–5.
001859
The lifting shoe is located at the lower end of the lifting jacks. The lifting
shoe grips under the load. At each lifting shoe there are two sensors.
Sensor alignment senses when the lifting shoe has contact with the
load from above, see Sensor alignment, description page 170. Sensor
clamping position senses when the lifting shoe has horizontal contact
with the load, see Sensor, clamping position, description page 171.
3
001857
2
001858
001858
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
D1 D13
1
2, 13
D790-1 11
D795
D794 D797-O
4
D4 12
C8 D3
5
10 3
P
B
LS
7 T
C8 T1 A
8 6 9
013030
2 The cab control unit (D790-1) sends front Checked by control Section 11 Common electrics, group
support jacks down or up on the CAN bus. system, error shown 11.5.3.1 Cab control unit
with error code.
4 Control unit, frame option (D797-O) acti- U = 24 V Section 11 Common electrics, group
vates the Solenoid valve support jacks 11.5.3.4 Control unit, frame option
down (Y6064) or Solenoid valve support D4: Diagnostic menu, see section 8 Control
jacks up (Y6063) and sends the status for system , group 8.4.11.3 SUPPORT JACKS,
the support jacks’ position on the CAN bus. menu 3
5 Solenoid valve support jacks down (Y6064) - Control valve, option frame, description
or Solenoid valve support jacks up (Y6063) page 174
pressurises the support jacks slide in Con- D4: Diagnostic menu, see section 8 Control
trol valve, option frame. system , group 8.4.11.3 SUPPORT JACKS,
menu 3
6 Control valve, option frame sends a load - Control valve, option frame, description
signal to shuttle valve, option frame and page 174
pressurises valve block, support jacks cylin-
der.
7 The shuttle valve sends pressure signal on - Section 10 Common hydraulics, group
to hydraulic oil pumps 1 & 2 10.5.3 Shuttle valve
8 Hydraulic oil pumps 1 & 2 pump oil from the See pressure plate on Section 10 Common hydraulics, group
hydraulic oil tank. left frame beam. 10.4.2 Axial piston pump with variable dis-
placement
9 Valve block support jacks pressurises hy- - Valve block, support jacks, description page
draulic cylinder support jacks. 180
10 The hydraulic cylinder lowers or raises the - Hydraulic cylinder, support jacks, description
support jack. page 178
11 Control unit KID (D795) activates the event - Section 11 Common electrics, group
menu for support jacks and blocks shifting 11.5.3.12 KID control unit
from neutral position.
12 Control unit, engine (D794) sends engine Checked by control Section 11 Common electrics, group
speed on the CAN bus. If the engine speed system, error shown 11.5.3.10 Engine control unit
is higher than 1000 rpm then the cab control with error code.
unit (D790-1) activates automatic lowering
of support jacks.
1
On machines with support jacks, the lowering/raising of support jacks
is controlled by a separate section in the control valve frame option.
6 2
The control valve is fitted on a bracket at the front end in the engine
compartment.
5 3
The control valve is controlled by Control unit, frame option (D797-O).
Control valve, option frame is made up of several sections, each sec-
4 tion controls one function. The following functions are controlled by
control valve, option frame.
• Support jacks
• Cab tilt
The control valve is an electro-hydraulically controlled, proportional
and pressure-compensated directional valve. Electrically controlled
000624
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
1
NOTE
6 2 Plug all connections immediately to protect the hydraulic
system from impurities.
5 3 4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
4
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
000624
NOTE
Check that the O-rings are intact and fitted correctly.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
010475
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
15 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
Hydraulic cylinder support jacks lowers the support jack up and down.
1 The hydraulic cylinder is located between support jacks and frame.
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)
The support jack consists of linkage and support. The linkage is de-
1 signed so that it locks automatically when it is loaded from below in its
lowered position.
2 The support jack is secured in the frame and in the drive axle’s attach-
ing bolts.
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)
Dynamic scale
The dynamic scale weighs the load regardless of boom position. The
weight is calculated as a function of boom angle, boom length and the
pressure in the lift cylinders. The dynamic scale uses Sensor, hydrau-
lic pressure lift cylinder, Sensor, boom angle (analogue sensor) and
Sensor, boom length (analogue sensor).
1 D1
3, 4
2 7, 12
D790-1 D795
006896
5 >˚ Pa Pa 8
2 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
weighing activated on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit
error code.
5 Sensor, boom angle (B771) sends a volt- U = 0.5-4.5 V Section 8 Control system, group 8.2.1.5
age signal proportional to boom angle to Sensor, boom angle
Control unit, frame rear (D797-R). D5: Diagnostic menu, see section 8 Control
system, group 8.4.10.4 OP, menu
6 Control unit, frame rear (D797-R) trans- Checked by control sys- Section 11 Common electrics, group
mits boom angle on the CAN bus. tem, error shown with 11.5.3.3 Control unit, frame rear
error code. D5: Diagnostic menu, see section 8 Control
system, group 8.4.10.4 OP, menu
9 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group
transmits Boom length 60 cm on the CAN tem, error shown with 11.5.3.5 Control unit, attachment
bus. error code. D8: Diagnostic menu, see section 8 Control
system group 8.4.9.5 ATTACH, menu 5
10 Sensor, hydraulic pressure lift cylinder U = 0.5 - 4.5 V Lift cylinder hydraulic pressure sensor, de-
piston side left (B768-L1) and Sensor hy- scription page 32
draulic pressure lift cylinder piston side D10: Diagnostic menu, see section 8 Con-
right (B768-R1) send a voltage signal to trol system, group 8.4.10.3 OP, menu 3
Control unit, frame front (D797-F).
11 Control unit, frame front (D797-F) trans- Checked by control sys- Section 11 Common electrics, group
mits weight information on the CAN bus. tem, error shown with 11.5.3.2 Control unit, frame front
error code.
12 The KID control unit (D795) updates the - Section 11 Common electrics, group
weight information in the display (fixed 11.5.3.12 KID control unit
glow).
8
D790-1 D795
D797-F D797-R
7 3,5
D6
D2 D4
6
006897
Pa Pa Pa Pa 2 m <˚ 4
2 Sensor, boom length (B777) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.6
voltage signal proportional to boom Sensor, boom length
length to Control unit, frame rear D2: Diagnostic menu, see section 8 Control
(D797-R). system, , group 8.4.10.4 OP, menu 4
3 Control unit, frame rear (D797-R) trans- Checked by control sys- Section 11 Common electrics, group
mits boom length information on the CAN tem, error shown with er- 11.5.3.3 Control unit, frame rear
bus. ror code.
4 Sensor, boom angle (B771) sends a volt- U = 0.5-4.5 V Section 8 Control system, group 8.2.1.5
age signal proportional to boom angle to Sensor, boom angle
Control unit, frame rear (D797-R). D4: Diagnostic menu, see section 8 Control
system, , group 8.4.10.4 OP, menu 4
5 Control unit, frame rear (D797-R) trans- Checked by control sys- Section 11 Common electrics, group
mits boom angle information on the CAN tem, error shown with er- 11.5.3.3 Control unit, frame rear
bus. ror code.
7 Control unit, frame front (D797-F) calcu- Checked by control sys- Section 11 Common electrics, group
lates and sends the weight on the CAN tem, error shown with er- 11.5.3.2 Control unit, frame front
bus. The weight is calculated by a ma- ror code.
chine-unique load curve based on sensor
values for boom angle, boom length and
pressure in the lift cylinders.
NOTE
The load curve is unique for each
machine.
8 The KID control unit (D795) shows - Section 11 Common electrics, group
weight information in the display. 11.5.3.12 KID control unit
Printer, description
page
–
Printer is an option for the dynamic scale function that makes it possi-
ble to save weights and print lists of saved weights.
The printer is connected to the KID control unit (D795) and is fitted on
a dashboard panel on the right side of the steering wheel.
The printer is controlled by the printer operating menu in the display,
where the driver selects the weights to be saved and what should be
printed.
004907
Printer location
Top lift
The container counter counts lifting when contact disappears with
locked twistlocks and twistlocks are not opened within 8 seconds.
Bottom lift
The container counter counts lifting when the clamp function is activat-
ed and lifting is started and unloading clamping position is not activat-
ed within 10 seconds.
1, 4, 7
D1
10
D790-1 D795
D797-R D791-1
3, 6, 9
D5
D2
2, 8 5
006898
2 The sensor for front left alignment Sensor directly oppo- Sensor alignment, description page 140
(7202L), sensor for front right alignment site indicator plate: U D2: Diagnostic menu, see section 8 Control
(7202R), sensor for rear left alignment = 24 V system, group 8.4.9.6 ATTACH, menu 6
(Y7203L) and sensor for rear right align-
ment (Y7203R) send a voltage signal to
the attachment control unit (D791-1).
3 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
4 Twistlocks are rotated to the locked po- - Twistlocks, function description page 130
sition and are closed with the 7.9.1
Twistlocks function.
5 The sensor for lock twistlocks left Sensor directly oppo- Sensor twistlocks, description page 141
(B7205L) and sensor for lock twistlocks site indicator plate: U D5: Diagnostic menu, see section 8 Control
right (B7205R) send a voltage signal to = 24 V system group 8.4.9.7 ATTACH, menu 7
the attachment control unit (D791-1).
7 The container is lifted with the function - Lifting/lowering, function description page 11
7.2 Lift and lower.
8 The sensor for front left alignment U=0V Sensor alignment, description page 140
(7202L), sensor for front right alignment D2: Diagnostic menu, see section 8 Control
(7202R), sensor for rear left alignment system, group 8.4.9.6 ATTACH, menu 6
(Y7203L) and sensor for rear right align-
ment (Y7203R) stop sending a voltage
signal to the attachment control unit
(D791-1).
9 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits no alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
10 If the twistlocks remain locked for 8 sec- - Section 11 Common electrics, group 11.5.3.1
onds, the cab control unit (D790-1) adds Cab control unit
one lift to the container counter.
1 3 4
2, 7
D4
D3
D1
D2
10
D790-1 D795
6, 9 D791-3 D791-4 6, 9
D5 D8 D5
5 8 5 8 D8
006899
Pos Explanation Signal description Reference
1 The attachment’s rear lifting jacks fold are - Raising/lowering of rear lifting jacks, function
lowered to operating position with the func- description page 148
tion 7.9.2 Lifting jacks. D1: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 1
3 The front lifting jacks are lowered with the - Raising/lowering of front lifting jacks, function
function 7.9.2 Lifting jacks. description page 144
D3: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 1
4 The lifting jacks clamp around the contain- - Clamp with left jacks, function description
er with the function 7.9.2 Lifting jacks. page 153
D4: Diagnostic menu, see section 8 Control
system , group 8.4.11.1 COMBI, menu 1
6 Control unit, attachment left jack pair Checked by control Section 11 Common electrics, group 11.5.3.7
(D791-3) and Control unit, attachment right system, error shown Control unit, attachment left jack pair
jack pair (D791-4) send clamping position, with error code. Section 11 Common electrics, group 11.5.3.8
lifting jacks on the CAN bus. Control unit, attachment right jack pair
7 The container is lifted with the function 7.2 - Lifting/lowering, function description page 11
Lift and lower.
8 Sensor alignment front jack left (B7213L) Sensor directly oppo- Sensor alignment, description page 170
and sensor alignment rear jack left site indicator plate: U D8: Diagnostic menu, see section 8 Control
(B7214L) send a voltage signal to Control = 24 V system , group 8.4.11.1 COMBI, menu 3
unit, attachment left jack pair (D791-3).
Sensor alignment front jack right (B7213R)
and sensor alignment rear jack right
(B7214R) send a voltage signal to Control
unit, attachment right jack pair (D791-4).
9 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
10 If clamping position remains active for 10 - Section 9 Frame, body, cab and accessories,
seconds, the cab control unit (D790-1) group 9.1 Controls and instruments
adds one bottom lift to the container
counter.
Bypassed or boom height Section 8 Control system, group 8.2.4 Height limitation
Height limitation
lower than height limitation
D1
+
2, 6
D790-1 D795
5 D797-R D797-F
D3 D4
006900
3 m <˚ 4
2 The cab control unit (D790-1) trans- Checked by control system, Section 11 Common electrics, group
mits synchronised lift on the CAN error shown with error code. 11.5.3.1 Cab control unit
bus.
3 Sensor, boom angle (B771) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.5 Sen-
voltage signal to Control unit, frame sor, boom angle
rear (D797-R). D3: Diagnostic menu, see section 8 Control
system , group 8.4.10.1 OP, menu 1
4 Sensor, boom length (B777) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.6 Sen-
voltage signal to Control unit, frame sor, boom length
rear (D797-R). D4: Diagnostic menu, see section 8 Control
system, , group 8.4.10.4 OP, menu 4
5 Control unit, frame rear (D797-R) Checked by control system, Section 11 Common electrics, group
transmits length and angle informa- error shown with error code. 11.5.3.3 Control unit, frame rear
tion on the CAN bus.
8 Control system
8 Control system
mm mm mm mm mm mm
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
The error code is shown automatically on the display.
000351
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
D E the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
000352
menu for service.
B
000389
• Engine:
XXX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
013390
• Transmission:
XX/YY Shown with error code number XX/YY on display.
B
013391
7
000396
8.2 Monitoring
8.2.1 Overload system
8.2.1.1 Mechanical overload system
Mechanical overload system, function description (model
page
–
year-2008)
3, 10
D795
4 2, 5, 7, 9 D797-R D793
8
D6
1 D1
006413
D4 >˚ 6
2 Control unit, frame rear (D797-R) sends Checked by control sys- Section 11 Common electrics, group
"Overload forward" on the CAN bus. tem; error indicated with 11.5.3.3 Control unit, frame rear
error code.
3 Control unit KID (D795) shows Event - Section 11 Common electrics, group
menu, overload forward. 11.5.3.12 KID control unit
4 Position sensor boom length 1.5 m Extension less than Sensor, boom length, description (position
(B777) sends a voltage signal to Control 1.5 m: U = 24 V sensor) page 13
unit, frame rear (D797-R) if the boom’s Extension more than D4: Diagnostic menu, see section 8 Control
extension is less than 1.5 m. 1.5 m: U = 0 V system , group 8.4.10.1 OP, menu 1
5 Control unit, frame rear (D797-R) sends Checked by control sys- Section 11 Common electrics, group
"boom length under 1.5m" on the CAN tem; error indicated with 11.5.3.3 Control unit, frame rear
bus. error code.
6 Sensor, boom angle (B771) sends a UB771/1 = 5 V Sensor, boom angle, description (angle sen-
voltage signal proportional to boom an- sor) page 12
UB771/2 = 0 V
gle to Control unit, frame rear (D797-R). D6: Diagnostic menu, see section 8 Control
UB771/3 = 0.5 - 4.5 V
system , group 8.4.10.4 OP, menu 4
7 Control unit, frame rear (D797-R) sends Checked by control sys- Section 11 Common electrics, group
"boom angle" on the CAN bus. tem; error indicated with 11.5.3.3 Control unit, frame rear
error code.
8 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group
transmits speed information on the CAN tem; error indicated with 11.5.3.9 Control unit, transmission
bus. error code.
10 The KID control unit (D795) activates - Section 11 Common electrics, group
the Event menu for overload on steering 11.5.3.12 KID control unit
axle.
3, 8
D795
D797-R D793
D4 2, 7 6
4
m
D5
1 D1
006414
<˚ 5
2 Control unit, frame rear (D797-R) sends Checked by control sys- Section 11 Common electrics, group
"Overload forward" on the CAN bus. tem; error indicated with 11.5.3.3 Control unit, frame rear
error code.
3 Control unit KID (D795) activates Event - Section 11 Common electrics, group
menu, overload forward. 11.5.3.12 KID control unit
4 Sensor, boom length (R777) sends a UB777/1 = 5 V Sensor, boom length, description (analogue
voltage signal proportional to the boom sensor) page 14
UB777/2 = 0 V
length to Control unit, frame rear D4: Diagnostic menu, see section 8 Control
(D797-R). UB777/3 = 0.5 - 4.5 V
system , group 8.4.10.4 OP, menu 4
6 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group
transmits speed information on the CAN tem; error indicated with 11.5.3.9 Control unit, transmission
bus. error code.
7 If boom length is less than 1.5 m and Checked by control sys- Section 11 Common electrics, group
boom angle is greater than 35 ° while tem; error indicated with 11.5.3.3 Control unit, frame rear
the machine is operated faster than error code.
10 km/h then Control unit, frame rear
(D797-R) sends "Overload on steering
axle" on the CAN bus.
8 The KID control unit (D795) activates - Section 11 Common electrics, group
the Event menu for overload on steering 11.5.3.12 KID control unit
axle.
6
D795
D4 3 D3 D1 1
006415
<˚ Pa Pa
3 Sensor, boom length (B777) sends a UB777/1 = 5 V Section 8 Control system, group 8.2.1.6
voltage signal proportional to the boom Sensor, boom length
UB777/2 = 0 V
length to Control unit, frame rear D3: Diagnostic menu, see section 8 Control
(D797-R). UB777/3 = 0.5 - 4.5 V
system , group 8.4.10.4 OP, menu 4
Alternatively, Sensor, boom length
(B777) may have a position sensor for
none or maximum boom extension.
4 Sensor, boom angle (BR771) sends a UB771/1 = 5 V Section 8 Control system, group 8.2.1.5
voltage signal proportional to the boom Sensor, boom angle
UB771/2 = 0 V
angle to Control unit, frame rear D4: Diagnostic menu, see section 8 Control
(D797-R). UB771/3 = 0.5 - 4.5 V
system , group 8.4.10.4 OP, menu 4
5 Control unit, frame front (D797-F) calcu- Checked by control sys- Section 11 Common electrics, group
lates and sends the weight, which is cal- tem; error indicated with 11.5.3.2 Control unit, frame front
culated and compared with a machine error code.
unique load curve based on the sensor
values for boom angle, boom length and
pressure in the lift cylinders.
NOTE
The load curve is unique for each
machine.
If the load is high then Control unit,
frame front (D797-F) sends Overload
forward on the CAN bus.
6 The KID control unit (D795) activates - Section 11 Common electrics, group
the event menu for overload, depending 11.5.3.12 KID control unit
on the load situation.
7 The transmission control unit (D793) Checked by control sys- Section 11 Common electrics, group
transmits speed information on the CAN tem; error indicated with 11.5.3.9 Control unit, transmission
bus. error code.
Sensors, steering axle load (B7221L and B7221R) detect when the
steering axle’s rear suspension decompresses. The sensors are fitted
on each side of the steering axle’s rear suspension.
Sensors, steering axle load, are inductive position sensors that are
supplied with voltage and send a voltage signal to Control unit, frame
rear (D797-R).
The sensor signals can be checked from the diagnostic menu, see
section 8 Control system , group 8.4.10.1 OP, menu 1.
005122
The boom’s angle is measured by a sensor that senses the boom’s an-
gle in relation to the frame. The sensor consists of a sensor housing,
potentiometer and arm. The sensor housing is mounted on the boom.
The arm is connected to the frame and turns the potentiometer when
the boom is angled.
The sensor is supplied with voltage by and sends a signal proportional
to the angle to Control unit, frame rear (D797-R).
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.10.4 OP, menu 4.
001093
Sensor, boom length (R777) senses the lift boom’s extension and is
located in the rear edge of the boom on the left-hand side.
The sensor is connected to a spring-loaded wire that is connected to
a rotary potentiometer via a gearbox. The wire is connected to the in-
ner boom. When the boom is extended, the wire acts on the potenti-
ometer and the signal is changed.
The sensor is supplied with voltage by and sends a voltage signal pro-
portional to the length to Control unit, frame rear (D797-R).
The signal can be checked from the diagnostic menu, see section
000471 8 Control system , group 8.4.10.4 OP, menu 4.
8.2.2 Bypass
Bypassing, description
page
–
When the overload system engages and turns off the hydraulic con-
trols, it may take place in a situation where it is necessary to bypass
the safety system.
Bypass is activated with a switch, there are between one and three
switches depending on the machine’s equipment:
• Switch, bypass
D ANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
Load centre limitation prevents the load from coming too close to the
machine. The load centre limitation is controlled by the control system
with signals from Sensor, boom angle, see Sensor, boom angle, de-
000358
scription (angle sensor) page 12 and Sensor, boom length, see Sen-
sor, boom length, description (analogue sensor) page 14. For
Event menu, load centre limitation.
example, this is used in connection with cab lift to prevent the contain-
er damaging the cab.
For details about lift, lower and extension, see section 7 Load han-
dling, group 7.2 Lifting/lowering and section 7 Load handling, group
7.3 Extension.
Load centre limitation reaches its limit, synchronised lift is activated
(see section 7 Load handling, group 7.10.4 Synchronised lift) this
function can be temporarily disengaged using Switch, bypass (see By-
passing, description page 15).
Load centre limitation values can be checked from the diagnostic
menu, see 8 Control system , group 8.4.10.5 OP, menu 5.
Height limitation is a part of the control system and prevents the ma-
chine lifting higher than a preset height, without the operator being in-
formed.
Height limitation is controlled by the control system with signals from
Sensor, boom angle, and Sensor, boom length. When boom angle
and extension indicate that permitted height is reached, lift and exten-
sion are blocked and display information height limitation is activated.
For details about lift, lower and extension, see section 7 Load han-
dling, group 7.2 Lifting/lowering and section 7 Load handling, group
7.3 Extension.
Height limitation can be temporarily disengaged using Switch, bypass
of load centre and height limitation (S1015), see Switch, bypass height
limitation, description page 4.
Height limitation values can be checked from the diagnostic menu, see
8 Control system , group 8.4.10.6 OP, menu 6.
PRESENT XXXXh
8.4 Diagnostics
Diagnostic test, general
page
–
009268
controlled.
OP EXTRA RMI
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system, CAN/
POWER, description page 20.
• Lighting, LIGHTS, description page 40.
• Cab functions, CAB, description page 53.
• Air conditioning, CLIMATE, description page 62.
• Hydraulic functions, HYD, description page 70.
• Engine, ENGINE, description page 75.
• Transmission, TRANSM, description page 82.
• Boom functions, BOOM, description page 101.
• Attachment functions, ATTACH, description page 109.
• Overload system, OP, description page 132.
• Optional functions, EXTRA, description page 137.
– Bottom lift, COMBI, menu 1 page 137.
– Hydraulic sliding/vertically adjustable cab, SLIDING-CAB,
menu 1 page 154.
– Support jacks, SUPPORT-JACKS, menu 1 page 158
– Mini-wheel or lever steering, EL-STEERING, menu 1 page
161
• RMI (Remote Machine Interface), RMI, description page 166
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
FEEDBACK 0
1. DIAG = Diagnostic menus
2. Menu group
3.Menu number
4.Total number of menus in the loop
5.Signal value
6.Variable
7. Menu heading
Menu group Indicates which menu group is selected, these groups are:
CAN/POWER, description page 20.
LIGHTS, description page 40.
CAB, description page 53.
CLIMATE, description page 62.
HYD, description page 70.
ENGINE, description page 75.
TRANSM, description page 82.
BOOM, description page 101.
ATTACH, description page 109.
EXTRA, description page 137.
Menu number Number of current menu. Every menu group consists of several menus in a loop.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value Measurement value or status for signal for variable. On the same row there are different types that are
interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.
8.4.1 CAN/POWER
CAN/POWER, description
page
–
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selection with function key for Enter.
TRANSM BOOM ATTACH
009268
OP EXTRA RMI
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN-bus
Signal value:
3 Ok.
2 Segment check
0 Error.
SEGMENT ERROR X
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Connection: -
Function: 11.6.2 Redundant CAN-bus
Signal value:
003177
SEGMENT ERROR X Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Connection: -
Function: 11.6.2 Redundant CAN-bus
Signal value:
0 No open circuit.
Description: Indicates which control units have contact with the cab
DIAG CAN/POWER 2(20) control unit (D790-1) via the redundant CAN bus. Note that certain
PRESENT REDCAN STATUS control units are optional and may not be installed on the machine.
RED.CON.CITIES
XYXYXYXY Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
000087
Signal value:
TRANSMISSION X Connection:
Volvo TWD1240VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TAD1250VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.
TRANSMISSION
Description: Indicates status for transmission in drivetrain’s CAN bus
DIAG CAN/POWER 3(20) Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
PRESENT DRIVE-TRAIN
CAN BUS STATUS Dana TE 32000 group 2.0, Circuit Dana TE 32000FF group 2.0
ENGINE X Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
000088
TRANSMISSION X and M2
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.
RELAY K315-2 XY
Signal value:
0 No signal.
006859
RELAY K315-2 XY
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
RELAY K315-2 XY
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
006860
RELAY K3009-2 XY
Signal value:
0 No signal.
Description: Status for control current to Relay K2, for emergency stop
DIAG CAN/POWER 5(X) switch voltage (K3009-1), 15E voltage.
EMERGENCY STOP, SW X
RELAY K3009-1 XY Circuit diagram: Circuit Power group 11.5
FEEDBACK X Connection: signal from D790-1/K10:11 to K3009-1/86
006860
RELAY K3009-2 XY
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value:
0 No signal.
006860
RELAY K3009-2 XY
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value:
003178
2. Circuit Extra equipment group 9.1, Circuit Drivetrain group 2.1,
Circuit Cab driver’s seat group 9.3, Circuit Lighting group 9.6, Cir-
cuit Working lights group 9.6 and Circuit Extra Sensor Instr. group
9.1
3. Circuit Joystick group 7.1
4. Circuit Power group 11.5, Circuit Brake group 4.0, Circuit Bypass
group 8.2, Circuit Sliding/Vertically adjustable Cab group 9.10,
Circuit Hyd Support jacks group 7.10, Circuit Twistlocks group
7.9, Circuit Spreading Sensor group 7.5, Circuit Extra equipment
group 9.1
5. Circuit Combi Att group 7.9
6. -
7. Circuit Sliding/Vertically adjustable Cab group 9.10
8. Circuit Alarm, audible signals group 9.7
9. Circuit Wiper group 9.5
10. Circuit Wiper group 9.5
Connection:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S199-1/5, S199-3/5, S199-
4/5, S220-2/1, S143/5, S100/5, S110/5, S105-3/5, S105-2/5,
S105-1/5
3. signal from digital out D790-1/K7:12 to S815/15
4. signal from digital out D790-1/K8:16 to S250/11, S107/5, S1005/
5, S1015/5, S1014/5, S177/3, S1013/3, S1003/3, S1003/4,
S1004/5, S199-2/5
5. signal from digital out D790-1/K9:1 to S1006/3, S1007/3, S1008/3
6. signal from digital out D790-1/K9:7 not connected
7. signal from digital out D790-1/K10:1 to B769-2/1
8. signal from digital out D790-1/K11:12 to S230/2
9. signal from digital out D790-1/K12:1 to M650-2/53a
10. signal from digital out D790-1/K12:3 to M650-3/53a
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. 7.1.1 Control lever
4. 11.5.1.4 Emergency stop voltage, 4.5 Parking brake system, 8.2.2
Bypass, 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab,
7.10.1 Support jacks, 7.9.1 Twistlocks
5. 7.9.2 Lifting jacks
6. -
7. 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
8. 9.3.10 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:
000093
EME STOP POWER X
Function: 11.5.1.3 Ignition voltage (15)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
000094
Connection: signal from digital out D797-F/K1:39 to S, 200, S204,
S216 and S220
Function: 9.6.4 Brake light, 2.2.6 NO (normally open) switch declutch,
4.3.7 NO (normally open) switch brake pressure, 4.3.8 NO (normally
open) switch brake light 4.5.5 NO (normally open) switch parking
brake
Signal value:
000095
Ri: redundant feed to D797-R/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
000097
EME STOP POWER X Circuit diagram: Circuit Power group 11.5
Connection: 15-voltage from K315-1/30 via F54/4 and 58-2/4 to
D797-O/K2:10
Function: 11.5.1.3 Ignition voltage (15)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
000098
cab group 9:10
Connection: digital out D797-O/K1:9 to B7222L, B7222R, B7223L,
B7223R
Function: 7.10.1.5 Sensor, raised support jacks, 7.10.1.6 Sensor, low-
ered support jacks
Signal value:
1 Feed active.
0 No feed.
000100
SENSOR SUPPLY XX.XXV
Function: 11.5.1.1 Battery voltage (30)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
00003179
Connection:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
Circuit diagram: Circuit Power group 11.5, Circuit Power att. group
11.5
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
and F52-1 to D791-2/K2:1, K2:11
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Connection:
Le: redundant feed to D791-2/K2:7
Ri: redundant feed to D791-2/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
000103
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
and F52-2 to D791-3/K2:1, K2:11
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30V (battery voltage).
1 Feed active.
0 No feed.
Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
and F52-2 to D791-4/K2:1, K2:11
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30V (battery voltage).
000104
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Connection:
Le: redundant feed to D791-4/K2:7
Ri: redundant feed to D791-4/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
24V SENS.SUP 791-4 XY B7225, B7202L, B7202R, B7203L, B7203R, B7204L, B7204R,
B7205L and B7205R
Function: 7.5.10 Position sensor spreading, 7.6.10 Sensor rotation
stop, 7.9.1.8 Sensor alignment, 7.9.1.9 Sensor twistlocks, 8.2.1.6
Sensor, boom length
Signal value:
003180
24V SENS.SUP 791-4 XY Circuit diagram: Circuit Over Height group 7.9
Connection: digital out from D791/K1:10 to B7231L and B7231R
Function: 7.9.1 Twistlocks
Signal value:
24V SENS.SUP 791-4 XY Circuit diagram: Circuit Combi Att group 7.9
Connection: digital out from D791-3/K1:26 to B7212L, B7213L,
B7214L, B7215L, B7216L, B7217L, B7218L, B7219L and B7220L
Function: 7.9.2.9 Sensor operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sen-
sor clamping position
Signal value:
003180
24V SENS.SUP 791-4 XY Circuit diagram: Circuit Combi Att group 7.9
Connection: digital out from D791-4/K1:26 to B7212R, B7213R,
B7214R, B7215R, B7216R, B7217R, B7218R, B7219R and B7220R
Function: 7.9.2.9 Sensor operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sen-
sor clamping position
Signal value:
SEGMENT ERROR X
onwards. Segment 1 is always between Control unit, cab (D790-1)
and Control unit, attachment(D791-1). The last segment is always be-
tween Control unit, KID (D795) and Control unit, cab (D790-1). The
segments in between vary depending on machine configuration.
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
D791-4 D791-3 D791-2 D791-1
CAN R CAN L CAN R CAN L CAN R CAN L CAN R CAN L Connection:
4 3 2
Function: 11.6.2 Redundant CAN-bus
1 9 8
0 No errors.
6 7
CAN L CAN R CAN L CAN R CAN L CAN R
>0 X > 0, the number indicates incorrect segment. Use circuit di-
006883
8.4.2 LIGHTS
LIGHTS, description
page
–
012083
OP EXTRA RMI
Signal value:
0 No signal.
012084
OPT OUTPUT (2X) XY
Signal value:
0 No signal.
012084
OPT OUTPUT (2X) XY Circuit diagram: Circuit Extra Wor.li. Att group 9.6
Connection: digital out from D791/K1:42 to E404-4R and E404-4L
Function: 9.6.11 Working lights attachment
Signal value:
OPTIONAL OUTPUT XX
Signal value:
0 No signal.
000109
OPTIONAL OUTPUT XX
RI: digital out from D797-R/K1:15 to E404-3R
Function: 9.6.10 Working light boom
Signal value:
OPTIONAL OUTPUT XX Connection: digital out from D790-1/K10:8, via relay K304/87 to
H404-5L and H404-5R
Function: 9.6.10 Working light boom
Signal value:
000110
Signal value:
0 No signal.
REAR LE XY RI XY
RI: digital out from D797-F/K1:29 to H417-1
Function: 9.6.2 Running lights
Signal value:
000111
REAR LE XY RI XY
RI: digital out from D797-R/K1:9 to H417-2
Function: 9.6.2 Running lights
Signal value:
REAR LE XY RI XY
RI: digital out from D797-R/K1:25 to H412R
Function: 9.6.3 Rear lights
Signal value:
000112
DIMMED XY
Signal value:
0 No signal.
000112
DIMMED XY
Signal value:
0 No signal.
0 No signal.
000114
REAR LE XY RI XY
LE: digital out from D797-F/K1:9 to H422
RI: digital out from D797-F/K1:10 to H423
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
REAR LE XY RI XY
LE: digital out from D797-R/K1:29 to H426
RI: digital out from D797-R/K1:39 to H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
000115
Signal value:
0 No signal.
Signal value:
Signal value:
0 No signal.
013260
Function: 9.6.5 Back-up light
Signal value:
0 No signal.
REVERSE ALARM XY
RI: digital out from D797-R/K1:33 to H411R
Function: 9.6.4 Brake lights
Signal value:
000117
REVERSE ALARM XY
RI: digital out from D797-R/K1:42 to H405R
Function: 9.6.5 Back-up light
Signal value:
ALARM
Description: Voltage feed to back-up alarm.
DIAG LIGHTS 11(13)
Circuit diagram: Circuit Reverse alarm group 9.7
PRESENT OUTPUT SIGNAL
BRAKE LIGHT LEXY RIXY Connection: digital out from D797-R/K1:30 to H965
REVERSE LGT LEXY RIXY
Function: 9.7.5 Back-up alarm
000117
REVERSE ALARM XY
Signal value:
000118
OUTPUT XXX
Signal value:
0 No signal.
OUTPUT XXX
Function: 9.10.2 Doors
Signal value:
0 No signal.
OUTPUT XXX
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).
50 Means 4-5 V.
8.4.3 CAB
CAB, description
page
–
012086
OP EXTRA RMI
OUTPUT REAR/ROOF XY
Signal value:
0 No signal.
WASHER, OUTPUT
page
–
OUTPUT REAR/ROOF XY
Signal value:
012087
OUTPUT REAR/ROOF XY window is activated.
Circuit diagram: Circuit Wipers group 9.5
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:
FEEDBACK X
X = 2 Interval less slow: signal from S162/J2, digital in D790-2/
K3:7
X = 3 Interval continuous: signal from S162/53, digital in D790-2/
K3:8
Function: 9.5 Wiping and cleaning of windows
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.
000122
FEEDBACK X
Signal value:
Description: Signal from motor wiper front, indicates when wiper mo-
DIAG CAB 2(10) tion is completed.
FRONT WIPER
SWITCH (1-3) X Circuit diagram: Circuit Wipers group 9.5
OUTPUT XY Connection: from M650-1/31b to digital in D790-1/K4:13
000122
FEEDBACK X
Function: 9.5.5 Wiper motor front
Signal value:
FEEDBACK X
Function: 9.5 Wiping and cleaning of windows
Signal value:
0 No signal.
000123
FEEDBACK X
Signal value:
FEEDBACK X
Function: 9.5.7 Wiper motor rear
Signal value:
FEEDBACK X
Signal value:
0 No signal.
000124
FEEDBACK X
Signal value:
Description: Signal from motor wiper roof, indicates when wiper mo-
DIAG CAB 4(10) tion is completed.
ROOF WIPER
SWITCH X Circuit diagram: Circuit Wipers group 9.5
OUTPUT XY Connection: from M650-3/31b to digital in D790-1/K12:4
000124
FEEDBACK X
Function: 9.5.6 Wiper motor roof
Signal value:
SWITCH JOYSTICK X
Signal value:
0 No signal.
HORN, OUTPUT
page
–
013382
SWITCH JOYSTICK X horn, signal to relay K3016/86)
Function: 9.7.1 Horn
Signal value:
SWITCH JOYSTICK
page
–
Description: Signal from the switch open twistlocks on the control le-
DIAG CAB 5(10) ver. The signal is used to activate the horn when there is no alignment.
HORN
SWITCH X Circuit diagram: Circuit Joystick group 7.1
OUTPUT XY Connection: signal from S815/20 to digital in D790-1/K7:15
013382
SWITCH JOYSTICK X
Function: 9.7 Signal system
Signal value:
0 No signal.
000126
OP X
Signal value:
SWITCH SEAT
page
–
OP X
Signal value:
ALARM
page
–
OP X
Function: 8.1.2 Information display
Signal value:
OP
page
–
000126
OP X
Signal value: X = 1,
FUEL, PROC
page
–
0 No signal.
000128
Connection: digital out D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil
Signal value:
006864
OUTPUT XY Circuit diagram: Circuit Central lubrication group 9.14
Connection: digital out D791/K1:14 to M693-2
Function: 9.14 Central lubrication
Signal value:
8.4.4 CLIMATE
CLIMATE, description
page
–
OP EXTRA RMI
000132
WATER VALVE FEEDB. XXX
Signal value: XXX = Cab’s interior temperature in tenths of degrees
(200 = 20 °C).
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(8) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit Climate system group 9.4
TEMP AMBIENT XXX Connection: signal from B775-2/2 to input D790-1/K4:10
000133
TEMP COOLANT
page
–
TEMP AMBIENT
page
–
TEMP DE-ICE
page
–
000133
TEMP DE-ICE XXX
Signal value: XXX = Refrigerant temperature in tenths of degrees (200
= 20 °C).
Signal value:
000135
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V
REQ. FAN SPEED XX.XXV Connection: signal from S139/3 to analogue in D790-1/K5:8
Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.
REQ. FAN SPEED XX.XXV Circuit diagram: Circuit Climate system group 9.4
Connection: signal from S117/3 to analogue in D790-1/K5:9
Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Up / - / down.
REQ. FAN SPEED XX.XXV Connection: signal from S118/2 to analogue in D790-1/K5:7
Function: 9.4 Heating, ventilation and climate control unit
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.
000137
COMPRESSOR XY
Function: 9.4.3 cab fan
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
COMPRESSOR XY
Function: 9.4.2 Fresh air and recirculation damper
Signal value:
Description: Voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(8) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing is control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temp. cab temperature and coolant temperature, so
it may be difficult to determine whether the valve is working as it
should.
24V
Circuit diagram: Circuit Climate system group 9.4
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
Function: 9.4.5 Water valve
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11
0V
No output signal, circuit OK. It can also be a short circuit as
H-bridge this is only detected when the output signal is active.
Description: Voltage feed to water valve, for closing. The valve is con-
DIAG CLIMATE 7(8) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing is control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temp. cab temperature and coolant temperature, so
it may be difficult to determine whether the valve is working as it
should.
24V
Circuit diagram: Circuit Climate system group 9.4
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
Function: 9.4.5 Water valve
M Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
0V
No output signal, circuit OK. It can also be a short circuit as
H-bridge this is only detected when the output signal is active.
Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(8) wise. Is connected to an H-bridge. Signal can only be diagnosed when
OUTPUT DRAUGHT VALVE the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit Climate system group 9.4
Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from
D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
Description: Voltage feed to motor for the air distributor, rotation coun-
DIAG CLIMATE 8(8) ter-clockwise. Motor is connected to an H-bridge. Signal can only be
OUTPUT DRAUGHT VALVE diagnosed when the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit Climate system group 9.4
Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from
D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
8.4.5 HYD
HYD, description
page
–
009272
OP EXTRA RMI
Signal value:
000142
Signal value:
NOTE
You can quickly test the sensors by lifting max. and running the
C+
lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure ±0.1 MPa.
000143
Description: Pressure on the lift cylinders’ piston side (C+). For voltage
DIAG HYD 3(6) value, see OP, description page 132. The sensor on the right-hand lift
PRESSURE LIFTING CYL
Le Ri cylinder is optional .
C- XXX XXX Circuit diagram: Circuit OP + Scale group 8.2
C+ XXX XXX
Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C+
page 134
Function: 8.2.1 Overload system
NOTE
You can quickly test the sensors by lifting max. and running the
C+ lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure ±0.1 MPa.
000143
Description: Signal from the NC switch for oil pressure, brake system.
DIAG HYDRAULIC 4(X)
Circuit diagram: Circuit Brake system group 4.0
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: signal from S204/2 to analogue in D797-F/K1:20
BRAKE LIGHT PRESS. X
Function: 4.3.7 NC switch oil pressure, brake system
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.
DECLUTCH PRESSURE X
Signal value:
0 No signal.
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit Brake system group 4.0
012404
VALVE XY
Signal value:
0 No signal.
P-BRAKE, VALVE
page
–
012404
VALVE XY
Signal value:
VALVE
Description: Voltage feed to Solenoid valve, engagement of hydraulics
DIAG HYD 6(6) for top lift.
PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM. Circuit diagram: Circuit Rotation, group 7.6
VALVE XY Connection: digital out D797-R/K1:31 to Y6003/1
000146
Function: 7.4 Side shift, 7.5 Spreading, 7.6 Rotation, 7.7 Tilt, 7.8 Lev-
elling 7.9.1 Twistlock, 7.9.2 Lifting jacks
Signal value:
8.4.6 ENGINE
ENGINE, description
page
–
012093
OP EXTRA RMI
Description: Required engine speed (in percent) which is sent from the
DIAG ENGINE 1(X) cab control unit (D790-1) to the engine control unit (D794) via the CAN
PRESENT INPUT SIGNAL bus drivetrain.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
Description: Engine speed from engine control unit (D794) to the cab
DIAG ENGINE 2(X) control unit (D790-1) via the CAN bus drivetrain. The actual value for
PRESENT INPUT SIGNAL engine speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
009281
Connection: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = Active speed in rpm.
009281
Connection: -
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
Signal value: XXXX = Active speed in rpm.
009282
D+ X Circuit diagram: Circuit Power group 11.5
Connection: signal from S150/19 to digital in D790-2/K2:2
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
D+ X
Signal value:
0 No signal.
D+ X
Function: 11.4.1 Alternator
Signal value:
0 No signal.
000152
Cummins: controlled by engine’s control system.
Function: 1.10.1 Preheating
Signal value:
0 No output signal.
Description: Engine oil pressure. CAN bus message from engine con-
DIAG ENGINE 6(X) trol unit (D794) to cab control unit (D790-1).
PRESENT INPUT SIGNAL
OIL PRESSURE XXX Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XXX Connection:
006868
OIL LEVEL XXX
Volvo TWD1240VE: signal from "43 Sensor, oil temperature/pres-
sure" to Control unit, engine (D794) "black connector" sleeve 14
Volvo TAD1250VE: signal from "28 Sensor, oil temperature and
oil pressure" to Control unit, engine (D794) "Connector B" sleeve
11
Cummins QSM11: signal from "oil pressure/temperature sensor"
to engine control unit (D794) "Sensor connector" sleeve 44
Function: 1.8.3 Sensor oil pressure engine
Signal Value: XXX = 10 corresponds to 100 kPa.
Description: Charge air pressure. CAN bus message from engine con-
DIAG ENGINE 6(X) trol unit (D794) to cab control unit (D790-1).
PRESENT INPUT SIGNAL
OIL PRESSURE XXX Circuit diagram: See supplier documentation, engine
BOOST PRESSURE XXX Connection:
006868
009284
INTAKE MAIN.TEMP XXX
Volvo TWD1240VE: signal from "43 Sensor, oil temperature/pres-
sure" to Control unit, engine (D794) "black connector" sleeve 1
Volvo TAD1250VE: signal from "28 Sensor, oil temperature and
oil pressure" to Control unit, engine (D794) "connector A" sleeve
31
Cummins QSM11: signal from "Oil pressure/temperature sensor"
sleeve 4 to Control unit, engine (D794) "Sensor connector" sleeve
42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 equals 20 °C.
009279
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
Description: SPN number for the first error code from engine control
DIAG ENGINE 8(X) unit (D794). SPN indicates the malfunction area, i.e. what component
PRESENT EDC ERROR or signal is defective. Error codes are shown with SPN/FMI in error
NR OF ACT ERROR XX code menus.
SPN XXXX
009279
Description: FMI number for the first error code from the engine control
DIAG ENGINE 8(X) unit (D794). FMI indicates error type, e.g. short circuit or low value. Er-
PRESENT EDC ERROR ror codes are shown with SPN/FMI in error code menus.
NR OF ACT ERROR XX
SPN XXXX Circuit diagram: -
009279
FMI XX Connection: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.
8.4.7 TRANSM
TRANSM, description
page
–
009274
OP EXTRA RMI
0 No signal.
0 No signal.
000160
SHIFT MODE X
Signal value:
0 No signal.
SWITCHES, REVERSE
page
–
SHIFT MODE X
Signal value:
0 No signal.
000161
GEAR X Connection: -
Function: 2.8 Control system, transmission
Signal value:
0 No output signal.
GEAR X Connection: -
Function: 2.8 Control system, transmission
Signal value:
0 No output signal.
GEAR X
Connection: -
Signal value: X = current gear.
OPERATING MODE X
Function: 2.8 Control system, transmission
Signal value:
1 Automatic.
0 Manual.
000162
OPERATING MODE X
Function: 2.8 Control system, transmission
Signal value:
1 Active error.
0 No errors.
OPERATING MODE X
Function: 2.8 Control system, transmission
Signal value:
0 Not used.
2 Not used.
3 Not used.
OLD FAULT X
Function: 2.8 Control system, transmission
Signal value:
1 Shifting in progress.
0 No activity.
000163
OLD FAULT X
Function: 2.8 Control system, transmission
Signal value:
0 No error codes.
OLD FAULT X
Function: 2.8 Control system, transmission
Signal value:
1 There are inactive error codes that have not been acknowl-
edged.
5
000164
4
1. Sensor, drum rpm (B752)
2.Temperature switch, torque converter (S221)
3.Sensor, engine speed and transmission tempera-
ture (B758/766)
4.Sensor, turbine rpm transmission (B751)
5.Sensor rpm output shaft (B758)
Description: Signal from sensor rpm output shaft (propeller shaft) (po-
DIAG TRANSM. 6(15) sition 5).
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Circuit diagram: Circuit Dana TE 32000 group 2.0
ENGINE SPEED XXXXHz Connection: signal from B758 till D793/ D3 and D793/ E3
TURBINE SPEED XXXXHz
Function: 2.3.9 Sensor rpm output shaft
Signal value: XXXXHz = frequency, indicates pulses from the sensor
1 2 3
in Hz (pulses /second). To convert to rpm, divide frequency by number
of teeth on output shaft’s gear.
5 000164
4
1. Sensor, drum rpm (B752)
2.Temperature switch, torque converter (S221)
3.Sensor, engine speed and transmission tempera-
ture (B758/766)
4.Sensor, turbine rpm transmission (B751)
5.Sensor rpm output shaft (B758)
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM. 6(15)
Circuit diagram: Circuit Dana TE 32000 group 2.0
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B7558/766 to D793/H3
ENGINE SPEED XXXXHz
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
TURBINE SPEED XXXXHz
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
1 2 3
of teeth on input shaft’s gear.
5
000164
4
1. Sensor, drum rpm (B752)
2.Temperature switch, torque converter (S221)
3.Sensor, engine speed and transmission tempera-
ture (B758/766)
4.Sensor, turbine rpm transmission (B751)
5.Sensor rpm output shaft (B758)
5
000164
4
1. Sensor, drum rpm (B752)
2.Temperature switch, torque converter (S221)
3.Sensor, engine speed and transmission tempera-
ture (B758/766)
4.Sensor, turbine rpm transmission (B751)
5.Sensor rpm output shaft (B758)
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM. 6(15)
Circuit diagram: Circuit Dana TE 32000FF group 2.0
ENGINE SPEED XXXXrpm
TURBINE SPEED XXXXrpm Connection: signal from B7530 to D793/F3 and D793/K3
DRUM SPEED XXXXrpm
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
OUTPUT SPEED XXXXrpm
Signal value: XXXXrpm = rotation speed.
1 2 3
5
013149
4
1. Sensor, drum rpm (B7520)
2.Temperature switch, torque converter (S2210)
3.Sensor, engine speed (B7530)
4.Sensor, turbine rpm transmission (B7510)
5.Sensor rpm output shaft (B7580)
6. Sensor temperature (B7660)
5
013149
4
1. Sensor, drum rpm (B7520)
2.Temperature switch, torque converter (S2210)
3.Sensor, engine speed (B7530)
4.Sensor, turbine rpm transmission (B7510)
5.Sensor rpm output shaft (B7580)
6. Sensor temperature (B7660)
5
013149
4
1. Sensor, drum rpm (B7520)
2.Temperature switch, torque converter (S2210)
3.Sensor, engine speed (B7530)
4.Sensor, turbine rpm transmission (B7510)
5.Sensor rpm output shaft (B7580)
6. Sensor temperature (B7660)
Description: Signal from sensor rpm output shaft (propeller shaft) (po-
DIAG TRANSM. 6(15) sition 5).
ENGINE SPEED XXXXrpm
TURBINE SPEED XXXXrpm Circuit diagram: Circuit Dana TE 32000FF group 2.0
DRUM SPEED XXXXrpm Connection: signal from B7580 till D793/ D3 and D793/ E3
OUTPUT SPEED XXXXrpm
Function: 2.3.9 Sensor rpm output shaft
Signal value: XXXXrpm = rotation speed.
1 2 3
5
013149
4
1. Sensor, drum rpm (B7520)
2.Temperature switch, torque converter (S2210)
3.Sensor, engine speed (B7530)
4.Sensor, turbine rpm transmission (B7510)
5.Sensor rpm output shaft (B7580)
6. Sensor temperature (B7660)
Dana)
Description: Status high and low side for control of solenoid valve RSP
DIAG TRANSM. 7(15) Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit Dana TE 32000 group 2.0
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
000165
00 No signal.
alternative Dana)
Description: Status of feed to solenoid valve VFS 2ND/4TH.
DIAG TRANSM. 7(15)
Circuit diagram: Circuit Dana TE 32000 group 2.0
OUTPUT STATUS
RSP DRIVE X X Connection: digital out from D793/D1 and D793/E1 to Y6069
2/4 VFS SELECTION X
Function: 2.8 Control system, transmission
000165
1/3 VFS SELECTION X
Signal value:
1 Activated.
0 No signal.
alternative Dana)
Description: Status of feed to solenoid valve VFS 1 ST/3 RD.
DIAG TRANSM. 7(15)
Circuit diagram: Circuit Dana TE 32000 group 2.0
OUTPUT STATUS
RSP DRIVE X X Connection: signal from D793/ H1 and D793/ J1 to Y6067
2/4 VFS SELECTION X
Function: 2.8 Control system, transmission
000165
1 Activated.
0 No signal.
1/3 SELECTION X
1 Activated.
0 No signal.
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
000166
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
flow)
Description: Status for control current to clutch pack forward and re-
DIAG TRANSM. 8(15) verse.
SUPPLY
FWD/REV SUPPLY X Circuit diagram: Circuit Dana TE 32000FF group 2.0
2/4 SUPPLY X Connection: digital out from D793/B1 and D793/C1 to Y6300
013252
1/3 SUPPLY X
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value:
1 Activated.
0 No signal.
013252
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
006869
1/3 FEEDBACK XXXXmA
transmission
Signal value: XXXX = Measured value in mA.
transmission
Signal value: XXXX = Measured value in mA.
transmission
Signal value: XXXX = Measured value in mA.
006870
COOLER TEMP XXXXmV Connection: signal from B6067 to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:
alternative Dana)
Description: Signal from sensor transmission oil temperature.
DIAG TRANSM. 10(X)
Circuit diagram: Circuit Dana TE 32000 group 2.0
PRESENT SENSOR INPUT
PRESS FEEDBACK XXXXmV Connection: signal from B758/766 to D793/H3
TRANSM.TEMP XXXXmV
Function: 2.7.2 Sensor engine rpm and oil temperature transmission
006870
alternative Dana)
Description: Signal from oil temperature sensor in radiator, transmis-
DIAG TRANSM. 10(X) sion. The transmission uses a temperature-sensitive NO switch and
PRESENT SENSOR INPUT two resistors in the cable harness to generate different voltage levels.
PRESS FEEDBACK XXXXmV
TRANSM.TEMP XXXXmV Circuit diagram: Circuit Dana TE 32000 group 2.0
006870
013410
Signal value:
Signal value:
006871
SPEED LIMIT XXXX
Signal value: XXXXX = drive axle’s total gear ratio x 1024
flow)
Description: Drive axle gear ratio.
DIAG TRANSM. 11(X) Circuit diagram: -
PRESENT VALUE
AXLE RATIOx1024 XXXXX Connection: -
RADIUS XXXX Function: 2.8 Control system, transmission
SPEED LIMIT XXXX
013431
NOT USED
006872
8.4.7.13 TRANSM, menu 13
ACT ERROR AREA
page
–
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(15) ror code. In case of several error codes, the most serious error code
ACT ERROR AREA XXX is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
000171
TYPE
page
–
NUMBER OF OCCU.
page
–
TIME AGO
page
–
006873
Function: 2.8 Control system, transmission
Signal value: XXXX = Torque in Nm.
8.4.8 BOOM
BOOM, description
page
–
009275
OP EXTRA RMI
RELIEVE PRESS. IN XY
RI: digital out from D797-F/K1:31 to H6001/1
Function: 7.2.7 Valve block lift cylinder
Signal value:
012097
RELIEVE PRESS. IN XY
Signal value:
RELIEVE PRESS. IN XY
Signal value:
000177
RE: digital out from D797-F/K1:32 to H6051/1
Function: 7.2.7 Valve block lift cylinder
Signal value:
Signal value:
Description: Status for control current to control valve lift, lower and ex-
DIAG BOOM 4(8) tension (solenoid valve lift).
OUTPUT BOOM UP
REFERENCE XY Circuit diagram: Circuit Boom up/down group 7.2
REQUIRED VALUE XXX Connection: digital out from D797-F/K1:2 to Y6005/1
000178
FEEDBACK XXX
Function: 7.2.5 Control valve lift, lower and extension
Signal value:
Description: Present control current to control valve lift, lower and ex-
DIAG BOOM 4(8) tension (solenoid valve lift).
OUTPUT BOOM UP
REFERENCE XY Circuit diagram: Circuit Boom up/down group 7.2
REQUIRED VALUE XXX Connection: output signal actual value out from D797-F/K1:16 to
000178
Description: Status for control current to control valve lift, lower and ex-
DIAG BOOM 5(8) tension (solenoid valve lower).
OUTPUT BOOM DOWN
REFERENCE XY Circuit diagram: Circuit Boom up/down group 7.2
REQUIRED VALUE XXX Connection: digital out from D797-F/K1:3 to Y6004/1
000179
FEEDBACK XXX
Function: 7.2.5 Control valve lift, lower and extension
Signal value:
Description: Present control current to control valve lift, lower and ex-
DIAG BOOM 5(8) tension (solenoid valve lower).
OUTPUT BOOM DOWN
REFERENCE XY Circuit diagram: Circuit Boom up/down group 7.2
REQUIRED VALUE XXX Connection: output signal actual value out from D797-F/K1:17 to
000179
Description: Status for control current to control valve lift, lower and ex-
DIAG BOOM 6(8) tension (solenoid valve extension in).
OUTPUT BOOM IN
REFERENCE XY Circuit diagram: Circuit Boom in/out group 7.3
REQUIRED VALUE XXX Connection: digital out from D797-F/K1:5 to Y6007/1
000180
FEEDBACK XXX
Function: 7.3.5 Control valve lift, lower and extension
Signal value:
Description: Present value for control current to control valve lift, lower
DIAG BOOM 6(8) and extension (solenoid valve extension in).
OUTPUT BOOM IN
REFERENCE XY Circuit diagram: Circuit Boom in/out group 7.3
REQUIRED VALUE XXX Connection: output signal actual value out from D797-F/K1:19 to
000180
Description: Status for control current to control valve lift, lower and ex-
DIAG BOOM 7(8) tension (solenoid valve extension out).
OUTPUT BOOM OUT
REFERENCE XY Circuit diagram: Circuit Boom in/out group 7.3
REQUIRED VALUE XXX Connection: digital out from D797-F/K1:4 to Y6006/1
000181
FEEDBACK XXX
Function: 7.3.5 Control valve lift, lower and extension
Signal value:
Description: Present control current to control valve lift, lower and ex-
DIAG BOOM 7(8) tension (solenoid valve extension out).
OUTPUT BOOM OUT
REFERENCE XY Circuit diagram: Circuit Boom in/out group 7.3
REQUIRED VALUE XXX Connection: output signal actual value out from D797-F/K1:18 to
000181
000182
IN/OUT X/X
Function: 7.2.11 Sensor, boom angle (position sensor)
Signal value:
0 No signal.
IN/OUT X/X Circuit Boom in/out group 7.3 (Mechanical overload system)
Connection:
Mechanical overload system with analogue position sensor or
Electrical overload system:
Analogue signal in from B777/3 to analogue in D797-R/K1:22
Mechanical overload system:
Boom in: digital in from B769-3/C to digital in D797-R/K1:26
Boom out: digital in from B769-4/C to analogue in D797-R/K1:23
(software-generated signal from overload system)
Function: 7.3.11 Sensor, boom length
Signal value:
0 No signal.
8.4.9 ATTACH
ATTACH, description
page
–
009276
OP EXTRA RMI
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever zero posi-
tion.
0 No signal.
000185
30/35 STOP X
nised lift
Signal value:
0 No signal.
0 No signal.
BY-PASS HEIGHT X
Signal value:
0 No signal.
BY-PASS HEIGHT X
Signal value:
0 No signal.
000186
BY-PASS HEIGHT X
Connection: from S1014/S1015/1 to digital in D790-1/K8:14
Function: 8.2.2 Bypass
Signal value:
0 No signal.
0 No signal.
0 No signal.
006874
AUTO 20'-40' X Connection: from S199/-2 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:
0 No signal.
0 No signal.
EXTENSION 60CM X
Circuit diagram: Circuit Spreading Sensor group 7.5
Connection: from inductive sensor B777-3/C to digital in D791-1/K1:20
Function: 7.5.10 Position sensor spreading
Signal value:
0 No signal.
-2008)
000188
EXTENSION 60CM X Circuit diagram: Circuit OP + Scale group 8.2
Connection: from inductive sensor B7224/C to digital in D791-1/K1:21
Function: 7.10.2 Weight indicator
Signal value:
0 No signal.
Description: Signals from sensors alignment right front and left front.
DIAG ATTACHMENT 6(21)
Circuit diagram: Circuit Twistlock group 7.9
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Connection:
FRONT X X
LE: signal from B7202L/C to analogue in (used as digital)
000202
REAR X X
D791-1/K1:13
RI: signal from B7202R/C to digital in D791-1/K1:40
Function: 7.9.1.8 Alignment sensor
Signal value:
0 No signal.
Description: Signals from sensors alignment right rear and left rear.
DIAG ATTACHMENT 6(21)
Circuit diagram: Circuit Twistlock group 7.9
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Connection:
FRONT X X
LE: signal from B7203L/C to analogue in (used as digital)
000202
REAR X X
D791-1/K1:27
RI: signal from B7203R/C to digital in D791-1/K1:26
Function: 7.9.1.8 Alignment sensor
Signal value:
0 No signal.
001633
UNLOCKED TW X X
D791-1/K1:23
RI: signal from B7205R/C to analogue in (used as digital)
D791-1/K1:24
Function: 7.9.1.9 Sensor twistlock
Signal value:
0 No signal.
UNLOCKED TW X X
D791-1/K1:22
RI: signal from B7204R/C to analogue in (used as digital)
D791-1/K1:41
Function: 7.9.1.9 Sensor twistlock
Signal value:
0 No signal.
000189
Signal value:
Signal value:
000190
Function: 7.9.1.3 Attachment control valve
Signal value:
000191
Function: 7.9.1 Twistlocks
IND. ALIGNMENT XY
Signal value:
000191
Function: 7.9.1 Twistlocks
IND. ALIGNMENT XY
Signal value:
FEEDBACK XXX
Function: 7.6.3 Control valve attachment
Signal value:
000192
FEEDBACK XXX Y6008/2
Function: 7.6.3 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.
FEEDBACK XXX
Function: 7.6.3 Control valve attachment
Signal value:
000193
FEEDBACK XXX Y6009/2
Function: 7.6.3 Control valve attachment
Signal value: XXX = Measured current value in mA.
FEEDBACK XXX
Function: 7.5.3 Control valve attachment
Signal value:
000195
FEEDBACK XXX
Function: 7.5.3 Control valve attachment
Signal value:
006875
BUZZER AUTO 20-40 XY Connection: digital out from D791-1/K1:7 to Y6012-1/1
Function: 7.7.4 Lock valve tilt
Signal value:
006875
BUZZER AUTO 20-40 XY Connection: digital out from D791-1/K1:28 to H9003/1
Function: 7.5 Spreading
Signal value:
000197
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7
Connection:
Top lift attachment: output signal reference value out from D791-
2/K1:18 to Y6010/2
Combi attachment: output signal reference value out from D791-
4/K1:16 to Y6010/2
Function: 7.7.5 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.
000198
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7
Connection:
Top lift attachment: digital out from D791-2/K1:5 to Y6011/1
Combi attachment: digital out from D791-4/K1:3 to Y6011/1
Function: 7.7.5 Control valve attachment
Signal value:
000198
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7
Connection:
Top lift attachment: output signal actual value out from D791-2/
K1:19 to Y6011/2
Combi attachment: output signal actual value out from D791-4/
K1:17 to Y6011/2
Function: 7.7.5 Control valve attachment
Signal value: XXX = Measured current value in mA.
Connection:
Top lift attachment: digital out from D791-2/K1:30 to Y6034-1/1
Combi attachment: digital out from D791-3/K1:15 to Y6034-1/1
and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:
000199
Top lift attachment: digital out from D791-2/K1:31 to Y6034-2/1
Combi attachment: digital out from D791-3/K1:15 to Y6034-1/1
and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:
000200
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7
Connection:
Top lift attachment: output signal reference value out from D791-
2/K1:16 to Y6035/2
Combi attachment: output signal reference value out from D791-
3/K1:16 to Y6035/2
Function: 7.8.3 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.
006876
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7
Connection:
Top lift attachment: digital out from D791-2/K1:3 to Y6036/2
Combi attachment: digital out from D791-3/K1:3 to Y6036/2
Function: 7.8.3 Control valve attachment
Signal value:
006876
FEEDBACK XXX Circuit diagram: Circuit Tilt + Levelling group 7.7
Connection:
Top lift attachment: output signal actual value out from D791-2/
K1:17 to Y6036/2
Combi attachment: output signal actual value out from D791-3/
K1:17 to Y6036/2
Function: 7.8.3 Control valve attachment
Signal value: XXX = Measured current value in mA.
0 No signal.
0 No signal.
006878
DAMP DOWN X Connection: signal from B769/4 to analogue in D791-1/K1:21
Function: 7.2 lifting/lowering
Signal value: XXXX = distance to container in cm.
1 Damping active.
0 No damping.
8.4.10 OP
OP, description
page
–
009277
OP EXTRA RMI
2008)
Description: Signal from sensor steering axle load right and left (me-
DIAG OP 1(X) chanical overload system). It is sufficient that a sensor produces a sig-
PRESENT INPUT SIGNAL nal to activate an overload warning.
STEERING AXLE X X
BOOM ANGLE X Circuit diagram: Circuit OP + Scale group 8.2
008203
2008)
DIAG OP 1(X)
PRESENT INPUT SIGNAL Description: Status for boom angle to overload system indicates when
STEERING AXLE X X the boom angle is over 35 °.
BOOM ANGLE X
Circuit diagram: Circuit OP + Scale group 8.2
008203
EXTENSION X
Connection: signal from B771/3 to analogue in D797-R/K1:21
Function: 8.2.1.2 Sensor, boom angle
Signal value:
DIAG OP 1(X)
PRESENT INPUT SIGNAL Description: Signal from sensor boom length (position sensor boom
STEERING AXLE X X length 1.5 m). On machines with mechanical overload system with an-
BOOM ANGLE X alogue position sensors or electrical overload system the menu is
008203
EXTENSION X used to show the status for boom extension to the overload system.
Circuit diagram: Circuit OP + Scale group 8.2
Connection: signal from B777/C to analogue in (used as digital) D797-
R/K1:22
Function: 8.2.1.3 Sensor, boom length
Signal value:
Signal value:
0 No signal.
DIAG OP 3(5)
PRESENT INPUT SIGNAL Description: Signal from hydraulic pressure sensor, lift cylinder (C- rod
LIFT CYL LE RI side). See also PRESSURE LIFTING CYL, C- page 71 (for pressure
C- X.XXV X.XXV information).
C+ X.XXV X.XXV
Circuit diagram: Circuit OP + Scale group 8.2
Connection:
2
000207
1. Pressure C-
2.Pressure C+
DIAG OP 3(5)
PRESENT INPUT SIGNAL Description: Signal from hydraulic pressure sensor, lift cylinder (C+
LIFT CYL LE RI piston side). See also PRESSURE LIFTING CYL, C+ page 72 for
C- X.XXV X.XXV pressure.
C+ X.XXV X.XXV
Circuit diagram: Circuit OP + Scale group 8.2
Connection:
LE: signal from B768-L1 to analogue in D797-F/K1:21
2
000207
1. Pressure C-
2.Pressure C+
000208
Connection: signal from B771/3 to analogue in D797-R/K1:21
Function: 7.2.11 Sensor, boom angle
Signal value: X.XXV = 0.50 - 4.50 V
LOAD-CENTER XX.XXm
Signal value: XXXXkg = Weight in kg.
PRESENT LOAD
page
–
LOAD-CENTER XX.XXm
Signal value: XXXXkg = Weight in kg.
LOAD STR.AXLE
page
–
LOAD-CENTER XX.XXm
Signal value: XXXXkg = Weight in kg.
LOAD-CENTRE
page
–
006879
LOAD-CENTER XX.XXm
Function: 8.2.1 Overload system, 8.2.3 Load centre limitation
Signal value: XX.XXm = distance in metres
BOOM EXTENSION
page
–
BOOM HEIGHT
page
–
Description: Status for boom height at the top edge of the boom, the
DIAG OP 6(X) machine’s total height.
BOOM ANGLE XXX
EXTENSION XXX Circuit diagram: -
BOOM HEIGHT XXX Connection: -
006880
BOOM HEIGHT-NOSE
page
–
8.4.11 EXTRA
EXTRA, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This menu consists of optional functions:
CLIMATE HYD ENGINE
• Bottom lift-attachment, COMBI
TRANSM BOOM ATTACH
009278
OP EXTRA RMI • Sliding cab, SLIDING-CAB
• Support jacks, SUPPORT-JACKS
• Lever steering or mini-wheel, EL-STEERING
Confirm selection in main menu with function key for Enter.
8.4.11.1 COMBI
COMBI, menu 1
page
–
0/0 No signal.
2
3
000212
1. Knee
2.Jack
3.Clamping plate
0/0 No signal.
2
3
000212
1. Knee
2.Jack
3.Clamping plate
0/0 No signal.
3
000212
1. Knee
2.Jack
3.Clamping plate
COMBI, menu 2
page
–
0 No signal.
1
000214
0 No signal.
1
000214
COMBI, menu 3
page
–
0 No signal.
1
000216
1. Alignment sensor
0 No signal.
1
000216
1. Alignment sensor
COMBI, menu 4
page
–
000217
LEG LE X RI X
RI: signal from B7217R/C to digital in D791-4/K1:21
Function: 7.9.2.10 Sensor knee
Signal value:
0 No signal.
LEG LE X RI X
RI: signal from B7219R/C to digital in D791-4/K1:23
Function: 7.9.2.13 Sensor, lifting jacks
Signal value:
0 No signal.
COMBI, menu 5
page
–
LEG LE X RI X
RI: signal from B7218R/C to digital in D791-4/K1:22
Function: 7.9.2.10 Sensor knee
Signal value:
0 No signal.
000218
LEG LE X RI X
RI: signal from B7220R/C to digital in D791-4/K1:24
Function: 7.9.2.13 Sensor, lifting jacks
Signal value:
0 No signal.
COMBI, menu 6
page
–
0 No signal.
COMBI, menu 7
page
–
000220
REAR LE XY RI XY
RI: digital out from D791-3/K1:10 to H566R/1
Function: 7.9.2 Lifting jacks
Signal value:
REAR LE XY RI XY
RI: digital out from D791-3/K1:25 to H567R/1
Function: 7.9.2 Lifting jacks
Signal value:
COMBI, menu 8
page
–
000221
REAR XY
Function: 7.9.2 Lifting jacks
Signal value:
REAR XY
Function: 7.9.2 Lifting jacks
Signal value:
COMBI, menu 9
page
–
000222
FRONT LEGS DOWN XY
Signal value:
COMBI, menu 10
page
–
000223
LEGS LE XY RI XY
LE: digital out from D791-3/K1:5 to Y6056L/1
RI: digital out from D791-4/K1:5 to Y6056R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
LEGS LE XY RI XY
LE: digital out from D791-3/K1:32 to Y6013L/1
RI: digital out from D791-4/K1:32 to Y6013R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
COMBI, menu 11
page
–
000224
LEGS LE XY RI XY
LE: digital out from D791-3/K1:4 to Y6057L/1
RI: digital out from D791-4/K1:4 to Y6057R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
LEGS LE XY RI XY
LE: digital out from D791-3/K1:33 to Y6060L/1
RI: digital out from D791-4/K1:33 to Y6060R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
COMBI, menu 12
page
–
000225
LEGS LE XY RI XY
LE: digital out from D791-3/K1:31 to Y6058L/1
RI: digital out from D791-4/K1:31 to Y6058R/1
Function: 7.9.2.3 Solenoid valve lifting jacks
Signal value:
LEGS LE XY RI XY
LE: digital out from D791-3/K1:7 to Y6014L/1
RI: digital out from D791-4/K1:7 to Y6014R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
COMBI, menu 13
page
–
000226
LEGS LE XY RI XY
LE: digital out from D791-3/K1:30 to Y6059L/1
RI: digital out from D791-4/K1:30 to Y6059R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
LEGS LE XY RI XY
LE: digital out from D791-3/K1:9 to Y6061L/1
RI: digital out from D791-4/K1:9 to Y6061R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
COMBI, menu 14
page
–
000227
REAR X X
Signal value:
0 Sequence error
REAR X X
Signal value:
0 Sequence error
COMBI, menu 15
page
–
006881
OUT LE XY RI XY
LE: digital out from D791-3/K1:12 to Y6055L/1
RI: digital out from D797-4/K1:12 to Y6055R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
OUT LE XY RI XY
LE: digital out from D791-3/K1:11 to Y6054L/1
RI: digital out from D797-4/K1:11 to Y6054R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
COMBI, menu 16
page
–
000229
LE XY RI XY
Connection:
LE: digital out from D791-3/K1:42 to Y6053L
RI: digital out from D797-4/K1:42 to Y6053R
Function: 7.9.2.5 Valve block operating position
Signal value:
COMBI, menu 17
page
–
000230
0: no valve selected
1: Y6056L (knee out left front)
2: Y6057L (knee in left front)
3: Y6013L (jack down left front)
4: Y6060L (jack up left front)
5: Y6056R (knee out right front)
6: Y6057R (knee in right front)
7: Y6013R (jack down right front)
8: Y6060R (jack up right front)
9: Y6058L (knee out left rear)
10: Y6059L (knee in left rear)
11: Y6014K (jack down left rear)
12: Y6061L (jack up left rear)
13: Y6058R (knee out right rear)
14: Y6059R (knee in right rear)
15: Y6014R (jack down right rear)
16: Y6061R (jack up right rear)
17: Y6054L (clamp left)
18: Y6055L (clamp release left)
19: Y6054R (clamp right)
20: Y6055R (clamp release right)
Circuit diagram: Circuit Combi Att group 7.9
Connection: -
Function: 7.9.2.3 Control valve lifting jacks
Signal value: -
8.4.11.2 SLIDING-CAB
SLIDING-CAB, menu 1
page
–
This group handles functions for hydraulic sliding cab and hydraulic
DIAGNOSIS EXTRA vertically adjustable cab. The menu texts are created for hydraulic slid-
COMBI SLIDING-CAB ing cab.
SUPPORT-JACKS
EL-STEERING Confirm selection with function key for Enter.
000231
SWITCHES, FORWARD
Description: Signal from switch hydraulic sliding cab (forward) or
DIAG SLID-CAB 1(4) switch hydraulic vertically adjustable cab (up).
SWITCHES
FORWARD X Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
REVERSE X Connection: from S177/1 to digital in D790-1/K8:7
000215
OPENED DOORS X
Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from switch hydraulic sliding cab (backward) or
DIAG SLID-CAB 1(4) switch hydraulic vertically adjustable cab (down).
SWITCHES
FORWARD X Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10
REVERSE X Connection: from S177/7 to digital in D790-1/K8:6
000215
OPENED DOORS X
Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
0 No signal.
OPENED DOORS X
Function: 9.10.2 Doors
Signal value:
SLIDING-CAB, menu 2
page
–
000232
Function: 9.10.4.8 Sensor damping end position, 9.10.5.9 Sensor
damping end position
Signal value:
0 No signal.
K1:21
Function: 9.10.5.8 Sensor lowered cab
Signal value:
0 No signal.
SLIDING-CAB, menu 3
page
–
FEEDBACK XXX
Function: 9.10.4.4 Control valve option frame
Signal value:
000233
FEEDBACK XXX Y6016/2
Function: 9.10.4.4 Control valve option frame
Signal value: XXX = Current value: in mA for control of solenoid valve.
SLIDING-CAB, menu 4
page
–
FEEDBACK XXX
Function: 9.10.4.4 Control valve option frame
Signal value:
000234
FEEDBACK XXX Y6017/2
Function: 9.10.4.4 Control valve option frame
Signal value: XXX = Current value: in mA for control of solenoid valve.
8.4.11.3 SUPPORT-JACKS
SUPPORT-JACKS, menu 1
page
–
000235
SWITCHES, UP
Description: Signal from switch support jacks (up).
DIAG S-JACKS 1(4) Circuit diagram: Circuit Hyd support jacks group 7.10
SWITCHES
UP X Connection: from S1013/1 to digital in D790-1/K8:9
DOWN X Function: 7.10.1 Support jacks
000213
Signal value:
0 No signal.
SWITCHES, DOWN
Description: Signal from switch support jacks (down).
DIAG S-JACKS 1(4) Circuit diagram: Circuit Hyd support jacks group 7.10
SWITCHES
UP X Connection: from S1013/7 to digital in D790-1/K8:8
DOWN X Function: 7.10.1 Support jacks
000213
Signal value:
0 No signal.
SUPPORT-JACKS, menu 2
page
–
DOWN LE X RI X
RI: from B7222R/A, to digital in D797-O/K1:27
Function: 7.10.1.5 Sensor support jacks up
Signal value:
0 No signal.
000236
DOWN LE X RI X
• RI: from B7223R/A, to digital in D797-O/K1:41
Function: 7.10.1.6 Sensor support jacks down
Signal value:
0 No signal.
SUPPORT-JACKS, menu 3
page
–
000237
Function: 7.10.1.2 Control valve option frame
Signal value:
SUPPORT-JACKS, menu 4
page
–
8.4.11.4 EL-STEERING
EL-STEERING, menu 1
page
–
000239
PRESENT INPUT SIGNAL, SIGNAL 1
Description: Signal from mini-wheel (signal 1) or steering lever.
DIAG STEERING 1(5)
Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
PRESENT INPUT SIGNAL
SIGNAL 1 X.XXV Steering lever/mini wheel and Combi att. group 5.2
SIGNAL 2 X.XXV Connection:
001972
Connection:
Top lift attachment: signal from R825/H2 to digital in D790-1/K9:9
Combi attachment: signal from R825/H2 to digital in D790-3/
K1:22
Function: 5.2 Power assisted system
Signal value: X.XXV = 0.50 - 4.50 V
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/steering lever.
DIAG STEERING 2(5)
Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
SWITCHES
ON/OFF X Steering lever/mini wheel and Combi att. group 5.2
FORWARD X Connection:
000240
REVERSE X
Top lift attachment: signal from S113/1 to digital in D790-1/K9:5
Combi attachment: signal from S113/1 to digital in D790-3/K1:27
Function: 5.2 Power assisted system
Signal value:
0 No signal.
SWITCHES, FORWARD
Description: Signal from mini-wheel or steering lever (travel direction
DIAG STEERING 2(5) selector forward).
SWITCHES
ON/OFF X Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
FORWARD X Steering lever/mini wheel and Combi att. group 5.2
000240
REVERSE X Connection:
Top lift attachment: signal from S160-2/1 to digital in D790-1/K9:4
Combi attachment: signal from S160-2/1 to digital in D790-3/
K1:20
Function: 5.2 Power assisted system
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or steering lever (travel direction
DIAG STEERING 2(5) selector reverse).
SWITCHES
ON/OFF X Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
FORWARD X Steering lever/mini wheel and Combi att. group 5.2
000240
REVERSE X Connection:
Top lift attachment: signal from S160-2/7 to digital in D790-1/K9:3
Combi attachment: signal from S160-2/7 to digital in D790-3/
K1:13
Function: 5.2 Power assisted system
Signal value:
0 No signal.
EL-STEERING, menu 3
page
–
006882
Top lift attachment: signal from S149-2/1 to digital in D790-1/
K9:10
Combi attachment: signal from S149-2/1 to digital in D790-3/
K1:41
Function: 5.2 Power assisted system
Signal value:
0 No signal.
0 No signal.
EL-STEERING, menu 4
page
–
000242
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:4 to
Y636L/1
Function: 5.2.10 Control valve option frame
Signal value:
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:18 to
Y636L/2
Function: 5.2.10 Control valve option frame
Signal value: XXX = Current value: in mA for control of solenoid valve.
FEEDBACK XXX Connection: output signal, reference value out from D797-0/K1:18 to
Y636L/2
Function: 5.2.10 Control valve option frame
Signal value: XXX = Current value: in mA for control of solenoid valve.
EL-STEERING, menu 5
page
–
000243
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:5 to
Y636R/1
Function: 5.2.10 Control valve option frame
Signal value:
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:19 to
Y636R/2
Function: 5.2.10 Control valve option frame
Signal value: XXX = Current value: in mA for control of solenoid valve.
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:19 to
Y636R/2
Function: 5.2.10 Control valve option frame
Signal value: XXX = Current value: in mA for control of solenoid valve.
8.4.13 RMI
RMI, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers RMI (Remote Machine Interface) function.
CLIMATE HYD ENGINE
Confirm selection with function key for Enter.
TRANSM BOOM ATTACH
007442
OP EXTRA RMI
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: xxxx.xxxx = software number.
MIU TIME
page
–
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
007440
SMS XXX:UNS.DATA XXX
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.
007440
SMS XXX:UNS.DATA XXX
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.
Connection:-
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
ERR.VALID
page
–
Connection:-
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
ACT.ERR
page
–
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
8.5 Setup
Setup, general
page
–
Settings are built-in functions to adapt the functions to the unique ma-
chine individual. Settings are performed via menus in the display. Set-
tings are divided into initiation and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is done to compensate for mechanical and electrical toler-
ances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain func-
tions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
page
–
1 2
D ANGER
INIT STEERING 9(10)
START CURRENT The settings influence the functions. Adjustments
STEERING LEFT may impair the function. If uncertain, contact Cargot-
4 STORED VALUE XXXmA
3 ec Service.
000058
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.
START CURRENT
Specifies the start current to the solenoid valve for the selected func-
tion. The start current is the lowest current that can be actuated. In
practice, this controls how slowly a function can be operated. On func-
tions with analogue control activation (variable), e.g. lift, this is the cur-
rent that is triggered when the lever leaves the zero position. On
certain functions with digital activation (off/on) which are soft-started,
this is the current which is triggered immediately the function is activat-
ed.
END CURRENT
Specifies the max. current to the solenoid valve for the selected func-
tion. The max. current is the highest current that can be triggered. In
practice, it controls how quickly a function can be operated. On func-
tions with analogue control activation (controllable), e.g. lift, this is the
current when the lever is in the end position. On certain functions with
digital activation (off/on) which are soft-started, this is the current
which is triggered after the ramp time when the function is activated.
The interval between START CURRENT and END CURRENT is the
active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during damp-
ing. The interval is specified as 0-100% of the active range between
START CURRENT and END CURRENT.
Overview initiations
Function Menu
INIT DRIVE-TRAIN, menu 9 page 194
1 Engine, speed limitation (limitation of engine speed )
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page 191
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page 192
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page 192
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page 193
5.2 Power assisted system (product option joystick control or mini-wheel), lever re- INIT STEERING, menu 1 page 186
sponse
Function Menu
5.2 Power assisted system (product option joystick control or mini-wheel), speed INIT STEERING, menu 2 page 187
dependent INIT STEERING, menu 3 page 187
INIT STEERING, menu 4 page 188
INIT STEERING, menu 5 page 188
INIT STEERING, menu 6 page 189
5.2 Power assisted system (product option joystick control or mini-wheel), steering INIT STEERING, menu 7 page 189
angle right INIT STEERING, menu 8 page 189
5.2 Power assisted system (product option joystick control or mini-wheel), steering INIT STEERING, menu 9 page 190
angle left INIT STEERING, menu 10 page 190
7.2 Lifting/lowering, lift speed during operation INIT BOOM, menu 9 page 176
7.2 Lifting/lowering, damping at container (top lift) INIT ATTACH, menu 15 page 182
7.2 Lifting/lowering, damping at container (bottom lift) INIT ATTACH, menu 16 page 182
Function Menu
8.2.4 Height limitation INIT BOOM, menu 11 page 176
TIMES RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INITIATION BOOM 1(8)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".
8.5.1.1 BOOM
INIT BOOM
page
–
This function menu group handles initiation of the boom functions lift,
INITIATION lower and extension.
BOOM ATTACHMENT
SLIDING-CAB STEERING
D ANGER
000651
DRIVE-TRAIN
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
PRESENT VALUE XXXmA the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, lift (Y6005)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, lift (Y6005)
Signal value: XXXmA = 0 - 999 mA
005044
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, lower (Y6004)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.2.5 Control valve lift, lower and extension
Component: Solenoid valve, lower (Y6004)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: solenoid valve boom out (Y6006)
Signal value: XXXmA = 0 - 999 mA
005047
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.2.5 Control valve lift, lower and extension
Component: solenoid valve boom out (Y6006)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve lift, lower and extension
Component: solenoid valve boom in (Y6007)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.2.5 Control valve lift, lower and extension
Component: solenoid valve boom in (Y6007)
Signal value: XXXmA = 0 - 999 mA
004930
PRESENT VALUE XXX just the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for lift speed.
Function: 7.2 Lifting/lowering
Component: -
Signal Value: XXX = lift speed as a percentage of max. value.
OPTION LC-LIMIT
INIT BOOM 10(11)
OPTION LC-LIMIT
Description: Limit value for load centre limitation in metres. Distance
STORED VALUE XX.XX
004931
NOTE
On machines with vertically adjustable cab, a load centre less
than the cab’s frontmost point cannot be selected.
PRESENT VALUE: Indicates the current value for load centre. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for load centre.
Function: 8.2.3 Load centre limitation
Component: -
Signal Value: XX.XX = load centre limitation in metres.
OPTION HEIGHT-LIMIT
INIT BOOM 11(11)
OPTION HEIGHT-LIMIT
Description: Limit value for height limitation in metres. Distance to the
STORED VALUE XX.XX
004932
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
BOOM ATTACHMENT
SLIDING-CAB STEERING
D ANGER
001157
DRIVE-TRAIN
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.6.3 Control valve attachment
Component: Solenoid valve rotation clockwise (Y6008)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.6.3 Control valve attachment
Component: Solenoid valve anticlockwise (Y6009)
Signal value: XXXmA = 0 - 999 mA
005093
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.6.3 Control valve attachment
Component: Solenoid valve rotation anticlockwise (Y6009)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.6.3 Control valve attachment
Component: Solenoid valve anticlockwise (Y6009)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.7.5 Control valve attachment
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)
Signal value: XXXmA = 0 - 999 mA
005096
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.7.5 Control valve attachment
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.8.3 Control valve attachment
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.8.3 Control valve attachment
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)
Signal value: XXXmA = 0 - 999 mA
006756
PRESENT VALUE XXXX speed for top lift, the distance between the attachment and the con-
tainer.
PRESENT VALUE: Indicates the current value for the distance. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm.
PRESENT VALUE XXXX PRESENT VALUE: Indicates the current value for the distance. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm
8.5.1.3 SLIDING-CAB
INIT SLIDING-CAB
page
–
This function handles the initiation of hydraulic sliding cab or cab hy-
INITIATION draulic cab lift.
BOOM ATTACHMENT The sliding cab is smooth started by means of the control current to
SLIDING-CAB STEERING the solenoid valves being increased from a low start value to a max.
001645
DRIVE-TRAIN level. When the cab reaches an end position the speed is dampened
by means of the control current being reduced.
D ANGER
The settings affect the function of the hydraulic slid-
ing cab, vertically adjustable cab and tiltable cab. Ad-
justments can impair functionality. Contact Cargotec
Service in the event of uncertainty.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
8.5.1.4 STEERING
INIT STEERING
page
–
BOOM ATTACHMENT
SLIDING-CAB STEERING D ANGER
002954
DRIVE-TRAIN
The settings affect the functions joystick control or
mini-wheel. Adjustment can impair functionality. If in
doubt, contact Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
or mini-wheel)
X Component: -
U = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement
003131
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP1 in km/h.
V [kph] = machine speed in km/h
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = percent of control current to solenoid valve at
BP2
%BP3 = percent of control current to solenoid valve at
BP3
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP2 in km/h.
V [kph] = machine speed in km/h
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = percent of control current to solenoid valve at
BP2
%BP3 = percent of control current to solenoid valve at
BP3
V [kph] or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = percent of control current to solenoid valve at
BP2
%BP3 = percent of control current to solenoid valve at
BP3
003135
V [kph] or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = percent of control current to solenoid valve at
BP2
%BP3 = percent of control current to solenoid valve at
BP3
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R key.
STORED VALUE: indicates stored value for start current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636R)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R key.
STORED VALUE indicates stored value for max. current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636R)
Signal value: XXXmA = 0 - 999 mA
003138
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering left (Y636L)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering left (Y636L)
Signal value: XXXmA = 0 - 999 mA
8.5.1.5 DRIVETRAIN
INIT DRIVE-TRAIN
page
–
003140
DRIVE-TRAIN step can be performed separately, independently of other steps.
The machine must be stationary with applied parking brake to en-
able access to the menus.
After changes have been made, the ignition must be turned off
and on for the changes to be saved and start to apply.
START IN 2ND
INIT DRIVE-TRN 1(6)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
0=NO 1=YES in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
003151
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed in km/h
005052
PRESENT VALUE XXX NOTE
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = engine speed (rpm)
005054
PRESENT VALUE XXX NOTE
If the rpm is set too low, kick-down may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not at
all.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
Not used.
Not used.
004935
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.
004938
PRESENT VALUE XXX duction when changing direction of travel forward - reverse. This
makes it possible to change direction of travel without releasing the ac-
celerator pedal. Engine speed drops to that set in menu 3 (see INIT
DRIVE-TRAIN, menu 3 page 192). If no value is set in menu 3, engine
speed goes to idle speed.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value:
X = 1, activated
X = 0, deactivated
8.5.2 Calibration
Calibration, description
page
–
SCALE
This menu handles calibration of sensors to weight indication.
CALIBRATION
There are two variants of weight indicator, fixed or dynamic scale, see
SCALE STEERING section 7 Load handling , group 7.10.2 Weight indicator. The current
DRIVE-TRAIN RETURN 000062 option on the machine is programmed and does not need selection,
see:
Weight indicator, calibration (product alternative fixed scale) (only
model year -2008) page 198
Weight indicator, calibration (product alternative dynamic scale) page
200
EL-STEERING
This menu handles calibration of the steering lever for lever steering,
CALIBRATION see:
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVETRAIN
This function handles calibrations for engine and transmission. The
CALIBRATION menu loop contains two different calibrations which are not connected
to each other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration page 203
000078
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
000063
PRESENT VALUE X.XXV Variable (position 4): BOOM Name of the affected input sig-
FULLY RETRACTED nal/control signal.
1. Menu group
2.Sequence number (the total number of sequences is Description: Setting sensor A short description of what is
indicated in brackets) boom length (R777) for boom ex- calibrated and the meaning of
3.Signal value tension in the innermost position. the variables.
4.STORED indicates stored value, PRESENT indi-
CALIBR VALUE: Indicates
cates current value of the signal to be calibrated
stored signal value from boom
5. Heading of menu figure
length (R777) for boom exten-
sion in the innermost position.
PRESENT VALUE: Indicates the
current signal value from sensor
boom length (R777).
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Park the machine on level ground without load and centre the at-
tachment.
2 Navigate to the service menu and press ENTER.
000056
STORED SUM XX.XV measuring position has been achieved for " 'Extension' 'Lift' ".
11 Wait approximately five seconds to stabilise the pressure.
NOTE
New values can only be saved when the boom is in the
measuring position.
Negative values indicate shifted contacts on the pressure
sensors.
Large variations between the right and left indicate errors in
sensor signals.
13 Scroll to CALIBR SCALE, menu 9.
CALIBR SCALE 9(X) 14 Lifting a known reference load and move the boom into measur-
BOOM IN MEAS. POS X X
WITH LOAD XX.XT ing position.
LE XX.XV RI XX.XV "BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
006806
STORED SUM XX.XV measuring position has been achieved for " 'Extension' 'Lift' ".
15 Wait approximately five seconds to stabilise the pressure.
16 Enter the weight of the reference load with the + and - keys. Save
the setting with ENTER.
NOTE
New values can only be saved when the boom is in the
measuring position.
I M P OR TA NT
Check that the correct weight for the reference load is
shown in the menu before the setting is saved. Incor-
rectly input weight means that the scale indicates in-
correctly.
Checking calibration
17 Scroll to CALIBR SCALE, menu 10.
CALIBR SCALE 10(X) 18 Lift a reference weight and check that the control system calcu-
PRESS BUTTON
lates the correct weight of the load that the machine is lifting,
LOAD XX.XT LOAD.
006806
NOTE
Check when stationary. (Operating generates dynamic forc-
es.)
20 Back out of calibration with the R-key.
scale)
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Warm the hydraulic oil to operating temperature, min. 40 °C.
2 Park the machine on level ground without load and centre the at-
tachment.
000056 3 Navigate to the service menu and press ENTER.
NOTE
Some options, such as height limitation and load centre lim-
itation, mean that bypass must be used to reach the boom’s
end positions.
6 CALIBR SCALE, menu 1.
CALIBR SCALE 1(X)
7 Lower the boom to the lowest position (0°).
MINIMUM BOOM ANGLE
8 Save the setting with ENTER
STORED VALUE X.XXV
011329
011332
PRESENT VALUE X.XXV
011333
PRESENT XXXX XXXX
21 Wait approximately five seconds to stabilise the pressure.
22 Save the setting with ENTER.
23 Scroll to CALIBR SCALE, menu 6.
CALIBR SCALE 6(X)
24 Extend the boom completely.
LOAD SENSOR BOOM 0t
EXTENDED LE RI 25 Wait approximately five seconds to stabilise the pressure.
CALIBR XXXX XXXX
26 Check that "LOAD SENSOR BOOM" is set to 0 t. If not, adjust
010454
I M P OR TA NT
Check that the correct weight is shown in the menu
before the setting is saved. Incorrectly input weight
means that the scale indicates incorrectly.
Checking calibration
27 Scroll to CALIBR SCALE, menu 7.
CALIBR SCALE 7(X)
28 Lift a reference load and check that the control system calculates
ALLOWED LOAD XXXXXKg
PRESENT LOAD XXXXXKg the correct weight of the load that the machine is lifting.
LOAD STR.AXLE XXXXXKg PRESENT LOAD = Reference load ± 500 kg. Weight is given in
006804
NOTE
Check when stationary. (Operating generates dynamic forc-
010455
es.)
30 Back out of calibration with the R-key. When the code menu ap-
pears, press Enter.
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
000077
PRESENT VALUE X.XXV steering control (R825).
STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).
Component: Lever steering control (R825)
Function: 5.1.3 Joystick
9 Move steering lever to required position for max. angle right.
10 Store the position with function key for Enter.
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(4) see Calibration, work instructions page 197
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
CALIBR VALUE X.XXV Description: setting accelerator’s pedal zero position.
000079
DRIVE-TRAIN, menu 2
5 ACCELERATOR, THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(4) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, (R690).
THE PEDAL TO FLOOR
CALIBR VALUE X.XXV CALIBR VALUE: Indicates current calibrated control value from
000080
Transmission, calibration
page
–
D ANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
SCALE STEERING
DRIVE-TRAIN RETURN
000062
000081
ACTION X XXXXrpm PHASE: Indicates current phase in the calibration.
0. Pre-filling of clutch
1. Calibration of clutch
4. Calibration complete
5. Calibration incorrect
6. Calibration paused
NOTE
If the machine starts to move during calibration, use the foot-
brake to keep the machine stationary.
I M P OR TA NT
Calibration can be interrupted at any time by selecting
travel direction reverse.
accessories
9.1 Controls and instruments
Controls and instruments, overview
page
–
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
004852
14
013031
16 23 Switch hazard lights (S109)
Left-hand instrument panel 24 Switch headlights (S100)
1 2 3 4
12
5
11 6
10 9 8 7
005080
13 14 15 16
1 2 3 4
15 6
14 7
13 8
006734
12 11 10 9
Switch, replacement
page
–
NOTE
The instructions apply to switches in general.
000338
Inward, Washing of windscreen, roof window and rear win-
handle dow.
The signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.3.1 CAB,
menu 1.
A
used to flash with the headlights.
The signal can be checked with the diagnostic menu,
see section 8 Control system , group 8.4.2.6 LIGHTS,
menu 6.
The fire extinguisher is located at the entry on the left frame beam. Us-
age instructions are found on the fire extinguisher.
9.2.4 Buzzer
Seat buzzer, description
page
–
9.3 Seat
Seat, general
page
–
seat)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• right armrest
• seat belt (option until model year 2007)
4
• left armrest
• seat heating
• head restraint
5
8 6
006825
7
Controls, standard seat
1. Lumbar support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest rake adjustment
5. Springing adjustment
6. Seat cushion angle adjustment
7. Seat height adjustment
8. Front/rear adjustment
9120)
BE-GE 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and
springing to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • right armrest
• seat belt (option until model year 2007)
8 6
006826
• left armrest
7
Controls BE-GE 9120 • seat heating
1. Lumbar support adjustment
2. Right armrest adjustment • head restraint
Isringhausen 6800)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
The Isringhausen 6800 seat has the following equipment:
• head restraint
• armrest
• air suspension (with external compressor)
• air-adjusted lumbar support
• seat belt
• seat heating
11
10
34 567
004691
9 8 2
Controls, Isringhausen 6800
1. Front/rear adjustment
2. Seat cushion adjustment
3. Seat height lowering
4. Seat cushion angle
5. Seat height raising
6. Backrest rake
7. Damping adjustment
8. Seat heating
9. Level damping OFF/ON
10. Lumbar support adjustment
11. Armrest
Seat, changing
page
–
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.
6 Fit in the reverse order.
NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.
1
006276
The heating coil’s function is to warm the back and seat cushions in
the operator’s seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied voltage upon warm-up of the cab
control unit (D790-1) by the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.8 CAB, menu 8.
GE)
BE-GE 9120:
Isringhausen 6800:
Compressed air-suspended seat
9.3.8 Armrest
Armrests, description
page
–
The arm rest is fixed to the backrest and is individually adjustable ver-
tically (around the attachment point). Depending on options there is
also an arm rest for the left-hand side:
• Mini-wheel
• Joystick control
description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 28 °C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through ducts in the cab interior. It is then directed
to the windscreen (defroster) or the feet.
heating system.
Principle illustration, climate control system The function of the climate control system is to:
1. Fluid reservoir/filter dryer with integrated pressure • heat the air when it is cold
switch
• dehumidify the air when it is damp
2. Heating element and evaporator
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser
• defrost (defroster function)
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
D. Low-pressure gas
E. Outdoor air for cab ventilation
F. Heated or cooled air to the cab
G. Outdoor air for eliminating heat
function description
2 1 D3 3 26
D1
25
D4 D2
4 ˚C D23
D6
˚C
D5 D15 6
7 D790-1 D790-2 D795
D9
15 D15 D797-R D794
M 16 D21 12 D10
14 22 23
5 ˚C Pa ˚C
M D17
D14 21
19 20 C 24
13
M 18
D13 17
D9 9
M
10
˚C
8 11
006416
Pos Explanation Signal description Reference
1 The temperature switch (S139) sends a Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
voltage signal to the cab control unit Unaffected: U = 0-0.5 V D1: Diagnostic menu, see section 8 Control
(D790-1). system , group 8.4.4.5 CLIMATE, menu 5
Lower: U = 4.5-5.0 V
2 The fan switch (S118) sends a voltage Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
signal to the cab control unit (D790-1). Unaffected: U = 0-0.5 V D2: Diagnostic menu, see section 8 Control
Lower: U = 4.5-5.0 V system , group 8.4.4.5 CLIMATE, menu 5
3 The air distribution switch (S117) sends Scroll up: U = 2.0–2.5 V Controls and instruments, overview page 5
a voltage signal to the cab control unit Unaffected: U = 0 V D3: Diagnostic menu, see section 8 Control
(D790-1). system , group 8.4.4.5 CLIMATE, menu 5
Scroll down: U = 4.5-5.0V
4 The cab temperature sensor (B775-1) R = 10 kΩ at 25 °C Sensor, cab temperature, description page
sends the cab control unit (D790-1) a 56
voltage signal proportional to the tem- D4: Diagnostic menu, see section 8 Control
perature. system , group 8.4.4.1 CLIMATE, menu 1
7 The cab control unit (D790-1) regulates Checked by control sys- Section 11 Common electrics, group
temperature and air distribution with sig- tem, error shown with er- 11.5.3.1 Cab control unit
nals from sensors and controls. ror code.
9 The cab control unit (D790-1) controls U = 0.5–4.5 V Water valve, description page 42
the water valve (Y673), which directs D9: Diagnostic menu, see section 8 Control
hot water to heat exchanger heating. system , group 8.4.4.7 CLIMATE, menu 7
The water valve’s opening (%) is sent and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling the
water valve’s position.
10 The engine temperature sensor sends Checked by control sys- Section 1 Engine
the engine control unit (D794) a voltage tem, error shown with er- D10: Diagnostic menu, see section 8 Con-
signal proportional to engine tempera- ror code. trol system , group 8.4.4.2 CLIMATE,
ture. menu 2
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 39
cab air. Heat is transferred from the en-
gine’s cooling system to the cab air.
12 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine temperature in the cooling sys- tem, error shown with er- 11.5.3.10 Engine control unit
tem on the CAN bus. ror code.
13 The cab control unit (D790-1) controls Checked by control sys- Fresh air filter or recirculation damper, de-
the recirculation actuator motor (M612) tem, error shown with er- scription page 33
which sets the fresh air or recirculation ror code. D13: Diagnostic menu, see section 8 Con-
damper in the required position. trol system , group 8.4.4.6 CLIMATE, menu
6
14 The cab control unit (D790-1) controls Checked by control sys- Cab fan, description page 36
the fan motor (M657), which increases tem, error shown with er- D14: Diagnostic menu, see section 8 Con-
airflow in the cab. ror code. trol system , group 8.4.4.6 CLIMATE, menu
6
16 The rear frame control unit (D797-R) Checked by control sys- Section 11 Common electrics, group
controls AC compressor engagement. tem, error shown with er- 11.5.3.3 Control unit, frame rear
ror code.
17 The rear frame control unit (D797-R) U = 24 V Compressor air conditioning, description
supplies voltage to the compressor’s so- (engine alternative Volvo) page 43
lenoid valve (645). D17: Diagnostic menu, see section 8 Con-
trol system , group 8.4.4.6 CLIMATE, menu
6
20 The moisture filter absorbs any moisture - Moisture filter, description page 48
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
21 The pressure switch (S246) sends a sig- U = 24 V Pressure switch, description page 48
nal to the rear frame control unit D21: Diagnostic menu, see section 8 Con-
(D797-R) if the pressure in the system trol system , group 8.4.4.3 CLIMATE,
becomes abnormally high or low. menu 3
22 The expansion valve adjusts the amount - Expansion valve, description page 49
of refrigerant that is let in to the evapora-
tor. If the temperature in the evapora-
tor’s outlet pipe increases, the
evaporator valve increases flow of re-
frigerant so that heat dissipation in the
evaporator increases.
25 The defroster switch on the KIT control Checked by control sys- Section 11 Common electrics, group
unit (D790-2) activates the defroster tem, error shown with er- 11.5.3.11 Control unit KIT
program of the climate control system ror code.
for six minutes.
26 The KID control unit (D795) shows the Checked by control sys- Section 11 Common electrics, group
heating and ventilation settings in the tem, error shown with er- 11.5.3.12 KID control unit
display. ror code.
checking
1 Machine in service position, see section B Safety.
2 Navigate to the service menu and press Enter.
000056
1 23
4 5 NOTE
000060
OP EXTRA HIST
Menu 2
6 Check of Sensor temperature outlet fan (B775-2), engine temper-
DIAG CLIMATE 2(8) ature, Sensor outdoor temperature (B774), Check of Sensor tem-
TEMP COIL XXX perature refrigerant (B775-1).
TEMP COOLANT XXX
TEMP AMBIENT XXX TEMP COIL: temperature that the air has in the air distributor is
000133
TEMP DE-ICE XXX measured by Sensor temperature outlet fan (B775-2).
TEMP COOLANT: engine temperature sent on the CAN-bus.
TEMP AMBIENT: outdoor temperature measured by Sensor out-
door temperature (B774).
TEMP DE-ICE: cooling circuit’s temperature measured by Sen-
sor temperature refrigerant (B775-1). If the compressor is activat-
ed the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.
Menu 3
The sensor is located on the dryer filter which is fitted right rear in
the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8)
WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2
PRESENT INPUT SIGNAL
WATER VALVE XX.XXV V. This is checked by turning the temperature control and chang-
DRAUGHT VALVE XX.XXV ing temperature setting from min. to max.
000135
NOTE
Air to the round panel vents is not controlled by the air con-
ditioning unit.
Menu 5
9 Checks switches for temperature, air distribution and fan speed.
DIAG CLIMATE 5(8)
REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V; low-
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV er U = 4.5-5 V.
REQ. DRAUGHT XX.XXV REQ. DRAUGHT: home position U = 0 V; against windscreen U
000136
Menu 6
10 Checks cab fan (M657), fresh air and recirculation damper
DIAG CLIMATE 6(8)
PRESENT OUTPUT SIGNAL (M612) and compressor’s electromagnetic clutch (M645) .
FAN SPEED XXX FAN SPEED: increase and decrease fan speed, value should in-
RECIRKULATION XY crease from 0 to 255 in steps.
000137
COMPRESSOR XY
RECIRCULATION: press in the bypass switch (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
NOTE
Compressor activation can only be tested when the engine
is running and the system is filled.
Menu 7
11 Checks direction selector for Water valve (Y673).
DIAG CLIMATE 7(8) CLOCKWISE: When temperature is increased and the water
OUTPUT WATER VALVE valve opens shows "CLOCKWISE 11 11" and "COUNTER-
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY CLOCKWISE 00 11".
COUNTER-CLOCKWISE: When temperature is lowered and the
water valve closes shows "CLOCKWISE 00 11" and "COUNTER-
24V CLOCKWISE 11 11".
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
M not changing position. The water valve does not open if en-
gine temperature is low, or if outdoor temperature is high.
000138
0V
Menu 8
12 Checks direction selector for air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windscreen
OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY and the air distributor changes position shows "CLOCKWISE 00
ANTI-CLOCKWISE XY XY 11" and "COUNTER-CLOCKWISE 11 11".
COUNTER-CLOCKWISE: when the air is directed against the
feet and the air distributor changes position shows "CLOCKWISE
24V 11 11" and "COUNTER-CLOCKWISE 00 11".
NOTE
The ones are only shown for a moment when the air distrib-
utor changes position, zeros are shown when the air distrib-
M utor is not changing position.
000139
0V
1 Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is stopped. The cabin fan forces air
into the cab. The pause heater is automatically switched off when the
temperature in the cab is six degrees below the value set on the cli-
mate control system. The pause heater is activated with the pause
heater switch when the ignition is on.
3 2
004909
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
( ), but the maximum airflow may be affected.
2
003208
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6.
2
003208
replacement
1 Machine in service position, see section B Safety.
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6.
1
003209
3 Remove the bolts which secure the wiper motor in the protective
plate.
4 Remove the protective plate.
7 Remove the bolts which secure the plate and cab fan.
The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210
WARN IN G
Personal injury, environmental damage.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
16 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
The water valve controls the climate control system’s capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is electrically controlled.
The signal can be checked from the diagnostic menu, see 8 Control
system , group 8.4.4.1 CLIMATE, menu 1 , 8.4.4.4 CLIMATE, menu 4
and 8.4.4.7 CLIMATE, menu 7.
002229
1. Water valve
2. Steering valve
The coolant temperature sensor sits on the engine and detects engine
coolant temperature. See supplier documentation, engine.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.4.2 CLIMATE, menu 2.
For location, see section 1 Engine.
9.4.7 Compressor
Compressor air conditioning, description (engine
page
–
alternative Volvo)
WARN IN G
Personal injury, environmental damage.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
Cummins QSM11)
WARN IN G
Personal injury, environmental damage.
1 Read the safety instructions for refrigerant, see sec-
tion B Safety.
8 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
9.4.8 Condenser
Condenser, description
page
–
Condenser, replacement
page
–
WARN IN G
Personal injury, environmental damage.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
The moisture filter collects the liquid refrigerant, binds moisture and fil-
ters impurities. The reservoir functions as an expansion tank in the
1 2 cooling circuit.
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
002227
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
1 2 mally high or low.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.4.3 CLIMATE, menu 3.
002227
WARN IN G
1 2 Personal injury, environmental damage.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
002227
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
The expansion valve is the part in the circuit that separates the high-
pressure side from the low-pressure side. The refrigerant arrives at the
expansion valve under high pressure and leaves it under low pres-
sure. After the expansion valve, the refrigerant converts to a gaseous
state and is transported to the compressor once again.
The amount of refrigerant that passes the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.
WARN IN G
Personal injury, environmental damage.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
1
3
002226
2
WARN IN G
Personal injury, environmental damage.
NOTE
Requires special authorisation.
1 Machine in service position, see section B Safety.
2 Drain the AC system of refrigerant.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
8 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
I M P OR TA NT
Working on the air conditioning requires special au-
thorisation.
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLI-
MATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.
002230
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor
There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windscreen. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).
001839
3 The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.4.2 CLIMATE, menu 2.
002226
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
1
3
002226
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
Wiper roof are of the type sector wiper. Wiping angle is approx. 180
degrees.
The rear wiper is a sector wiper type. The wiping angle is approx.
180 degrees.
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This minimises the time from activation of switch
washing and washer fluid spraying on the windscreen.
The washer nozzles are mounted on the wiper arms.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.3.1 CAB, menu 1.
004924
003619
A B
Washer fluid reservoir without protective plate.
A. Washer fluid reservoir
B. Washer motors
The wiper motor drives the front windscreen wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.3.2 CAB, menu 2.
The wiper motor drives the roof window’s wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.3.4 CAB, menu 4.
3 Detach the washer hose and the connector to the wiper motor.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
6 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
The wiper motor drives the rear window wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.3.3 CAB, menu 3.
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
The lights are shut off automatically after 5 minute’s idling in order to
prevent discharge of the batteries. Extra working lights are shut off af-
ter 2 minutes. Lighting is activated automatically again when the oper-
ator sits in the seat, a gear is selected or the accelerator pedal is
pressed.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 5 4
D4
D5
D1 D3 8
D2 9
14 10
D9
6 D6 15 D8
D17
D16 17 13 D10
16 M D13
D790-1 D790-2
26 7, 12 19 11 33
D32 D27 D797-R D797-F D791-1
D31 18 D18 D22 D23
Pa D34 D35
D29
24
D30 D21 34
32 D28 35
007417
D20 25
27 28 29 30 31 20 21 22 23
2 The switch for attachment work lights (S105-2) Switch in ON position: U D2: Diagnostic menu, see section 8
sends a voltage signal to the cab control unit = 24 V Control system group 8.4.2.2 LIGHTS,
(D790-1). menu 2
3 The switch for boom working lights (S105-3) Switch in ON position: U D3: Diagnostic menu, see section 8
sends a voltage signal to the cab control unit = 24 V Control system group 8.4.2.3 LIGHTS,
(D790-1). menu 3
4 The headlights switch (S100) sends a voltage Switch in ON position: U D4: Diagnostic menu, see section 8
signal to the cab control unit (D790-1). = 24 V Control system group 8.4.2.4 LIGHTS,
menu 4
5 The revolving beacon switch (S110) sends a Switch in ON position: U D5: Diagnostic menu, see section 8
voltage signal to the cab control unit (D790-1). = 24 V Control system , group 8.4.2.9
LIGHTS, menu 9
6 The door NC switch (S226-LE & S226-RI) Door open: U = 24 V Interior lighting cab, description page
sends a voltage signal to the cab control unit 72
(D790-1). D6: Diagnostic menu, see section 8
Control system group 8.4.2.12
LIGHTS, menu 12
7 The cab control unit (D790-1) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit
error code.
8 The multi-function lever (S162) sends a volt- Lever in high beam posi- Gear and multi-function lever, descrip-
age signal to the KIT control unit (D790-2). tion: US162/56a = 24 V tion page 12
D8: Diagnostic menu, see section 8
Control system group 8.4.2.6 LIGHTS,
menu 6
9 The direction indicator lever (S161) sends a Left: US161/6 = 24 V D9: Diagnostic menu, see section 8
voltage signal to the KIT control unit (D790-2). Control system group 8.4.2.7 LIGHTS,
Right: US161/1 = 24 V
menu 7
10 The interior lighting switch of the KIT control Checked by control sys- D10: Diagnostic menu, see section 8
unit (D790-2) sends a voltage signal to the KIT tem, error shown with Control system group 8.4.2.12
control unit (D790-2). error code. LIGHTS, menu 12
11 The KIT control unit (D790-2) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.11 Control unit KIT
error code.
12 The cab control unit (D790-1) supplies voltage Checked by control sys- Section 11 Common electrics, group
to the lights in and around the cab. tem, error shown with 11.5.3.1 Cab control unit
error code.
13 The cab working lights (E404-1L & E404-1R) Light on: U = 24 V Working lights, cab, description page
are switched on when the cab working lights 70
are activated. D13: Diagnostic menu, see section 8
Control system group 8.4.2.1 LIGHTS,
menu 1
14 Relay extra working lights boom (K304) is acti- UK304/30 = 24 V Working lights, boom, lights page 71
vated when the boom working lights are acti-
UK304/85 = 0 V
vated and supplies voltage to the extra working
lights boom (E404-5L & E404-5R). Working lights boom
switched on:
UK304/86 = 24 V
UK304/87 = 24 V
UK304/87 = 0 V
15 Extra working lights boom (E404-5L & E404- Light on: U = 24 V Working lights, boom, lights page 71
5R) are switched on when boom working lights
are activated.
16 Rotating beacon (H428) is lit when rotating Light on: U = 24 V Revolving beacon, description page 70
work light is activated. D16: Diagnostic menu, see section 8
Control system group 8.4.2.9 LIGHTS,
menu 9
17 Interior lighting comes on when a door is Light on: U = 24 V Interior lighting cab, description page
opened or if activated when the switch on the 72
KIT control unit (D790-2). D17: Diagnostic menu, see section 8
Control system group 8.4.2.12
LIGHTS, menu 12
18 NO switch, brake lights (S216) sends a voltage Brake pressure over 0.2 Section 4 Brakes, group 4.3.8 NO
signal to Control unit, frame front (D797-F). MPa: U = 24 V (normally open) switch, brake lights
D18: Diagnostic menu, see section 8
Control system group 8.4.2.10
LIGHTS, menu 10
19 Control unit frame front (D797-F) supplies Checked by control sys- Section 11 Common electrics, group
power to the front lights on the machine. tem, error shown with 11.5.3.2 Control unit, frame front
error code.
20 The front direction indicators (H422 & H423) Light on: U = 24 V Driving direction indicator, description
come on when they or the warning lights are page 69
activated. D20: Diagnostic menu, see section 8
Control system group 8.4.2.8 LIGHTS,
menu 8
21 The front running lights (H416-1 & H417-1) Light on: U = 24 V Running lights, description page 68
come on together with the headlights. D21: Diagnostic menu, see section 8
Control system group 8.4.2.5 LIGHTS,
menu 5
22 Headlights low beams (E400L & E400R) are lit Light on: U = 24 V Headlights, description page 68
when headlights are activated. D22: Diagnostic menu, see section 8
Control system group 8.4.2.6 LIGHTS,
menu 6
23 Headlights high beam (E402L & E402R) are lit Light on: U = 24 V Headlights, description page 68
when high beam is activated. D23: Diagnostic menu, see section 8
Control system group 8.4.2.6 LIGHTS,
menu 6
26 Control unit frame rear (D797-R) supplies pow- Checked by control sys- Section 11 Common electrics, group
er to the rear lights on the machine. tem, error shown with 11.5.3.3 Control unit, frame rear
error code.
27 Tail lights (H412L & H412R) red are lit when Light on: U = 24 V Tail light, description page 68
headlights are activated. D27: Diagnostic menu, see section 8
Control system group 8.4.2.5 LIGHTS,
menu 5
28 Brake lights (H411L & H411R) are lit when the Light on: U = 24 V Brake light, description page 69
brake is activated. D28: Diagnostic menu, see section 8
Control system group 8.4.2.11
LIGHTS, menu 11
29 The rear direction indicators (H426 & H427) Light on: U = 24 V Driving direction indicator, description
come on when they or the warning lights are page 69
activated. D29: Diagnostic menu, see section 8
Control system group 8.4.2.8 LIGHTS,
menu 8
30 The rear running lights (H416-2 & H417-2) are Light on: U = 24 V Running lights, description page 68
switched on when the headlights are activated. D30: Diagnostic menu, see section 8
Control system group 8.4.2.5 LIGHTS,
menu 5
31 The white reversing lights (E405L & E405R) Light on: U = 24 V Reversing light, description page 69
come on when reverse gear is selected. D31: Diagnostic menu, see section 8
Control system , group 8.4.2.11
LIGHTS, menu 11
32 Working lights boom (E404-3L & E404-3R) are Light on: U = 24 V Working lights, boom, lights page 71
switched on when boom working lights are ac- D32: Diagnostic menu, see section 8
tivated. Control system group 8.4.2.3 LIGHTS,
menu 3
33 The attachment control unit (D791-1) supplies Checked by control sys- Section 11 Common electrics, group
voltage to the attachment’s lights. tem, error shown with 11.5.3.5 Control unit, attachment
error code.
34 Working lights attachment (E406-L & E406R) Light on: U = 24 V Attachment work lights, description
are switched on when the attachment’s work- page 72
ing lights are activated. D34: Diagnostic menu, see section 8
Control system group 8.4.2.2 LIGHTS,
menu 2
35 Extra working lights attachment (E404-4L & Light on: U = 24 V Attachment work lights, description
E404-4R) are switched on when the attach- page 72
ment’s working lights are activated. D35: Diagnostic menu, see section 8
Control system group 8.4.2.2 LIGHTS,
menu 2
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 4 5 6 7 8
006426
20 18, 19 17 16 15 14 13, 12, 11 10 9
1. Rotating beacon (H428) 13. Headlights, low beam (E400L & E400R)
Headlights, high beam (E402L & E402R)
2. Interior lighting 14. NO switch, brake lights (S216)
3. Control unit KIT (D790-2) 15. Control unit, frame front (D797-F)
4. Multi-function lever (S162) 16. Switch, see section 9 Frame, body, cab and accessories,
group 9.1 Controls and instruments
5. Cab working lights (E404-1L & E404-1R) 17. Door NC (normally closed) switch (S226-LE & S226-RI)
6. 18. Control unit cab (D790-1)
Extra working lights boom (E404-5L & E404-5R)
7. Working lights boom (E404-3L & E404-3R) 19.
Relay extra working lights boom (K304)
8. Attachment control unit (D791-1) 20. Control unit, frame rear (D797-R)
9. Working lights attachment (E406-L & E406R) 21. Rear running lights (H416-2 & H417-2)
Extra working lights attachment (E404-4L & E404-4R)
10. Extra working lights front (E404-7L, E404-8L, E404-7R & 22. Reversing lights (E405L & E405R), white
E404-8R)
11. Direction indicators front (H422 & H423) 23. Tail lights (H421L & H412R), red
Brake lights (H411L & H411R)
12. Front running lights (H416-1 & H417-1) 24. Direction indicators rear (H426 & H427)
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system , group 8.4.2.6 LIGHTS, menu 6.
The running lights are located on the right and left-hand sides of the
machine to provide surrounding traffic and the environment an indica-
tion of the machine’s position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.5 LIGHTS, menu 5.
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine’s position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.
The brake lights are located in the rear of the machine to provide sur-
rounding traffic and the environment an indication that the machine is
braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
NC switch). The signal travels to the front frame control unit (D797-F),
which supplies power to the brake lights.
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.
The reversing lights are located in the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is travelling backwards. In addition, this provides the operator en-
hanced view when operating in darkness.
Reversing lights are controlled by the selected travel direction with the
gear selector and multi-function lever (S162) that sends a voltage sig-
nal to the KIT control unit (D790-2).
The reversing lights are supplied voltage by Control unit, frame rear
(D797-R).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.
The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction indicators are controlled by selecting with the switch for
direction indicators (S161) that sends a voltage signal to the KIT con-
trol unit (D790-2).
The direction indicators are supplied voltage by Control unit, frame
front (D797-F) and Control unit, frame rear (D797-R).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.8 LIGHTS, menu 8.
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
Work lights on the cab provide visibility when handling a load in dark-
ness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.1 LIGHTS, menu 1.
lights)
D ANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non lights.
Handle the headlights with care since the light is un-
der gas pressure and may explode.
NOTE
The xenon light is filled with different gases and metals. Replaced
xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
The lifting boom can be equipped with two extra working lights ( ).
lights)
See Work lights, changing (product alternative Xenon lights) page 71.
Work lights on the attachment provide enhanced view when load han-
dling in darkness.
The work lights are controlled by selecting with the attachment work
light switch. The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.2 LIGHTS, menu 2.
lights)
See Work lights, changing (product alternative Xenon lights) page 71.
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background illumination in all switches, function keys and ro-
tary controls. This is so that the driver will be able to read their func-
tions and settings in darkness. Brightness is controlled by the plus and
minus keys.
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.12 LIGHTS, menu 12.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3
D2 5
D1 D3 6
18
16
17 D6
D18 D19 D5
D14 19
14
15 M
7 20
D15 D790-1 4 D790-2 D795
8
D797-R D797-F D791-1
D9 D10 12 21
9 10 D11 D13 D22
13 22
11
007418
Pos Description Signal description Reference
1 The revolving beacon switch Switch in ON position: U = D1: Diagnostic menu, see section 8 Control
(S110) sends a voltage signal to 24 V system group 8.4.2.9 LIGHTS, menu 9
the cab control unit (D790-1).
2 The switch for warning lights (haz- Switch in ON position: U = D2: Diagnostic menu, see section 8 Control
ard) (S109) sends a voltage signal 24 V system group 8.4.2.8 LIGHTS, menu 8
to the cab control unit (D790-1).
3 The parking brake switch (S107) Switch in ON position: U = D3: Diagnostic menu, see section 8 Control
sends a voltage signal to the cab 24 V system group 8.4.5.4 HYD, menu 4
control unit (D790-1).
4 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics, group 11.5.3.1
transmits activation messages on error shown with error code. Cab control unit
the CAN bus
5 The multi-function lever (S162) Signal button pressed in: Gear and multi-function lever, description
sends a voltage signal to the KIT US162/H = 24 V page 12
control unit (D790-2). D5: Diagnostic menu, see section 8 Control
system , group 8.4.3.5 CAB, menu 5
6 The direction indicator lever (S161) Left: US161/6 = 24 V D6: Diagnostic menu, see section 8 Control
sends a voltage signal to the KIT system group 8.4.2.7 LIGHTS, menu 7
Right: US161/1 = 24 V
control unit (D790-2).
8 Control unit frame rear (D797-R) Checked by control system, Section 11 Common electrics, group 11.5.3.3
supplies power to the rear lights error shown with error code. Control unit, frame rear
and buzzer on the machine.
9 The rear direction indicators (H426 Light on: U = 24 V Driving direction indicator, description page
& H427) come on when the warning 69
lights are activated. D9: Diagnostic menu, see section 8 Control
system group 8.4.2.8 LIGHTS, menu 8
10 The reversing lights (E405L & Light on: U = 24 V Reversing light, description page 69
E405R) come on when reverse D10: Diagnostic menu, see section 8 Control
gear is selected. system group 8.4.2.11 LIGHTS, menu 11
11 Back-up alarm (H965) is activated Reverse gear engaged: U = Reverse alarm, description page 76
when reverse gear is selected. 24 V D11: Diagnostic menu, see section 8 Control
system group 8.4.2.11 LIGHTS, menu 11
12 Control unit frame front (D797-F) Checked by control system, Section 11 Common electrics, group 11.5.3.2
supplies power to the front lights on error shown with error code. Control unit, frame front
the machine.
13 The front direction indicators (H422 Light on: U = 24 V Driving direction indicator, description page
& H423) come on when they are 69
activated. D13: Diagnostic menu, see section 8 Control
system group 8.4.2.8 LIGHTS, menu 8
14 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 76
is activated. D14: Diagnostic menu, see section 8 Control
system , group 8.4.3.5 CAB, menu 5
15 Rotating beacon (H428) is lit when Light on: U = 24 V Revolving beacon, description page 76
hazard lights are activated. S15: Diagnostic menu, see section 8 Control
system , group 8.4.2.9 LIGHTS, menu 9
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
17 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 76
the horn is activated.
18 The operator-in-seat NO switch Operator in seat: U = 24 V Sensor operator in seat, description page 23
(S230) sends a voltage signal to D18: Diagnostic menu, see section 8 Control
the cab control unit (D790-1) when system group 8.4.3.6 CAB, menu 6
there is a load on the operator’s
seat.
20 In the event of warnings, the KID A clicking sound is audible Section 11 Common electrics, group
control unit (D795) activates the when then termination resis- 11.5.3.12 KID control unit
warning light to draw the operator’s tor is activated.
attention to the warning message.
21 The attachment control unit (D791- Checked by control system, Section 11 Common electrics, group 11.5.3.5
1) supplies voltage to the automatic error shown with error code. Control unit, attachment
spreading buzzer during automatic
spreading.
22 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling group 7.5.13 Buzz-
(H9003) is activated when auto- er, automatic spreading 20’-40’
matic spreading 20'-40' is D22: Diagnostic menu, see section 8 Control
activated. system , group 8.4.9.15 ATTACH, menu 15
1 2 3 4 5
16, 17
6
006427
15 13, 14 12 11 10 9 8 7
1. Rotating beacon (H428) 10. Switch, see section 9 Frame, body, cab and accesso-
2. Control unit KIT (D790-2) ries, group 9.1 Controls and instruments
3. Buzzer cab (H853) 11. Horn (H850)
4. Control unit KID (D795) 12. Make-contact operator in seat (S230)
5. Attachment control unit (D791-1) 13. Control unit cab (D790-1)
6. 14.
Automatic spreading buzzer (H9003) Relay loud horn (K3016)
7. Direction indicators front (H422 & H423) 15. Control unit, frame rear (D797-R)
8. Control unit, frame front (D797-F) 16. Direction indicators rear (H426 & H427)
9. 17. Back-up alarm (H965)
Loud horn (H850-1)
9.7.1 Horn
Horn, description
page
–
001247
The horn is located under the cab (the compressed air horn is located
in the rear edge of the cab roof).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.5 CAB, menu 5..
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the operator’s seat (see Sensor operator in seat, descrip-
tion page 23) indicates to the control system if the operator leaves the
seat.
The buzzer is located in the steering wheel panel.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.6 CAB, menu 6..
When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to take caution.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.2.11 LIGHTS, menu 11.
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.
A E B
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Windscreen (front side window)
The window panes are secured with key adhesive and silicone adhe-
sive.
NOTE
The purpose of this instruction is to describe how silicone adhe-
sive 923854.0100 should be handled in connection with replace-
ment of the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0100 is a quick-hardening, two-
component silicone adhesive that can withstand tempera-
tures between -50 °C and +200 °C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 °C cuts hardening time in
half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired harden-
ing.
Fixing time:
10-20 minutes at 20 °C
approx. 5 minutes at 60 °C
Hardening time:
approx. 24 hours at 20 °C
approx. 1 hour at 60 °C
Full strength is obtained after 7 days.
9.9.1 Windscreen
Windscreen, description
page
–
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good allround visibility from the opera-
tor’s station.
For location, see Glass/windows/mirrors, description page 78.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 78.
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 changed, then all bolts must be
removed before the silicone adhesive is cut away.
C AUTION
Figure 1: Removing key strip
Acetone may not come into contact with a roof win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windscreen or a side window is to be changed, then the
1 2 3
window panes must be adjusted so that the upper edge on the
side window has the same height as the top edge of the roof (see
figure 2) and so that the distance between windscreen and side
window is as shown in figure 3.
Use spacers against the roof member to ensure that the distanc-
es are obtained.
006268
1,0
1
Figure 2: Adjusting side window - cab roof
1. Side window
2. Rubber strip
3. Cab frame/door opening
006269
1,0
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
The side windows are secured in the cab and doors with key strips.
For further details, see Glass/windows/mirrors, description page 78.
NOTE
The method describes a general procedure.
3 Remove the wedge strip which runs around the whole window.
4 Carefully remove any glass remains from the rubber strip.
7 Thread the rubber strip around the whole window; use special
tools.
WARN IN G
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Check the roof window’s surface at regular intervals,
and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!
The cab has a rearview mirror (position A) located in the cab as well
as rearview mirrors (position B) on left and right front wing. The func-
tion of the rearview mirror is to give the operator vision around the ma-
chine.
001510
3
1. IR diodes
As an option the machine can be equipped with an extra camera at the
2. Camera
front of the machine for improved vision in front of the machine.
3. Microphone
Switching between the display of the image from the front and rear
cameras is controlled with a button on the monitor.
The monitor shows picture and sound from the back-up camera. The
CA.SE
L
1 picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle sig-
MENU
BRI
4 007416
5
1. Selection of camera
2. Menu
3. Brightness
4. Volume setting
5. Switching ON/OFF
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
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
page
–
The cab has two doors - the left is the operator’s door and the right is
the emergency exit. The door has:
• rail
• handle
• key lock
1 2 3
The cab undercarriage is fitted on the machine’s chassis (frame) via a
mounting. The mounting runs in a lift mast which is secured in the ma-
chine’s chassis behind the right-hand front wing which means that the
cab is positioned above the right-hand drive wheel.
The lift mast consists of outer mast, inner mast lift cylinder and chains.
The inner mast runs in the outer mast on ball bearing rollers.
4
001873
Manual sliding cab means that the cab can be moved forward to facil-
itate access for service and maintenance in the engine compartment.
The cab is pushed for and aft by hand. Two cable chains on each side
ensure that hoses and electric cabling to and from the cab are not
damaged when the cab is moved. The cab is secured in the rear posi-
tion during operation with two lock handles at the rear edge of the cab.
A
D ANGER
The cab may start to move.
Fatal danger!
B C
A. Position, lock handle WARN IN G
B. Lock pin
C. Lock handle for securing cab
It is important to that the lock handles are intact! They
should be checked regularly. However, it is not in-
cluded as part of the service schedule for preventive
maintenance!
D1 2
D2
1
3, 13
D790-1
D12
D797-O
4,14
5
D4
P1
A 12
7 LS
TP 11, 17
T1 B
8 6, 9, 15 10, 16
006901
Pos Explanation Signal description Reference
1 Switch (S177) sliding cab sends a voltage U = 24 V Controls and instruments, overview page 5
signal to Control unit, cab (D790-1). D1: Diagnostic menu, see section 8 Control
system , group 8.4.11.2 SLIDING CAB,
menu 1
3 The cab control unit (D790-1) sends cab Checked by control Section 11 Common electrics, group 11.5.3.1
forward or cab backward on the CAN bus. system, error shown Cab control unit
with error code.
4 Control unit frame option (D797-O) sup- I = 435–650 mA Section 11 Common electrics, group 11.5.3.4
plies voltage to servo valve sliding cab for- Control unit, frame option
ward or servo valve sliding cab backward D4: Diagnostic menu, see section 8 Control
on control valve option frame. system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
5 Servo valve sliding cab forward or servo - Control valve, option frame, description page
valve sliding cab backward pressurises 93
the sliding cab slide in control valve, op- D4: Diagnostic menu, see section 8 Control
tion frame. system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
6 Control valve, option frame sends control - Control valve, option frame, description page
signal to shuttle valve option. 93
7 The shuttle valve sends the strongest con- - Shuttle valve, frame option, description page
trol signal to main pumps if several func- 97
tions are activated at the same time.
8 The main pumps pump oil from the tank. Pressure plate "Max. Section 10 Common hydraulics, group 10.4.2
pressure hydraulic oil Axial piston pump with variable displacement
pumps" on left frame
member.
9 Control valve, option frame pressurises - Control valve, option frame, description page
valve block sliding cab. 93
10 Valve block sliding cab pressurises hy- - Valve block, manual sliding cab, description
draulic motor for sliding cab. page 97
11 Hydraulic motor, sliding cab pulls the cab - Hydraulic motor, sliding cab, description page
forward or backward. 97
12 Sensor end position (B769-2) sends a U = 24 V Sensor, end position damping, description
voltage signal to the cab control unit page 100
(D790-1) when cab is close to the end po- D12: Diagnostic menu, see section 8 Control
sition. system , group 8.4.11.2 SLIDING CAB, menu 2
13 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
"dampen sliding cab" on the CAN bus. system, error shown Cab control unit
with error code.
14 Control unit, frame option (D797-O) re- - Section 11 Common electrics, group 11.5.3.4
duces control current to servo valve, slid- Control unit, frame option
ing cab forward or servo valve, sliding cab D4: Diagnostic menu, see section 8 Control
backward in control valve, option frame. system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
15 Control valve, option frame reduces the - Control valve, option frame, description page
hydraulic pressure to valve block sliding 93
cab. D4: Diagnostic menu, see section 8 Control
system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
16 Valve block sliding cab lets pressure - Valve block, manual sliding cab, description
through to hydraulic motor sliding cab. page 97
17 Hydraulic motor sliding cab reduces the - Hydraulic motor, sliding cab, description page
speed of sliding cab. 97
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics , group 10.4.2 Axial piston pump
with variable displacement.
• Support jacks
• Cab tilt
1. Load signal (LS) Servo valve sliding cab backward controls servo pressure to valve
slide steering so that this controls oil pressure to hydraulic motor slid-
2. Pressure supply (P)
ing cab forward.
3. Tank return (T1)
4. Connection hydraulic motor (B) Servo valve sliding cab backward regulates electrically with the sole-
5. Tank return (TP) noid valve sliding cab backward (Y6017), which is activated by Control
6. Connection hydraulic motor (A) unit, frame option (D797-O).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.11.2 SLIDING CAB, menu 4.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
1
NOTE
6 2 Plug all connections immediately to protect the hydraulic
system from impurities.
5 3 4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
4
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
000624
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
15 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
Valve block sliding cab is fitted on hydraulic motor sliding cab and pre-
vents the motor rotating when sliding cab is not activated.
1 2 3 4 5 6
The hydraulic motor is located furthest forward on the right-hand side
of the cab chain. The hydraulic motor pulls the chain which in turn pulls
the cab forward and backward.
001862
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Remove the protective cover.
4 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
5 Detach the chain from its mounting.
6 Detach the hydraulic hoses from the motor.
7 Remove the ring gear.
8 Remove the hydraulic motor from its mounting.
1. Protective cover
9 Replace the hydraulic motor.
2. Hydraulic motor
3. Chain tensioner
10 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
11 Fit in the reverse order.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
14 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
1 2 3 4 5 6
The chain pulls the cab forward and backward and is secured in the
front and rear edges on the cab undercarriage. The chain tension is
adjusted by moving the hydraulic motor for sliding cab.
001862
Sensor end position damping indicates when the cab is near the end
position and is used to activate end position damping.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.
2
D1
D2
1
3, 16, 22 D15
D790-1
D797-O D13 15
4, 14, 17
D4 D17
10
5 18
12, 21
11, 20 13
P1 A
LS B
TP
7
T1 T3
6, 9, 19
8
013033
Pos Explanation Signal description Reference
1 Switch vertically adjustable cab U = 24 V Controls and instruments, overview page 5
(S177) sends a voltage signal to D1: Diagnostic menu, see section 8 Control sys-
Control unit, cab (D790-1). tem , group 8.4.11.2 SLIDING CAB, menu 1
3 The cab control unit (D790-1) sends Checked by control sys- Section 11 Common electrics, group 11.5.3.1
cab up or cab down on the CAN tem, error shown with er- Cab control unit
bus. ror code.
5 Servo valve, raise cab (Y6016) or - Control valve, option frame, description page
servo valve, lower cab (Y6017) 104
pressurises the sliding cab slide in D4: Diagnostic menu, see section 8 Control sys-
control valve, option frame. tem , group 8.4.11.2 SLIDING CAB, menu 3 and
4
6 Control valve, option frame sends a - Control valve, option frame, description page
control signal to shuttle valve op- 104
tion.
7 The shuttle valve sends the strong- - Shuttle valve, frame option, description page 97
est control signal to main pumps if
several functions are activated at
the same time.
8 The main pumps pump oil from the See pressure plate on left Section 10 Common hydraulics, group 10.4.2
tank. frame beam. Axial piston pump with variable displacement
9 Control valve, option frame pressu- - Control valve, option frame, description page
rises the accumulator and the load 104
control valve.
11 The load control valve lets the pres- - Load control valve, description page 105
sure through to hydraulic cylinder
for vertically adjustable cab.
When lowering, the load control
valve changes position and restricts
flow from hydraulic cylinder for ver-
tically adjustable cab.
12 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab lifts or lowers the cab. scription page 106
13 Sensor lowered cab (B777-2) stops U = 24 V Sensor, lowered cab, description page 110
sending a voltage signal to Control D13: Diagnostic menu, see section 8 Control
unit, frame option (D797-O) when system , group 8.4.11.2 SLIDING CAB, menu 2
the cab leaves the lowest position.
14 Control unit, frame option (D797-O) Checked by control sys- Section 11 Common electrics, group 11.5.3.4
sends "cab up" on the CAN bus. tem, error shown with er- Control unit, frame option
ror code.
15 Sensor end position damping U = 24 V Sensor, end position damping, description page
(B769-2) sends a voltage signal to 111
the cab control unit (D790-1) when D15: Diagnostic menu, see section 8 Control
cab is close to the end position. system , group 8.4.11.2 SLIDING CAB, menu 2
17 Control unit, frame option (D797-O) - Section 11 Common electrics, group 11.5.3.4
reduces the control current to servo Control unit, frame option
valve raise cab (Y6016) or servo D17: Diagnostic menu, see section 8 Control
lower valve cab (Y6017) in control system , group 8.4.11.2 SLIDING CAB, menu 3
valve, option frame. and 4
18 Servo valve, raise cab (Y6016) or - Control valve, option frame, description page
servo valve, lower cab (Y6017) con- 104
trols the pressure to the sliding cab D17: Diagnostic menu, see section 8 Control
slide in control valve, option frame. system , group 8.4.11.2 SLIDING CAB, menu 3
and 4
19 Control valve, option frame reduces - Control valve, option frame, description page
hydraulic pressure to valve block 104
vertically adjustable cab.
20 Valve block lift cylinder for vertically - Load control valve, description page 105
adjustable cab lets pressure
through to hydraulic cylinder for ver-
tically adjustable cab.
21 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab reduces the speed of scription page 106
raising or lowering the cab.
22 When the cab is lifted the cab con- Maximum speed: 5 km/h. Section 11 Common electrics, group 11.5.3.1
trol unit (D790-1) activates speed Cab control unit
limitation.
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics , group 10.4.2 Axial piston pump
with variable displacement.
1
The vertically adjustable cab is controlled by a separate section in con-
trol valve, option frame, for details see Control valve, option frame, de-
6 2
scription page 93.
Servo valve raise cab regulates electrically with the solenoid valve
1. Load signal (LS) raise cab (Y6016), which is activated by Control unit, frame option
2. Pressure supply (P) (D797-O).
3. Tank return (T1) The signal can be checked from the diagnostic menu, see section 8
4. Connection, hydraulic cylinder (B) Control system , group 8.4.11.2 SLIDING CAB, menu 3.
5. Tank return (TP)
6. Connection, hydraulic cylinder (A) Servo valve lower cab
Servo valve lower cab controls servo pressure to valve slide raise/low-
er cab so that this drains hydraulic cylinder, vertically adjustable cab,
for lowering the cab.
Servo valve lower cab regulates electrically with the solenoid valve
raise cab (Y6017), which is activated by Control unit, frame option
(D797-O).
Servo valve lower cab can be checked from the diagnostic menu, see
section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 4.
The accumulator stores pressure so that the cab does not lower if the
engine stops and the machine becomes depressurised.
The load control valve reduces the speed when lowering the cab.
When the pressure is released behind the valve, the valve slide chang-
000621 es position and restricts the channel through the valve.
1 2 3
The hydraulic cylinder lifts the inner mast and thus the cab.
4
001873
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Raise the cab so high to secure its position with both lock lugs
(position A).
Lower the cab so that it rests on the safety brackets.
C AUTION
Risk of fatal danger under raised cab.
A Secure the cab with the lock lugs (position A) on both
sides of the cab frame.
001977
NOTE
Plug all hydraulic connections immediately.
008206
NOTE
Plug all hydraulic connections immediately.
7 Attach hoisting equipment to the hydraulic cylinder.
8 Remove the hydraulic cylinder’s retaining brackets from the fixed
part of the cab frame.
9 Tilt and lift the hydraulic cylinder out upwards.
10 Transfer parts to the new hydraulic cylinder.
11 Fit the hydraulic cylinder in the reverse order.
12 Start the engine and check for leaks.
000621
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
15 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
1 2 3
The mast holds the cab secure and enables raising and lowering.
4
001873
The sensor indicates when the cab is completely lowered. When the
cab is raised, the machine’s speed is reduced and the transmission is
1 blocked in second gear.
The signal can be checked from the diagnostic menu, see section 8
2
Control system , group 8.4.11.2 SLIDING CAB, menu 2.
000618
Sensor damping end position indicates when the cab is close to end
position. This is used to activate end-position damping. When the cab
1 is raised, the machine’s speed is reduced and the transmission is
blocked in second gear.
2
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.
000618
A
001978
On the mast are two lock lugs which are used to secure the cab in the
raised position during maintenance work with raised cab.
A
001977
A. Lock lug
Left instrument panel is located in the left corner of the cab. It contains
rotary controls, switches, and ventilation.
The panel is mounted on the driver’s seat. The panel includes switch-
es for load handling functions and safety switches to interrupt ongoing
load handling functions. The control lever is located next to the panel.
9.11.5 Insulation
Insulation, description
page
–
Sun blinds can be chosen for the front window (windscreen) and the
roof window.
1. Sun visor, front window: Can be raised and lowered using a cord
on the right-hand side. Stops in selected position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window.
9.12 Frame
Frame, description
page
–
4
6 7 8
3 2
001511
1
9.13 Body
Body, description
page
–
3
2 1
002213
1. Wings
2. Hood engine compartment
3. Counterweight
9.13.1 Wings
Wings, description
page
–
There are wings over the wheels to protect from dirt thrown up by the
wheels during operation. The design of the counterweight (see Coun-
terweight, description page 118) acts as a mudguard for the rear
wheels.
The wings can be equipped with extra mudguards when the machine’s
work environment requires such ( ).
9.13.4 Counterweights
Counterweight, description
page
–
D ANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pin does not move even when the pump is running,
Overview - central lubrication pump unit and distribu-
troubleshoot the pump unit.
tion block. Example illustration.
1. Lubricant nipple, lubricating grease filler orifice
2. Safety valve
NOTE
3. Lubricant nipple, manual system lubrication The system can be lubricated manually through the grease
4. Indicator pin nipple on the distribution block (position 3).
5. Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. At replacement, the new pump unit should be set
in the same way as the old one.
If the machine is not lubricated correctly, pause and run-time can be
adjusted. Primarily, run-time should be adjusted so that all lubrication
points on the machine are greased every time. If large amounts of
grease are pressed out at all lubrication points, pause-time can be
increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Pause-time
Example illustration
Pause-time is the length of the interval between greasings. The inter-
1. Pause time setting (red)
val is adjusted in whole hours between 1 and 15 hours. Pause-time is
2. Run time setting (blue)
adjusted with the red handle (position 1).
3. Manual pump operation
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause-time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
Run-time is how long the pump is activated every time. Run-time can
be adjusted between 2 and 30 minutes. Pause-time is adjusted with
the blue handle (position 2).
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and run-
ning time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motor’s run and pause
time.
When the central lubrication works, it greases the lubrication points
one at a time in series. If a stop should occur in a lubrication point, the
pressure will increase and the safety valve will release grease and
also the following lubrication points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased Therefore, it is very important to
check the safety valve.
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example illustration, central lubrication components through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
3. Distribution block
If there is clogging in the system, that line will be pressurised, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks’ connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3 Lines
Lines, description
page
–
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
9.15 Paint/coatings
Paint/coatings, description
page
–
NOTE
Touching up, the surfaces to be touched up must be thoroughly
cleaned.
Please contact Cargotec for information about other surface treatment
and material colours.
10 Common hydraulics
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 Attachment relief valve .......................................................................... 4
10.2.3 Pipes and hoses .................................................................................... 4
10.3 Tanks and accumulators ............................................................................ 5
10.3.1 Tank ....................................................................................................... 5
10.3.2 Pipes and hoses .................................................................................... 5
10.4 Pumps ........................................................................................................ 6
10.4.1 Gear pump with fixed displacement ....................................................... 6
10.4.2 Axial piston pump with variable displacement ..................................... 12
10.4.3 Pipes and hoses .................................................................................. 30
10.5 Hoses, pipes and valves .......................................................................... 31
10.5.1 Pipes and hoses .................................................................................. 31
10.5.2 Priority valve ........................................................................................ 32
10.5.3 Shuttle valve ........................................................................................ 32
10.5.4 Collection block, filtered returns ........................................................... 34
10.5.5 Collection block, unfiltered returns ....................................................... 34
10.6 Temperature control, cleaning and hydraulic oil ....................................... 35
10.6.1 Tank heater .......................................................................................... 36
10.6.2 Hydraulic oil cooler .............................................................................. 37
10.6.3 Cooling fan ........................................................................................... 38
10.6.4 Sensor hydraulic oil temperature ......................................................... 39
10.6.5 Radiator bypass valve ......................................................................... 40
10.6.6 Breather filter hydraulic oil tank ........................................................... 42
10.6.7 Oil filter ................................................................................................. 43
10.6.8 Hydraulic oil ......................................................................................... 47
10.6.9 Hydraulic oil fine-filter .......................................................................... 47
10.6.10 Pipes and hoses .................................................................................. 48
10.7 Auxiliaries ................................................................................................. 49
10.7.1 Hydraulic cylinders ............................................................................... 49
10 Common hydraulics
mm mm mm mm mm mm
000434
The relief valve is located on the lift cylinder beam. See section 7 Load
handling, group 7.4.8 Attachment relief valve.
002269
The hydraulic oil tank forms part of the side panel on the right-hand
1 2 1 3 4
side of the machine. The oil filters for the working hydraulics are fitted
inside the tank. These are accessible through hatches on top of the
tank.
Hydraulic oil is filled directly into the tank through the filler caps on the
filter manhole covers. For oil capacity and grade, see section F Tech-
nical data. The entire filter unit can be removed to facilitate access for
cleaning. There is a drain plug at the bottom of the tank.
The tank has filtered venting which allows changes in the tank volume
due to usage and temperature variations.
5 5
The oil level is checked on the level glass on the tank’s side when all
hydraulic cylinders are in the bottom position.
001457
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
–
There are two gear pumps with fixed displacement. One (position 1)
supplies the brake system with pressure, see section 4 Brakes , group
4.3.1 Brake oil pump. The other gear pump (position 2) circulates hy-
draulic oil for working hydraulics through the cooler and filter.
The gear pump pumps oil using two gear wheels that rotate opposite
each other. One is driven by the pump’s input shaft and the other ro-
tates freely. The gear pump’s flow is directly dependent on the speed
of the input shaft.
The cooling pump is fitted on the right main pump and is driven by the
main pump shaft from the transmission’s power take-off. Pump speed
1 is directly dependent on engine speed. Pump flow increases and en-
gine speed increases.
2
000006
alternative Rexroth)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Mark up and release the hydraulic hoses from the gear pump.
6 Remove the spacer ring from the gear pump or axial piston pump.
Clean the O rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the gear pump, see section F Technical data.
NOTE
Only use silicone on the side facing the gear pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
C AUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
010475
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
If the pump is replaced due to malfunction, change the oil
and filters as well.
17 If the brake fluid pump is replaced:
Check the brake pressure; see section 4 Brakes, group 4.3.1
Brake fluid pump.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the brake and hydraulic systems, see Workshop
Manual section B Safety.
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
4 Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters and the contact to the new
pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
9 Close the drain valve and tighten the lock ring on the accumulator
charging valve.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
If the pump is replaced due to malfunction, change the oil
and filters as well.
8 7
000528
D790-1
1
D797-R 7, 16 12
P P
P1
LS D16 LS
P
2, 13 EF CF
LS 15
P
8
4, 17 5, 9 C15
C3 C14
C6 C10
No 1 No 2 No 3 No 4
11
006417
6 6, 10 3, 14 3, 14
2 Control signal goes to the shuttle valve that See pressure plate Servo Shuttle valve, description (hydraulic oil
sends the load signal on to hydraulic oil pressure lift and exten- pump alternative Rexroth) page 32
pumps No. 3 and No 4. sion on left frame
member.
3 Hydraulic oil pumps No. 3 and No. 4 in- See pressure plate Max. Axial piston pump with variable displace-
crease the flow. pressure hydraulic oil ment, description (hydraulic oil pump al-
pumps on left frame ternative Rexroth) page 12
member.
4 Solenoid valve, unloading main pump See pressure plate Servo Section 7 Load handling, group 7.3.9
(Y6062) leads load signal on to hydraulic oil pressure lift and exten- Valve block pump unloading
pump No. 1 and the shuttle valve sion on left frame
(position 5). member.
5 The shuttle valve sends load signal on to See pressure plate Servo Shuttle valve, description (hydraulic oil
hydraulic oil pump No. 2. pressure lift and exten- pump alternative Rexroth) page 32
sion on left frame
member.
8 Solenoid valve top hydraulics (Y6003) con- - Section 7 Load handling, group 7.4.2
trols an unloaded constant pressure to hy- Valve block top lift hydraulics
draulic oil pump No. 2, this functions as a
load signal.
9 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil
hydraulic oil pump No. 2. pump alternative Rexroth) page 32
10 Hydraulic oil pump No. 2 increases the See pressure plate Max. Axial piston pump with variable displace-
flow. pressure hydraulic oil ment, description (hydraulic oil pump al-
pumps on left frame ternative Rexroth) page 12
member.
11 When Solenoid valve top hydraulics - Section 7 Load handling, group 7.4.2
(Y6003) is not activated, the unloaded Valve block top lift hydraulics
pressure is directed to tank.
12 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve
13 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil
hydraulic oil pumps No. 3 and 4. pump alternative Rexroth) page 32
14 Hydraulic oil pumps No. 3 and No. 4 in- See pressure plate Steer- Axial piston pump with variable displace-
crease the flow. ing pressure, on left ment, description (hydraulic oil pump al-
frame member. ternative Rexroth) page 12
15 The priority valve controls the pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority
from the pumps to the steering valve. ing pressure, on left valve
frame member.
16 For boom in Control unit frame rear U = 24 V Section 11 Common electrics, group
(D797-R) activates Solenoid valve pump 11.5.3.3 Control unit, frame rear
unloading (Y6062). Diagnostic menu, see section 8 Control
system , group 8.4.8.2 BOOM, menu 2
17 Solenoid valve pump unloading (Y6062) - Section 7 Load handling, group 7.3.9
leads the pressure from the control valve to Valve block pump unloading
the tank.
D790-1
1 12
D797-R
P P
7, 16
LS
LS P1
D7 D7 P
2, 13 EF CF
LS 15
P
4, 17 5, 9 C15
C6 C6
8, 11, 18
6, 10 3, 14
No 1 No 2
011051
Pos Explanation Signal description Reference
1 The lift and extension control valve See pressure plate Servo Section 7 Load handling, group 7.2 Lifting/
sends a load signal when a function is pressure lift and exten- lowering
activated. sion on left frame mem-
ber.
2 Control signal goes to the shuttle valve See pressure plate Servo Shuttle valve, description (hydraulic oil pump
that sends the load signal on to hydrau- pressure lift and exten- alternative Rexroth) page 32
lic oil pump No. 2. sion on left frame mem-
ber.
3 Hydraulic oil pump No. 2 increases the See pressure plate Max. Axial piston pump with variable displace-
flow. pressure hydraulic oil ment, description (hydraulic oil pump alter-
pumps on left frame native Sauer-Danfoss) page 13
member.
4 Solenoid valve, unloading main pump See pressure plate Servo Section 7 Load handling, group 7.3.9 Valve
(Y6062) leads load signal on to hydrau- pressure lift and exten- block pump unloading
lic oil pump No. 1 and the shuttle valve sion on left frame mem-
(position 5). ber.
5 The shuttle valve sends load signal on to See pressure plate Servo Shuttle valve, description (hydraulic oil pump
hydraulic oil pump No. 1. pressure lift and exten- alternative Rexroth) page 32
sion on left frame mem-
ber.
8 Solenoid valve top hydraulics (Y6003) - Section 7 Load handling, group 7.4.2 Valve
controls an unloaded constant pressure block top lift hydraulics
to hydraulic oil pump No. 1, this func-
tions as a load signal.
9 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil pump
hydraulic oil pump No. 1. alternative Rexroth) page 32
10 Hydraulic oil pump No. 1 increases the See pressure plate Max. Axial piston pump with variable displace-
flow. pressure hydraulic oil ment, description (hydraulic oil pump alter-
pumps on left frame native Rexroth) page 12
member.
11 When Solenoid valve top hydraulics - Section 7 Load handling, group 7.4.2 Valve
(Y6003) is not activated, the unloaded block top lift hydraulics
pressure is directed to tank.
12 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve
13 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil pump
hydraulic oil pump No. 2. alternative Rexroth) page 32
14 Hydraulic oil pump No. 2 increases the See pressure plate Steer- Axial piston pump with variable displace-
flow. ing pressure, on left ment, description (hydraulic oil pump alter-
frame member. native Rexroth) page 12
15 The priority valve controls the pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority
from the pumps to the steering valve. ing pressure, on left valve
frame member.
16 For boom in Control unit frame rear U = 24 V Section 11 Common electrics, group
(D797-R) activates Solenoid valve 11.5.3.3 Control unit, frame rear
pump unloading (Y6062). Diagnostic menu, see section 8 Control sys-
tem , group 8.4.8.2 BOOM, menu 2
17 Solenoid valve pump unloading (Y6062) - Section 7 Load handling, group 7.3.9 Valve
leads the pressure from the control block pump unloading
valve to Solenoid valve (Y6003).
18 When Solenoid valve top hydraulics - Section 7 Load handling, group 7.3.9 Valve
(Y6003) is not activated, the unloaded block pump unloading
pressure is directed to tank.
alternative Rexroth)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, approx. 50 °C.
2 Stop the engine
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
4 Start the engine and run it at idling speed.
5 Check the standby pressure for one pump at a time in the follow-
ing order:
Hydraulic oil pump 1: 1.8 MPa
Hydraulic oil pump 2: 2.1 MPa
Hydraulic oil pump 3: 2.9 MPa
Hydraulic oil pump 4: 3.1 MPa
1. Hydraulic oil pump 1 The settings apply to standard machine, certain machines can
2. Hydraulic oil pump 2 have higher standby pressure. For correct standby pressure, see
3. Hydraulic oil pump 3 pressure plate. However, the difference in pressure between the
4. Hydraulic oil pump 4 different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run extension
function against end-position (overflow).
Run out the boom to max and continue to request max. extension
with the control lever. This will cause the overflow of the exten-
sion function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa All pumps should give the same pressure. The order between the
pumps is of no importance.
8 Stop the engine
MPa
9 Transfer the pressure gauge to the next pump and repeat steps
MPa
3–8 on all four pumps.
MPa MPa MPa
MPa
MPa
MPa MPa
001028
920643.0024
alternative Sauer-Danfoss)
NOTE
Read the safety instructions for oil before working, see Workshop
Manual section B Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, approx. 50 °C.
2 Stop the engine
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
4 Start the engine and run it at idling speed.
5 Check the standby pressure for one pump at a time in the follow-
ing order:
Hydraulic oil pump 1: 2.9 MPa
Hydraulic oil pump 2: 3.0 MPa
The settings apply to standard machine, certain machines can
1. Hydraulic oil pump 1 have higher standby pressure. For correct standby pressure, see
2. Hydraulic oil pump 2 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 extension
function against end-position (overflow).
Run out the boom to max and continue to request max. extension
with the control lever. This will cause the overflow of the exten-
sion function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa Both pumps should give the same pressure. The order between
the pumps is of no importance.
MPa
MPa
MPa
A49195.0400
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump’s suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 47.
2 Disconnect the main power supply.
3 Depressurise the brake and hydraulic systems, see section
B Safety.
4 Release the brake fluid pump or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
7 Mark up and detach the hydraulic hoses from the axial piston
pump.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
C AUTION
Be careful and make sure that no gasket remains fall
down into the gearbox.
NOTE
Check that the O-rings are intact and fitted correctly.
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the gearbox transmission. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.
15 Fill the pump with oil through the connections on the top.
NOTE
Check that the O-rings are intact and fitted correctly.
17 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to step
20.
Clean the O rings’ contact surfaces on the spacer ring.
18 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the gear pump, see section F Technical data.
NOTE
Only use silicone on one side, the side facing the brake
pump.
C AUTION
Vent the axial piston pump before starting the engine.
C AUTION
Hydraulic oil may be directed the wrong way.
010475
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the hydraulic system as well.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump’s suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 47.
2 Disconnect the main power supply.
3 Depressurise the brake and hydraulic systems, see section B
Safety.
4 Release the brake fluid pump or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
8 Attach lifting equipment to the axial piston pump.
9 Remove the axial piston pump.
Remove the attaching bolts and lift the pump away.
10 Clean the flange on the gearbox, removing all silicone remnants.
C AUTION
Be careful and make sure that no gasket remains fall
down into the gearbox.
NOTE
Check that the O-rings are intact and fitted correctly.
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the gearbox transmission. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.
NOTE
Check that the O-rings are intact and fitted correctly.
17 Brush sealing silicone on the gear pump’s sealing surface; see
section F Technical data.
C AUTION
Vent the axial piston pump before starting the engine.
The illustration shows the gear pump pre-assembled
on hydraulic oil pump 1 The oil in the axial piston pump may cavitate and
cause product damage.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the hydraulic system as well.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
3 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump one at a time and let oil flow out. Tighten the connec-
tions when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather fil-
ter.
5 Turn on the main electric power and start the engine.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tightly.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
8 Stop the engine
9 Wash the engine compartment.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Hoses with ORFS couplings are used almost exclusively. For maxi-
mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose may 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,
see section F Technical data.
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the connec-
tion.
• Never reuse oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil bar-
rels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.
alternative Rexroth)
A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
1 activated at the same time.
Depending on options, there are two to four shuttle valves. The shuttle
2 valves are fitted on a bracket for oil filling between the engine and
transmission.
3 The shuttle valves choose between the following control signals:
1. Chooses between the pressure signal from the control valve for
4
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to hydraulic oil pump 4. See Axial piston pump with variable dis-
placement, description (hydraulic oil pump alternative Rexroth)
page 12.
2. Chooses between the pressure signal from the control valve for
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
hydraulic oil pump 2. See Axial piston pump with variable dis-
placement, description (hydraulic oil pump alternative Rexroth)
002203
page 12.
1. Shuttle valve attachment
2. Shuttle valve control 3.
Chooses between the pressure signal from shuttle valve steering
3. Shuttle valve for mini-wheel or joystick control
(position 2) and the pressure signal from the control valve option
4. Shuttle valve option frame frame. The shuttle valve sends the pressure signal on to hydraulic
oil pumps 3 and 4. See Axial piston pump with variable displace-
ment, description (hydraulic oil pump alternative Rexroth) page
12.
This shuttle valve is fitted if the machine is equipped with joystick
control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attach-
ment(position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
hydraulic oil pump 2. See Axial piston pump with variable dis-
placement, description (hydraulic oil pump alternative Rexroth)
page 12.
This shuttle valve is fitted if the machine is equipped with support
jacks, hydraulic sliding cab or vertically adjustable cab.
alternative Sauer-Danfoss)
A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
1 activated at the same time.
Depending on options, there are two to four shuttle valves. The shuttle
2 valves are fitted on a bracket for oil filling between the engine and
transmission.
3 The shuttle valves choose between the following pressure signals:
1. Chooses between the pressure signal from the control valve for
4
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to main pump 1. See Axial piston pump with variable displace-
ment, description (hydraulic oil pump alternative Sauer-Danfoss)
page 13.
2. Chooses between the pressure signal from the control valve for
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
hydraulic oil pump 2. See Axial piston pump with variable dis-
placement, description (hydraulic oil pump alternative Sauer-Dan-
002203
4.
Chooses between the pressure signal from shuttle valve attach-
ment (position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
hydraulic oil pump 1. See Axial piston pump with variable dis-
placement, description (hydraulic oil pump alternative Sauer-Dan-
foss) page 13.
This shuttle valve is fitted if the machine is equipped with support
jacks, hydraulic sliding cab or vertically adjustable cab.
The block collects several return lines from different components and
1 2 leads these on back to the tank through the tank filters.
The block is fitted on top of the lifting beam in front of the transmission.
003205
The block collects several return lines from different valves and leads
1 2 these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is fitted to the side of the lifting beam in front of the transmis-
sion.
003205
function description
The oil of the hydraulic system is cooled and cleaned through circula-
tion by a separate pump through the radiator and filters. The radiator
˚C
has a temperature-regulated electric fan that prevents overheating.
9 ˚C
D795 Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, hy-
D797-R draulic oil temperature sensor and bypass valve.
D3 4 D4 The hydraulic oil pump pumps oil (from the tank) which is cooled in the
hydraulic oil cooler and cleaned by the oil filters in the tank. Some of
5 M the oil is filtered by the fine filter. An electric cooling fan increases the
air flow through the cooler when the temperature needs to be lowered.
2
A bypass valve leads the hydraulic oil past the cooler directly to the
tank if the resistance through the cooler and filters is too high. The
8 temperature sensor controls fan activation and temperature display.
1 6
7
007414
˚C 3
2 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description page 37
3 The hydraulic oil temperature sensor U = 0.5-4.5 V Sensor hydraulic oil temperature, descrip-
(B776) sends Control unit frame rear tion page 39
(D797-R) a voltage signal proportional to D3: Diagnostic menu, see section 8 Control
the hydraulic oil temperature. system , group 8.4.5.1 HYD, menu 1
4 Control unit frame rear (D797-R) trans- Hydraulic fan active: Section 11 Common electrics, group
mits temperature on the CAN bus and U = 24 V 11.5.3.3 Control unit, frame rear
supplies power to the cooling fan as nec- D4: Diagnostic menu, see section 8 Control
essary. system , group 8.4.5.1 HYD, menu 1
5 The cooling fan (M668) increases air flow - Cooling fan, description page 38
through the radiator.
6 The hydraulic oil filters clean the hydrau- - Hydraulic oil filter, description page 43
lic oil.
7 Some of the oil is pumped through the - Fine filter hydraulic oil, description page 47
hydraulic oil fine-filter for deep cleaning.
8 If resistance through the oil cooler and - Cooler bypass valve, description page 40
hydraulic oil filter becomes too great, the
cooler bypass valve opens and directs
the oil to the tank.
C AUTION
The tank heater is connected to high voltage. Connec-
tion and reconnection of the tank heater may only be
performed by personnel authorised for work with high
voltage.
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs off high current. Heater output is adapted through
different connections and adaptation to different operating voltages -
110, 230 or 400 V AC. Higher voltage generates higher heater output.
The heater is mounted in a hole in the connection cover at the bottom
of the short side of the tank.
The tank heater can be equipped with a programmable thermostat
000430
001013
NOTE
Read the safety instructions for oil before working, see section B
Safety.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
2. Connector NOTE
3. Radiator Check that the O-rings are intact and fitted correctly.
10 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The electric cooling fan is forcing. The cooling fan is located at the rear
of the cooler. The fan draws air from the machine’s outside through the
cooler. Openings in the side cover allows air to pass through the
cooler.
The radiator is supplied voltage by Control unit frame rear (D797-R)
upon activation when the engine is running. The cooling fan is activat-
ed when oil temperature is 65 °C in the hydraulic oil tank and is deac-
tivated when oil temperature is 55 °C.
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system , group 8.4.5.1 HYD, menu 1.7
001014
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Check that the O-rings are intact and fitted correctly.
5 Connect the cabling to the sensor.
008222
6 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.
007426
NOTE
Read the safety instructions for oil before working, see section B
Safety.
I M P OR TA NT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old one. Use Loctite when fitting the bypass valve.
007426
Bypass valve
6 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The hydraulic oil level is checked with the boom com-
pletely lowered and retracted.
001454
The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
001455
NOTE
Read the safety instructions for oil before working, see section B
Safety.
I M P OR TA NT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Magnetic rod
8 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
I M P OR TA NT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
NOTE
The filter holders are heavy, loosen them carefully.
5 Clean the filter holders.
6 Remove the filter inserts.
NOTE
Note the location of the O-rings.
7 Fit the O-rings on the filter inserts and filter holders. Lubricate the
O-rings with hydraulic oil.
003602
High-pressure filter, under machine 9 Fit the filter holder and drain plug.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
C AUTION
Hydraulic oil may be directed the wrong way.
Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
C AUTION
Overfilling of oil, leakage, and environmental damage.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
I M P OR TA NT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
The fine filter is located on the frame member in the engine compart-
ment. The filter is connected to hydraulic oil pump cooling and filtra-
tion. The filter is connected in parallel to the hydraulic oil filters in the
hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
I M P OR TA NT
Make sure that the area around the filter is clean when
working.
5 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
10.7 Auxiliaries
10.7.1 Hydraulic cylinders
Hydraulic cylinders, repairs
page
–
C AUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leak-
age can be detected. High pressure causes the seals
to close tighter, which prevents detection of leaks.
1 Carefully check the source of the leakage before taking any ac-
tion. It may be possible to rectify the fault without disassembly.
2 Check for external leakage:
• At cylinder end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces. Both faults can be rectified with the cylinder
in situ.
• Between cylinder head an 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.
1. Piston rod
2. Scraper This could be due to a worn piston seal.
3. Cylinder head
4. Piston rod seal Dismantling of cylinders
5. O-ring with thrust ring
6. Cylinder barrel
7. Sleeve coupling C AUTION
8. Welded cylinder end face
9. Piston
Before dismantling always check that the piston rod
10. Piston seal, double-acting
is clean and free from all residual paint. Also check
11. Example of weld
that connections and couplings are free from burrs
and impact marks. Make sure that the chamfer up to
the chromium surface of the piston rod is free from
burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connec-
tions.
2 Plug the cylinder connections and hoses without delay.
Inspection of surfaces
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the fol-
lowing descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a
layer thickness of 20-50 my. Slight damage to the chromium
plating may not necessarily be the direct cause of leakage.
• all sliding surfaces (dynamic surfaces), e.g. cylinder barrel
and piston rod. These are always the hardest to seal.
C AUTION
When fitting the cylinder head:
5
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
7. O-ring
6
4
5 001499
5
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
Thrust ring and O-ring
The thrust 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 thrust ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the thrust ring and the
3
sealing surface by the hydraulic pressure in the cylinder.
4 When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
2
001506
1
1. Hydraulic pressure
2. O-ring
3. Thrust ring
4. Sealing surface, cylinder head
Scraper
øD+10
The purpose of the scraper is to scrape the piston rod clean and pre-
1 vent impurities from entering the cylinder barrel.
The scraper is fitted with a special fitting tool, which has a greater outer
diameter than the scraper so that the press force against the scraper
2 ceases right when the scraper is pressed into position. If the scraper
were to be pressed in further, the metal capsule will 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
3 head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
C AUTION
3 No tool must be applied from the inside. This could
give rise to burrs on the cylinder head which could in
turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
On the single-acting V-ring seal it is always the long side that seals
2
against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is al-
ways inserted in the V shape so that it cannot touch and thereby dam-
age a sealing surface. A mark from a screwdriver on a sealing surface
3 can have a devastating effect and cause major leakage.
6 4
002370
5
1. Hydraulic pressure
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 an assembly together with the thrust
ring.
Always assemble by hand. No tools should be used as they could eas-
ily damage the surface of the piston.
For easier assembly the seal can be heated in hot water to make it
soft.
Lubricate with hydraulic oil.
002950
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that can cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal-
ing body. then thrust rings and farthest out guide rings.
2 First fit the sealing body, then the thrust rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
11 Common electrics
11 Common electrics
mm mm mm mm mm mm
I M P OR TA NT
Never turn off the voltage with the battery disconnect
A switch when the engine is running. This could dam-
age the alternator.
11.2.2 Fuses
Fuses, replacement
page
–
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
WARN IN G
Battery electrolyte contains corrosive sulphuric acid
WARN IN G
Risk of explosion!
Personal injury!
disconnect switch.
WARN IN G
Risk of explosion if the battery short circuits (also
causes loss of capacity).
Fire hazard, personal injury!
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.
000269
11.4 Alternator
11.4.1 Alternator
Alternator, description (engine alternative Volvo)
page
–
QSM11)
The alternator generates current during operation and supplies this to
the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system , section 8.4.6.4 ENGINE, menu 4.
007444
Alternator, replacement
page
–
operation
1 2 3 4
D1 D2 D3 D4
- +
D8 D7 D9
D11
007420
D10 D12 D13 D14
2 The interior lighting switch of the cab control - Section 9 Frame, body, cab and accessories, group
unit (D790-2) sends a voltage signal to the 9.6.12 Interior lighting
cab control unit (D790-1). D2: Diagnostic menu, see section 8 Control system,
group 8.4.2.12 LIGHTS, menu 12
3 The switch for warning lights (S109) sends U = 24 V Section 9 Frame, body, cab and accessories, group
a voltage signal to the cab control unit 9.6.7 Warning lights
(D790-1). D3: Diagnostic menu, see section 8 Control system,
group 8.4.2.8 LIGHTS, menu 8
4 When the ignition (S150) is turned to posi- U = 24 V Section 9 Frame, body, cab and accessories, group
tion I, it sends a voltage signal to the cab 9.1 Controls and instruments
control unit (D790-1). D4: Diagnostics menu, see section 8 Control sys-
tem, group 8.4.1.4 CAN/POWER, menu 4
5 The cab control unit (D790-1) activates a - Cab control unit, description page 19
hold circuit, which activates the control
unit’s control logic.
7 The cab control unit (D790-1) supplies volt- UK2:7 = 24 V Control unit, frame front, description page 20
age to the control logic of the other control D7: Diagnostics menu, see section 8 Control sys-
UK2:8 = 24 V
units via the redundant voltage feed. tem, group 8.4.1.8 CAN/POWER, menu 8
Redundant voltage feed Activated Redundant voltage feed for control units, description of op-
eration page 7
Redundant CAN bus Communication estab- Redundant CAN bus, description page 45
lished
- +
D4
1 2
D1 D2 D3 3 6
4, 5
007421
Pos Explanation Signal Reference
description
1 Warning light comes on and sends a U = 24 V Section 9 Frame, body, cab and accessories, group
voltage signal to the cab control unit 9.6.7 Warning lights
(D790-1). D1: Diagnostic menu, see section 8 Control system ,
group 8.4.2.8 LIGHTS, menu 8
2 When the start key is turned to posi- U = 24 V Section 9 Frame, body, cab and accessories, group
tion I, it sends a voltage signal to the 9.1 Controls and instruments
cab control unit (D790-1). D2: Diagnostics menu, see section 8 Control system,
group 8.4.1.4 CAN/POWER, menu 4
3 The cab control unit (D790-1) sup- U = 24 V Cab control unit, description page 19
plies voltage to ignition voltage relay D3: Diagnostics menu, see section 8 Control system,
K315-1 in the frame electronic box group 8.4.1.4 CAN/POWER, menu 4
and ignition voltage relay K315-2.
6 Ignition voltage relay K315-2 supplies U = 24 V Control unit, engine, description (engine alternative
voltage to the engine control unit Volvo TWD1240VE) page 28
(D794).
7 Drivetrain’s CAN-bus establishes Checked by control Drivetrain CAN bus, description page 48
communication. system, error
shown with error
code.
8 Ignition voltage to the cab control unit UK1:2 = 24 V Cab control unit, description page 19
(D790-1). D8: Diagnostics menu, see section 8 Control system,
UK1:3 = 24 V
group 8.4.1.6 CAN/POWER, menu 6
UK1:4 = 24 V
9 Ignition voltage to Control unit, frame UK2:1 = 24 V Control unit, frame rear, description page 21
rear (D797-R). D9: Diagnostics menu, see section 8 Control system,
UK2:9 = 24 V
group 8.4.1.10 CAN/POWER, menu 10
10 Ignition voltage to Control unit, frame UK2:1 = 24 V Control unit, frame front, description page 20
front (D797-F). D10: Diagnostics menu, see section 8 Control sys-
UK2:9 = 24 V
tem, group 8.4.1.8 CAN/POWER, menu 8
UK2:10 = 24 V
11 Ignition voltage to Control unit, frame UK2:10 = 24 V Control unit, frame option, description page 22
option (D797-O). D11: Diagnostics menu, see section 8 Control sys-
tem, group 8.4.1.12 CAN/POWER, menu 12
12 Ignition voltage to the transmission UA1 = 24 V Transmission control unit, description page 27
control unit (D793). D12: Diagnostics menu, see section 8 Control sys-
tem, group 8.4.1.15 CAN/POWER, menu 15
Safety switch Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
3, 4 6
- +
D4 D5
D2
D7 D8
007422
D12 D11 D10 D9
2 The cab control unit (D790-1) supplies UK3009-1/86 = 24 V Cab control unit, description page 19
voltage to the emergency stop switch volt- D2: Diagnostics menu, see section 8 Con-
age relay (K3009-1) in the frame electron- trol system , group 8.4.1.5 CAN/POWER,
ic box. menu 5
3 The emergency stop switch voltage relay UK3009-2/87 = 24 V Electronic box frame, description page 17
(K3009-1) supplies voltage to the emer- D3: Diagnostics menu, see section 8 Con-
gency stop switch voltage relay (K3009-2) trol system , group 8.4.1.5 CAN/POWER,
in the frame electrical distribution box. menu 5
5 The cab control unit (D790-1) activates UK3009-2/86 = 24 V Cab control unit, description page 19
the emergency stop switch voltage relay D5: Diagnostics menu, see section 8 Con-
(K3009-2) in the electronic box. trol system , group 8.4.1.5 CAN/POWER,
menu 5
6 The emergency stop switch voltage relay UK3009-2/87 = 24 V Electronic box frame, description page 17
K3009-2 supplies voltage to emergency
stop switch circuit.
000039
Safety switch
The electronic box is mounted on the rear wall of the cab, on the left.
Located there are:
• Control unit cab (D790-1)
• Circuit fuses
6 • Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied
• Connectors
• Relays
•
Voltage converter 24 V to 12 V
• Connector customer accessory. Output voltage 24 V, max. 10 A.
1
Connector 2-pin Universal mate-n-lock. For part number see
Spare parts catalogue.
2
3 NOTE
This connector is not on the machine if the machine is
4 equipped with voltage converter.
5
008230
9 7
F5
68
8-1
X1
F5
K1
8-2
• Main fuses
8-3
K3 K4
K2
• Transmission control unit (D793)
8 • Power relays for voltage feed to the machine’s functions.
004923
1. Circuit fuses
2. Socket for programming transmission control unit
(D793)
3. Power relay (K315-1)
4. Main fuses
5. Transmission control unit (D793)
6. Main fuse
7. Relay (K315-2)
8. Power relay (K3009-1)
9. Power relay (K3009-2)
1 2 3 4 5
15
7
14
010503
13 12 11 10 9 8
The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3
000041
2 The cab control unit has four indicator lights that indicate the control
1. Connection terminals - fan, work lights, windscreen unit’s function (see illustration).
wiper
2. Connection terminals, other Light 1 Green light on when there is battery voltage to the unit.
3. Light 1, battery voltage The light is physically controlled by voltage feed to the
4. Light 2, redundant voltage feed, redundant CAN control unit.
bus and power supply Light 2 Flashes green when the redundant voltage feed to the
5. Light 3, communication control units and redundant CAN bus communication
6. Light 4, error indication are active. No power in the system.
Shines with a steady green when power electronics
and 15-voltage are supplied voltage.
Control unit, frame front (D797-F) processes input data from sensors
1 and sends control signals to relays and solenoid valves in the ma-
chine’s front half.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
D ANGER
The lowering speed must correspond. If speed lower-
ing is too high there is a risk of rollover.
Control unit, frame rear (D797-R) processes input data from sensors
1 and sends control signals to relays and solenoid valves for functions
in the machine’s rear half.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
1
Control unit, frame option (D797-O) is a unit that processes input data
2 from sensors and sends control signals to relays and solenoid valves
for the optional functions in the machine’s front half.
3
The control unit has four indicator lights that indicate the control unit’s
4 function (see illustration).
The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves for functions
for the top lift attachment.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
1
The attachment control unit, option (D791-2) processes input data
2 from sensors and sends control signals to relays and solenoid valves
for optional functions on the top lift attachment.
3
The control unit has four indicator lights that indicate the control unit’s
4 function (see illustration).
1
Control unit, attachment left jack pair (D791-3) processes input data
2 from sensors and sends control signals to relays and solenoid valves
to control the left jack pair on the attachment with lifting jacks. See sec-
3 tion 7 Load handling , group 7.9.2 Twistlock and lifting jacks.
4 The control unit has four indicator lights that indicate the control unit’s
function (see illustration).
6 Start the machine and drive to a free space. Operate the folding
DIAG COMBI 14(17) sequence for lifting jacks up and down. Use the diagnostic menu
SEQUENCE MODE Combi, menu 14 and check that the lifting jacks go through all the
LE RI sequence modes from 1-5.
FRONT X X
000227
REAR X X
Diagnostic menu Combi, menu 14
1
Control unit, attachment right jack pair (D791-4) processes input data
2 from sensors and sends control signals to relays and solenoid valves
to control the right jack pair on the attachment with lifting jacks. See
3 section 7 Load handling , group 7.9.2 Twistlock and lifting jacks.
4 The control unit has four indicator lights that indicate the control unit’s
function (see illustration).
6 5
Light 2 Flashes green when one or more of the following is
1. Light 1, battery voltage
missing: redundant voltage feed left, redundant volt-
2. Light 2, redundant voltage feed and power supply
age feed right or 15-voltage.
3. Light 3, communication
4. Light 4, error indication Shines green when redundant voltage feed left, redun-
5. Control signals (inputs and outputs) dant voltage feed right and 15-voltage are supplied
6. Power supply (redundant voltage feed for control voltage.
units, redundant CAN bus) and input data Light 3 Single yellow flash during communication with display
(KID) or cab control unit (D790-1).
Double yellow flash during communication with display
and cab control unit (D790-1).
6 Start the machine and drive to a free space. Operate the folding
DIAG COMBI 14(17) sequence for lifting jacks up and down. Use the diagnostic menu
SEQUENCE MODE Combi, menu 14 and check that the lifting jacks go through all the
LE RI sequence modes from 1-5.
FRONT X X
000227
REAR X X
Diagnostic menu Combi, menu 14
000045
Function button M Select display group.
1. Display
Function button S Select display group mode.
2. Status lights
3. Function keys Status light D Yellow light indicates test mode.
TWD1240VE)
The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
1 The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
2 The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
trol system.
007427
3
The control unit monitors the following values to optimise engine
Control unit, engine performance.
1. Connector 1 (black)
• engine rpm
2. Connector 2 (red)
3. Cooling duct for control unit (fuel) • camshaft’s position
• boost pressure
• charge-air temperature
• coolant temperature
• oil pressure
• oil temperature
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.
TAD1250VE)
The engine control unit (D794) is part of drivetrain control and handles
1 engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
2 communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
3 information on to other units.
The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
trol system.
007424
The control unit monitors the following values to optimise engine
Control unit, engine performance.
1. Cooling duct for control unit (fuel) • engine rpm
2. Connector A (black)
• camshaft’s position
3. Connector B (grey)
• boost pressure
• charge-air temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.
Cummins)
The engine control unit (D794) is part of drivetrain control and handles
1 2 3
engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
007423 trol system.
The control unit monitors the following values to optimise engine per-
formance.
1. Connector OEM
2. Connector, Actuator • engine rpm
3. Connector, Sensor • 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 cor-
rect fuel volume and to check the condition of the engine.
The KIT control unit (D790-2) handles functions for the gear selector
1 2
and multi-function lever, the direction indicator switch and start key po-
sitions II and III. It also handles the key panel (B) for the control system
and its panel for warning and indicator lights (A).
The KIT control unit (D790-2) has several individual function keys and
indicator lights (see illustration).
See the operator’s manual for detailed information on warning and in-
dicator lights and function keys.
000049
The KID control unit (D795) displays to the operator information sent
1 2 by the control unit, such as speed, in the form of messages, status, er-
ror indications, etc.
There is an indicator light to the right of the display that is activated
with a red light when there is a serious malfunction in the control sys-
tem. The error code and information are shown on the display.
See the operator’s manual for detailed information on the display.
000051
1. LCD display
2. Series of diodes that serve as an indicator light for
major error.
1
Control unit, cab option (D790-3) is only available on machines with
2 both combi attachment and joystick control or combi attachment and
mini-wheel. The control unit handles the signals to and from the joy-
3 stick or mini-wheel and sends the information further on the CAN bus.
4 The control unit has four indicator lights that indicate the control unit’s
function (see illustration).
6 5
Light 2 Flashes green when one or more of the following is
1. Light 1, battery voltage
missing: redundant voltage feed left, redundant volt-
2. Light 2, redundant voltage feed and power supply
age feed right or 15-voltage.
3. Light 3, communication
4. Light 4, error indication Shines green when redundant voltage feed left and
5. Control signals (inputs and outputs) right and 15-voltage are supplied voltage.
6. Power supply (redundant voltage feed for control Light 3 Single yellow flash during communication with either
units, redundant CAN bus) and input data KID control unit (D795) or cab control unit (D790-1).
Double yellow flash during communication with both
KID control unit (D795) and cab control unit (D790-1).
11.5.5 Cables
Connectors, overview
page
–
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
X051 Electronic box cab Power supply, Control unit cab (D790-1)
CAN-bus
X061 Electronic box cab Earth connection, Control unit KID (D795)
Power supply, Control unit KIT (D790-2)
Windscreen wiper front
Actuator, recirculation
X201 Electronic box frame Earth connection and power supply, Control unit transmission (D793)
X210 Between engine and transmission Power supply and earth connection, Control unit engine (D794)
CAN bus, Control unit engine (D794)
X211 Control unit, frame front (D797-F) 42-pin connector to Control unit, frame front (D797-F)
X212 Control unit, frame front (D797-F) Power supply and earth connection, Control unit, frame front (D797-F)
CAN bus, Control unit, frame front (D797-F)
Temperature brake fluid
Safety switch
X221 Control unit, frame rear (D797-R) 42-pin connector to Control unit, frame rear (D797-R)
X231 Frame option control unit (D797-O) 42-pin connector to Control unit, frame option (D797-O)
X232 Frame option control unit (D797-O) Power supply and earth connection, Control unit, frame option (D797-O)
CAN bus, Control unit, frame option (D797-O)
Safety switch
X235 Frame option control unit (D797-O) Solenoid valve steering left and right (joystick control or mini-wheel)
X251 Control unit transmission (D793), 30-pin connector for Transmission control unit (D793)
electronic box frame
X252 Control unit transmission (D793), 18-pin connector for Transmission control unit (D793)
electronic box frame
X254 Electronic box frame Power supply and earth connection Control unit transmission (D793)
X260 Electronic box frame CAN bus, Control unit transmission (D793)
X279 Engine Power supply and earth connection, Control unit engine (D794)
CAN-bus Drivetrain
X301 Boom mounting Fuse holder power supply and earth connection to boom and attachment
X400 Boom nose Fuse holder power supply and earth connection to boom and attachment
X401 Boom nose CAN bus control units on boom nose and attachment
Redundant power supply control units on boom nose and attachment
X411 Attachment control unit (D791-1) 42-pin connector for attachment control unit (D791-1)
X414 Boom nose CAN bus and power supply control unit attachment right jack pair
(D791-4)
X421 Attachment control unit, option 42-pin connector for Control unit, attachment option (D791-2)
(D791-2)
X422 Attachment control unit, option Power supply and earth connection, Control unit, attachment option
(D791-2) (D791-2)
CAN bus attachment option control unit (D791-2)
Safety switch
X431 Control unit, attachment left jack 42-pin connector for Control unit, attachment left jack pair (D791-3)
pair (D791-3)
X432 Control unit, attachment left jack Power supply and earth connection, Control unit, attachment left jack pair
pair (D791-3) (D791-3)
CAN bus, Control unit, attachment left jack pair (D791-3)
Safety switch
X434 Combi attachment, left side front Sensor, clamping position left front jack
Sensor, alignment left front jack
X435 Combi attachment, left side rear Sensor, clamping position left rear jack
Sensor, alignment left rear jack
X441 Control unit, attachment right jack 42-pin connector for Control unit, attachment right jack pair (D791-4)
pair (D791-4)
X442 Control unit, attachment right jack Power supply and earth connection, Control unit, attachment right jack
pair (D791-4) pair (D791-4)
CAN bus, Control unit, attachment right jack pair (D791-4)
Safety switch
X443 Control unit, attachment right jack Solenoid valve, tilt in and out
pair (D791-4) Indicator lights: Front jacks up and down
Indicator lights: Clamping position front and rear jacks
X444 Combi attachment, right side front Sensor, clamping position right front jack
Sensor, alignment right front jack
Analogue inputs
Rheostat Resistance input 0–200 Ω. Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is equiva- E.g. hydraulic oil temper-
lent to temperature and the work range of approx. -40 to 150 °C. ature sensor and climate
There are two different resistance curves - one for the cab control unit control system tempera-
(D790-1) and one for the frame and attachment control units. ture sensor.
Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the slide in a solenoid valve gets hot, resistance drops. This gener- tional solenoid valves.
ates a lower current through the valve slide, which can cause the valve’s
servo pressure to remain constant. An internal ampermeter measures
current in the circuit and regulates the voltage level in order to maintain
the desired current value in the valve slide.
Voltage out, PNP A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. interior lighting and
PWM a grounding point as reference. background illumination
in switches.
Voltage out, re- A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
versed polarity, 24 V as reference.
NPN PWM
Digital inputs
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. input signal from a
with pull down and Signal in, U > 16 V generates logic one (1) breaker with search light-
search lighting ing.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. position sensors (in-
with pull down Signal in, U > 12 V generates logic one (1) ductive sensors) and
brake pressure (pressure
If there is no signal in, the input is grounded. switches).
Bandwidth 300 Hz, i.e. designed for slow sensors.
Digital outputs
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. side marker lights,
1.5 A Max. load 1.5 A solenoid valves.
High side driver, 5 Logic one (1) generates voltage out, U >= 22.5 V E.g. work lighting and
A Max. load 5 A wiper motors.
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A Max. load 10 A This output is only found
Open load 1.9 A on the frame and attach-
ment control units.
Max. instantaneous current load, 70 A
H-bridge Logic one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. climate control sys-
U=0V tem water valve (works in
Max. load 0.5 A both directions).
11.6 Communication
11.6.1 CAN-bus
CAN bus, description
page
–
a sharp signal.
• that the signal valve is given as the potential difference between
3 the cables, CAN + and CAN - (position 2 and 3).
000026
t [S]
• form of signal messages.
Messages 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
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
plete message is approx. 100 bits long. The illustration depicts how a
t [S]
message is structured.
Messages are sequential and signal is high (voltage
high) or low (voltage low). Start bit (B)
A. Length message Indicates that the transmission of a frame, i.e. a message, is now be-
B. Start bit ginning.
C. Identity field/Priority Identity field (C)
D. Check field (length of data segment)
E. Data segment Indicates what kind of information the message contains, e.g. meas-
F. Checksum for error detection urement information on engine speed.
G. Acknowledgement bit Does not indicate address to control unit. CAN does not work with ad-
dressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one control
Potential levels CAN + and CAN -
unit.
One control unit at a time sends the message. Other control units lis-
ten and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest prior-
ity (highest value in identity field) is concluded. This means that mes-
sages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the net-
work.
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 pro-
tocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages (divi-
sion)
• how control units are addressed in the network
• how bits in the message's data field shall be interpreted
and the engine control unit (D794). These have a separate CAN bus;
see Drivetrain CAN bus, description page 48.
Redundant CAN bus means that the control units are connected to a
D790-1 D790-2 D795
CAN R CAN L CAN R CAN L network that communicates via a CAN bus (see CAN bus, description
page 43) and that there are double communication routes on the net-
work. The network is divided into control units and segments (seg-
CAN L CAN R CAN L CAN R CAN L CAN R
003170
D797-R D797-O D797-F ments are cables between the control units). The number of active
segments depends on the number of control units the machine has,
Principle illustration, redundant CAN bus which depends on the machine’s equipment level (options).
The network is built on the CAN kingdom principle, which means that
one control unit is central and is the master unit. In this case, it is the
cab control unit (D790-1). Other control units in the network are sec-
ondary (slaves) and handle special areas, e.g. cab components.
The control units have two CAN bus connections - CAN L (left) and
CAN R (right). The control units are connected to one another in series
in a loop.
The redundant CAN bus can handle the loss of a segment. The link is
analysed upon start-up. If a segment is faulty, messages are sent via
another route.
If several segments are lost, one or more control units lose communi-
cation and work independently, often with significantly limited function-
ality.
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.
Redundant voltage feed Activated. Redundant voltage feed for control units, description of operation page 7
S5
S2
D791-1 S2
D791-2
22 3
10 D790-2 S3
S9 S8
S1 D790-1 S5
D795 S4
1, 11 9
S3
D791-3 S4 D791-4
D797-R D797-F
4 5
6 S6 D797-O S7 8
7
013023
The illustration shows two alternatives for how the segment numbering
is 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.
2 The attachment control unit (D791-1) A clicking sound is Attachment control unit, description page 23
sends a response back on the CAN bus audible when then Diagnostic menu, see section 8 Control sys-
via CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. activated. 8.4.1.2 CAN/POWER, menu 2
Termination resistors in the control
nodes ensure communication segment
by segment.
4 Control unit, attachment left jack pair A clicking sound is Control unit, attachment left jack pair, descrip-
(D791-3) sends a response back on the audible when then tion page 25
CAN bus via CAN L and sends the re- termination resistor is Diagnostic menu, see section 8 Control sys-
quest on via CAN R. activated. tem, group 8.4.1.1 CAN/POWER, menu 1 and
Termination resistors in the control 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
5 Control unit, attachment right jack pair A clicking sound is Control unit, attachment right jack pair, descrip-
(D791-4) sends a response back on the audible when then tion page 26
CAN bus via CAN L and sends the re- termination resistor is Diagnostic menu, see section 8 Control sys-
quest on via CAN R. activated. tem, group 8.4.1.1 CAN/POWER, menu 1 and
Termination resistors in the control 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
6 Control unit, frame rear (D797-R) sends A clicking sound is Control unit, frame rear, description page 21
a response back on the CAN bus via audible when then Diagnostic menu, see section 8 Control sys-
CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. activated. 8.4.1.2 CAN/POWER, menu 2
Termination resistors in the control
nodes ensure communication segment
by segment.
7 Control unit, frame option (D797-O) A clicking sound is Control unit, frame option, description page 22
sends a response back on the CAN bus audible when then Diagnostic menu, see section 8 Control sys-
via CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. activated. 8.4.1.2 CAN/POWER, menu 2
Termination resistors in the control
nodes ensure communication segment
by segment.
8 Control unit, frame front (D797-F) sends A clicking sound is Control unit, frame front, description page 20
a response back on the CAN bus via audible when then Diagnostic menu, see section 8 Control sys-
CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. activated. 8.4.1.2 CAN/POWER, menu 2
Termination resistors in the control
nodes ensure communication segment
by segment.
10 The KIT control unit (D790-2) is not con- A clicking sound is KIT control unit, description page 30
nected to the redundant CAN bus. The audible when then
KIT control unit (D790-2) does not com- termination resistor is
municate until ignition voltage (15) is ac- activated.
tivated.
11 If all control units have responded, the Checked by control Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) deactivates system, error shown tem, group 8.4.1.1 CAN/POWER, menu 1 and
the segment to the attachment control with error code. 8.4.1.2 CAN/POWER, menu 2
unit (D791-1).
If a control unit has not responded, the
cab control unit (D790-1) uses both
CAN L and CAN R to keep communica-
tion open and analyses which segment
is faulty.
The drivetrain CAN bus is based on the SAE J1939 standard where
4 6
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)
for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
Control units for engine and transmission come from the respective
transmission and engine supplier. The control units use the same
standard of communication and therefore the messages for each en-
gine are constructed using the same structure.
Communication with engine control unit (D794) and transmission con-
trol unit (D793) are separate from the redundant CAN bus.
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.1.3 CAN/POWER, menu 3.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Control unit, engine
4. Engine
5. Control unit transmission
6. Transmission
description
The machine has three or four sockets for communication between
control units and PC. Two are located in electronic box cab and one or
1 two in electronic box cab frame. It is the socket for communication with
engine alternative Volvo that varies.
2 Sockets for programming control units in the cab electrical distribution
box (position 1) are used for programming the control units in the cab,
on the frame, and on the attachment.
The socket for CAN bus drivetrain in the cab electronic box (position
2) is used for communicating with the engine and transmission via
CAN bus.
The VODIA socket in the frame electronic box (position 3) (Volvo en-
gine only) is used to connect the Volvo’s diagnostic tool - VODIA.
The socket for transmission control unit (D793) programming in the
frame electronic box (position 4) is used to program the transmission
control unit (D793).
For further details on communication between computer and machine,
contact Cargotec.
3
4
006887
Remote Machine Interface is a tool for reading data from the machine
at a distance. The RMI consists of a control unit which is connected to
007443
the machine, antenna for communication and GPS-antenna ( ) for
positioning.
RMI interface (A911)
RMI interface (A911) records communication on the CAN bus and
sends the information to a central RMI server. In the event of a fault in
the machine the control unit can send the information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.
From the RMI-server, data from the machine can be analysed and
processed for reading out different values. For example, when it is
time for service or if there are error codes stored in the machine.
NOTE
RMI only sends data from the machine, but no data can be sent
010504
010504
nection to external devices according to a predetermined protocol.
D Error codes
D Error codes
mm mm mm mm mm mm
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's
D E generated.
• Limitation, in case of certain error codes certain functions are im-
B
000389
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
000389
• Field D: Indicates type of error.
• Field E: Indicates which function is affected by error code.
• The book symbol means that there's information in the operator's
manual.
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
The error code is shown automatically on the display.
000351
• Information
C Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
D E See section 6 Inspection and maintenance in the Operator’s
manual.
000352
The error code is stored in the error code list under operating
menu for service.
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
7
000396
NOTE
In case of an error code, perform the actions recommended in the
error code table to find the problem.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading out error codes, other-
wise there is a risk of missing error codes.
1 Turn the start key to position I.
WARN IN G
Risk of machine damage.
1 23
4 5
000060
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number togeth-
er with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.
000389
• Function affected by the error is shown with a symbol in
field E
The book symbol is an instruction for the operator to read the
operator’s manual.
6 Use the error code tables to find more information about the error
code.
7 After action, check that no active error codes remain for the func-
tion in question.
1 Engine
mm mm mm mm mm mm
1 Too low value. Valid data, but lower than normal operating range.
alternative Volvo)
Description Limitation Action Connec- Diagnos-
tions and tic menu
components
Code J1587
94/FMI PID94/ Fuel pressure No limitation. Check cabling between Volvo -
FMI sensor, short control unit and compo- TWD1240VE:
circuited to volt- nent. D794/2:3
age, ground, or Check the sensor. Volvo
open circuit. TAD1250VE:
D794/B:16
98/FMI PID98/ Low oil level. No limitation. Check oil level. - ENGINE,
FMI menu 6
98/FMI PID98/ Oil level sensor, No limitation. Check cabling between Volvo ENGINE,
FMI short circuited to control unit and compo- TAD1250VE: menu 6
voltage, ground, nent. D794/B:3, B:4,
or open circuit. Check the sensor. A:31
100/1 PID100/1 Low engine oil Engine will shut Check oil level. - ENGINE,
pressure. down. Change oil filter. menu 6
Code J1587
100/3 PID100/3 Sensor oil pres- No limitation. Check cabling between Volvo ENGINE,
sure, cable short control unit and TWD1240VE: menu 6
circuited to supply component. D794/1:14
voltage. Check the sensor. Volvo
TAD1250VE:
D794/B:11
100/4 PID100/4 Oil pressure sen- No limitation. Check cabling between Volvo ENGINE,
sor, open circuit control unit and TWD1240VE: menu 6
or short circuit to component. D794/1:14
ground. Check the sensor. Volvo
TAD1250VE:
D794/B:11
102/1 PID102/1 Boost pressure Reduced en- Check the air filter. - ENGINE,
low. gine power. Check the turbocharger. menu 6
102/3 PID102/3 Sensor boost The engine jerks Check cabling between Volvo ENGINE,
pressure, cable more than nor- control unit and compo- TWD1240VE: menu 7
short-circuited to mal during ac- nent. D794/1:3
voltage. celeration or Check the sensor. Volvo
under load. TAD1250VE:
D794/A:22
102/4 PID102/4 Boost pressure The engine jerks Check cabling between Volvo ENGINE,
sensor, cable more than nor- control unit and compo- TWD1240VE: menu 7
short circuited to mal during ac- nent. D794/1:3
ground or open celeration or Check the sensor. Volvo
circuit. under load. TAD1250VE:
D794/A:22
105/0 PID105/0 High charge-air Engine will shut Check coolant level. - ENGINE,
temperature. down. Check that the charge-air menu 7
cooler is clean.
Check thermostat.
Check the sensor.
Code J1587
105/3 PID105/3 Charge air tem- No limitation. Check cabling between Volvo ENGINE,
perature sensor, control unit and compo- TWD1240VE: menu 7
cable short nent. D794/1:2
circuited to supply Check the sensor. Volvo
voltage or open TAD1250VE:
circuit. D794/A:47
105/4 PID105/4 Charge air tem- No limitation. Check cabling between Volvo ENGINE,
perature sensor, control unit and compo- TWD1240VE: menu 7
cable short nent. D794/1:2
circuited to Check the sensor. Volvo
ground or open TAD1250VE:
circuit. D794/A:47
106/FMI PID106/ Boost pressure The engine jerks Check cabling between Volvo ENGINE,
FMI sensor, short cir- more than nor- control unit and compo- TWD1240VE: menu 6
cuit to voltage, mal during ac- nent. D794/1:3
ground or open celeration or Check the sensor. Volvo
circuit. under load. TAD1250VE:
D794/A:22
110/0 PID110/0 High coolant tem- Volvo Check coolant level. - ENGINE,
perature. TWD1240VE: Check that radiator is menu 7
Engine will shut clean.
down.
Check thermostat.
Volvo
TAD1250VE: No Check the cap on the ex-
pansion tank.
limitation.
Check if there’s air in
coolant system.
Check the sensor.
110/3 PID110/3 Coolant tempera- Preheating is ac- Check cabling between Volvo ENGINE,
ture sensor, cable tivated even if control unit and compo- TWD1240VE: menu 7
short circuited to engine is warm. nent. D794/1:25
supply voltage or Check the sensor. Volvo
open circuit. TAD1250VE:
D794/B:27
Code J1587
110/4 PID110/4 Coolant tempera- Preheating is ac- Check cabling between Volvo ENGINE,
ture sensor, cable tivated even if control unit and compo- TWD1240VE: menu 7
short circuited to engine is warm. nent. D794/1:25
ground. Check the sensor. Volvo
TAD1250VE:
D794/B:27
111/1 PID111/1 Low coolant level. Volvo Check the coolant level, - -
TAD1250VE: top up if needed.
Engine will shut Check the sensor.
down.
Volvo
TAD1250VE: No
limitation.
111/FMI PID111/ Coolant level sen- Volvo Check cabling between Volvo -
FMI sor, short TWD1240VE: control unit and compo- TWD1240VE:
circuited to Engine will shut nent. D794/2:7
voltage. down. Check the sensor. Volvo
Volvo TAD1250VE:
TAD1250VE: No D794/B:23
limitation.
158/FMI PID158/ Low battery Engine may be Check and charge the - -
FMI voltage. difficult to start. batteries.
Check the alternator.
Check the battery ca-
bles.
Code J1587
172/FMI PID172/ Intake air temper- No limitation. Check cabling between Volvo ENGINE,
FMI ature sensor, control unit and compo- TWD1240VE: menu 7
short circuit to nent. D794/1:2
voltage, ground, Check the sensor. Volvo
or open circuit. TAD1250VE:
D794/A:47
175/0 PID175/0 High engine oil Reduced en- Check oil level. - ENGINE,
temperature. gine power. Check the lubrication menu 7
system’s thermostat.
Check the sensor.
175/3 PID175/3 Oil temperature No limitation. Check cabling between Volvo ENGINE,
sensor, cable control unit and compo- TWD1240VE: menu 7
short circuited to nent. D794/1:1
supply voltage or Check the sensor. Volvo
open circuit. TAD1250VE:
D794/A:31,
B:3, B:4
175/4 PID175/4 Oil temperature No limitation. Check cabling between Volvo ENGINE,
sensor, cable control unit and compo- TWD1240VE: menu 7
short circuited to nent. D794/1:1
ground. Check the sensor. Volvo
TAD1250VE:
D794/A:31,
B:3, B:4
190/FMI PID190/ Engine rpm too No limitation. Ease off throttle or select - -
FMI high. higher gear.
608/FMI PPID98/ Signal error for No limitation. Check the CAN bus driv- - CAN/
FMI start and stop. etrain. POWER,
menu 3
620/3 SID232/3 Voltage feed to Several error Check cabling between Volvo -
1079/2 sensor, cable codes for sensor control unit and compo- TWD1240VE:
short circuited to error. nent. D794/1:5
voltage. Reduced en- Volvo
gine power. TAD1250VE:
Incorrect instru- D794/B:17
ment values.
Code J1587
620/4 SID232/4 Voltage feed to Several error Check cabling between Volvo -
1079/3 sensor, cable codes for sensor control unit and compo- TWD1240VE:
short circuited to error. nent. D794/1:4
ground. Reduced en- Volvo
gine power. TAD1250VE.
Incorrect instru- D794/B:17
ment values.
626/3 PID45/3 Preheating relay, Preheating can- Check cabling between Volvo ENGINE,
cable short not be activated. control unit and compo- TWD1240VE: menu 5
circuited to volt- nent. D794/2:36
age. Check the relay. Volvo
TAD1250VE:
D794/B:25
626/4 PID45/4 Preheating relay, Preheating is Check cabling between Volvo ENGINE,
cable short continually acti- control unit and compo- TWD1240VE: menu 5
circuited to vated. nent. D794/2:36
ground. Check the relay. Volvo
TAD1250VE:
D794/B:25
626/5 PID45/5 Preheating relay, Preheating can- Check cabling between Volvo ENGINE,
open circuit on ca- not be activated. control unit and compo- TWD1240VE: menu 5
ble or defective nent. D794/2:36
component. Check the relay. Volvo
TAD1250VE:
D794/B:25
629/FMI SID254/ Engine control The engine will Change the control unit. - -
FMI unit (D794), inter- not start.
nal fault. Engine runs
roughly.
630/FMI SID253/ Engine control The engine will Re-program the control - -
FMI unit (D794), mem- not start. unit.
ory error.
636/3 SID21/3 Sensor rpm cam- Engine takes Check cabling between Volvo -
shaft, no signal. longer time to control unit and compo- TWD1240VE:
start than nor- nent. D794/1:7, 1:18
mal. Engine runs Check the sensor. Volvo
normally when it TAD1250VE:
has started. D794/B:45,
B:46
Code J1587
636/8 SID21/8 Sensor engine Engine takes Check cabling between Volvo -
rpm, camshaft, longer time to control unit and compo- TWD1240VE:
abnormal fre- start than nor- nent. D794/1:7, 1:18
quency. mal. Engine runs Check the sensor. Volvo
normally when it TAD1250VE:
has started. D794/B:45,
B:46
637/2 SID22/2 Engine speed Engine is ex- Check cabling between Volvo ENGINE,
sensor, flywheel, tremely difficult control unit and compo- TWD1240VE: menu 2
irregular signal. to start and runs nent. D794/1:30,
rough, if it starts. Check the sensor. 1:31
Volvo
TAD1250VE:
D794/B:37,
B:38
637/3 SID22/3 Sensor engine Engine is ex- Check cabling between Volvo ENGINE,
rpm, flywheel, ab- tremely difficult control unit and compo- TWD1240VE: menu 2
normal frequency. to start and runs nent. D794/1:30,
rough, if it starts. Check the sensor. 1:31
Volvo
TAD1250VE:
D794/B:37,
B:38
637/8 SID22/8 Sensor engine Engine is ex- Check cabling between Volvo ENGINE,
rpm, flywheel, ab- tremely difficult control unit and compo- TWD1240VE: menu 2
normal frequency. to start and runs nent. D794/1:30,
rough, if it starts. Check that the sensor is 1:31
connected correctly. Volvo
TAD1250VE:
D794/B:37,
B:38
639/FMI SID231/ Communication Engine off: en- Use diagnostic menu to Volvo CAN/
FMI error with Engine gine cannot be find incorrect segment. TWD1240VE: POWER,
control unit started. Check cabling between D794/2:1, 2:2 menu 3
(D794), configu- Engine on: en- control unit and compo- Volvo
ration error. gine goes to idle nent. TAD1250VE:
and can only be Check the control unit. D794/B:51,
stopped by us- B:55
ing the emer-
gency stop.
Code J1587
639/FMI SID231/ Communication Instruments and Use diagnostic menu to - CAN/
FMI error with Engine controls do not find incorrect segment. POWER,
control unit work. Check cabling between menu 3
(D794), configu- control unit and compo-
ration error. nent.
Check the control unit.
651/2 SID1/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:11,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
651/3 SID1/3 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:11,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
651/4 SID1/4 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:11,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
651/5 SID1/5 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:11,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
Code J1587
651/7 SID1/7 Incorrect com- Runs rough at Check fuel pressure. Volvo -
pression or defec- low rpm and low Check valve clearance. TWD1240VE:
tive injector load. D794/1:11,
cylinder 1. Check cabling between 1:12
control unit and compo-
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:20,
Perform compression A:24
test and check cylinder 1.
651/11 SID1/11 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:11,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
652/2 SID2/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:22,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:20,
A:24
652/3 SID2/3 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:22,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:12,
A:16
652/4 SID2/4 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:22,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:12,
A:16
Code J1587
652/5 SID2/5 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 1. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:22,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:12,
A:16
652/7 SID2/7 Incorrect com- Runs rough at Check fuel pressure. Volvo -
pression or defec- low rpm and low Check valve clearance. TWD1240VE:
tive injector load. D794/1:22,
Check cabling between
cylinder 2. 1:12
control unit and compo-
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:12,
Perform compression A:16
test and check cylinder 2.
652/11 SID2/11 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 2. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:22,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:12,
A:16
653/2 SID3/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 3. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:23,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:28,
A:32
653/3 SID3/3 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 3. cylinders, control unit and compo- TWD1240VE.
sounds rough nent. D794/1:23,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:28,
A:32
Code J1587
653/4 SID3/4 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 3. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:23,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:28,
A:32
653/5 SID3/5 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 3. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:23,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:28,
A:32
653/7 SID3/7 Incorrect com- Runs rough at Check fuel pressure. Volvo -
pression or defec- low rpm and low Check valve clearance. TWD1240VE:
tive injector load. D794/1:23,
Check cabling between
cylinder 3. 1:12
control unit and compo-
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:28,
Perform compression A:32
test and check cylinder 3.
653/11 SID3/11 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 3. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:23,
and has reduced Check the injector. 1:12
power. Volvo
TAD1250VE:
D794/A:28,
A:32
654/2 SID4/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 4. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:34,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:52,
A:56
Code J1587
654/3 SID4/3 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 4. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:34,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:52,
A:56
654/4 SID4/4 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 4. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:34,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:52,
A:56
654/5 SID4/5 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 4. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:34,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:52,
A:56
654/7 SID4/7 Incorrect com- Runs rough at Check fuel pressure. Volvo -
pression or defec- low rpm and low Check valve clearance. TWD1240VE:
tive injector load. D794/1:34,
Check cabling between
cylinder 4. 1:24
control unit and compo-
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:52,
Perform compression A:56
test and check cylinder 4.
654/11 SID4/11 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 4. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:34,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:52,
A:56
Code J1587
655/2 SID5/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 5. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:35,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:44,
A:48
655/3 SID5/3 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 5. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:35,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:44,
A:48
655/4 SID5/4 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 5. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:35,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:44,
A:48
655/5 SID5/5 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 5. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:35,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:44,
A:48
655/7 SID5/7 Incorrect com- Engine runs on 5 Check that cabling to the Volvo -
pression or defec- cylinders, injectors is not damaged. TWD1240VE:
tive injector sounds rough Check cabling between D794/1:35,
cylinder 5. and has reduced control unit and compo- 1:24
power. nent. Volvo
Check the injector. TAD1250VE:
D794/A:44,
Perform compression
A:48
test and check cylinder 5.
Code J1587
655/11 SID5/11 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 5. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:35,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:44,
A:48
656/2 SID6/2 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 6. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:36,
and has reduced Check the component. 1:24
power. Volvo
TAD1250VE:
D794/A:36,
A:40
656/3 SID6/3 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 6. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:36,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:36,
A:40
656/4 SID6/4 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 6. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:36,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:36,
A:40
656/5 SID6/5 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 6. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:36,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE:
D794/A:36,
A:40
Code J1587
656/7 SID6/7 Incorrect com- Runs rough at Check fuel pressure. Volvo -
pression or defec- low rpm and low Check valve clearance. TWD1240VE:
tive injector load. D794/1:36,
cylinder 6. Check cabling between 1:24
control unit and compo-
nent. Volvo
TAD1250VE:
Check the injector.
D794/A:36,
Perform compression A:40
test and check cylinder 6.
656/11 SID6/11 Electric failure, in- Engine runs on 5 Check cabling between Volvo -
jector cylinder 6. cylinders, control unit and compo- TWD1240VE:
sounds rough nent. D794/1:36,
and has reduced Check the injector. 1:24
power. Volvo
TAD1250VE
D794/A:36,
A:40
677/FMI PPID3/ Starter motor re- The engine will Check cabling between Volvo ENGINE,
FMI lay, short circuit to not start. control unit and compo- TWD1240VE: menu 5
SID39/ voltage/ground. Engine starts im- nent. D794/2:31
FMI mediately when Check the motor. Volvo
ignition is turned TAD1250VE
on. D794/B:29
1485/3 PPID5/3 Main relay, cable The instrument Check cabling between Volvo -
short circuited to panel loses volt- control unit and compo- TWD1240VE:
voltage. age when the ig- nent. D794/1:32
nition key is Check the relay. Volvo
turned to the TAD1250VE:
start position. D794/A:8
The engine will
not start.
2017/ PSID201 Communication Engine off: en- Use diagnostic menu to Volvo CAN/
FMI /FMI error with Engine gine cannot be find incorrect segment. TWD1240VE: POWER,
control unit started. Check cabling between D794/2:1, 2:2 menu 3
(D794), configu- Engine on: en- control unit and compo- Volvo
ration error. gine goes to idle nent. TAD1250VE:
and can only be Check the control unit. D794/B:51,
stopped by us- B:55
ing the emer-
gency stop.
Code J1587
2047/xx Undetectable er- - Contact the engine sup- D794 -
ror code from the plier for further informa-
engine. tion.
Error codes
above 2047 can-
not be shown in
the display.
Possible error
codes: 2791,
520192, 520194,
520195.
2791/3 PPID19 Internal EGR: The engine con- Check the wiring (boost Volvo -
Wiring error trol unit limits en- pressure sensor). TAD1250VE:
(boost pressure gine output. Contact an authorised D794/B:30
sensor). IEGR cannot be Volvo Penta workshop.
Mechanical error activated. Check the component
on IEGR. (IEGR).
2791/4 PPID19 Internal EGR: The engine con- Check the wiring (boost Volvo -
Wiring error trol unit limits en- pressure sensor). TAD1250VE:
(boost pressure gine output. Contact an authorised D794/B:30
sensor). IEGR cannot be Volvo Penta workshop.
Mechanical error activated. Check the component
on IEGR. (IEGR).
2791/5 PPID19 Internal EGR: The engine con- Check the wiring (boost Volvo -
Wiring error trol unit limits en- pressure sensor). TAD1250VE:
(boost pressure gine output. Contact an authorised D794/B:30
sensor). IEGR cannot be Volvo Penta workshop.
Mechanical error activated. Check the component
on IEGR. (IEGR).
2791/7 PPID19 Internal EGR: Could damage Check the wiring (boost Volvo -
Mechanical error the turbine pressure sensor). TAD1250VE:
on IEGR. wheel of the tur- Contact an authorised D794/B:30
bocharger and Volvo Penta workshop.
increase force
Check the component
and emissions.
(IEGR).
Code J1587
520192/ PPID8 Low piston cool- No limitation. Check that engine oil - -
3 ing pressure. pressure is over 175 kPa.
520194/ PPID4 Start input CIU: Engine cannot Check that start key con- D794 -
3 Short circuited to be started. nections are not dam-
minus (-). Engine starts im- aged.
520194/ PPID4 Start input CIU: Engine cannot Check that start key con- D794 -
4 Short circuited to be started. nections are not dam-
minus (-). Engine starts im- aged.
520195/ PPID6 Stop input on con- The engine can Check that the connec- Volvo -
4 trol unit: only be stopped tions and wiring are not TAD1250VE:
Short circuited to with the auxiliary damaged. D794/B:27
minus (-). stop. Volvo
Activated too TWD1240VE:
long. D794/2:6
91/3 PID091/3 Electrical error, ac- Engine does not Check cabling between - -
celerator pedal, ca- respond to throt- control unit and compo-
ble short circuited to tle. nent.
supply voltage. Check the component.
91/4 PID091/4 Electrical error, ac- Engine does not Check cabling between - -
celerator pedal, ca- respond to throt- control unit and compo-
ble short circuited to tle. nent.
ground. Check the component.
91/8 PID091/8 Electrical error, ac- Engine does not Check cabling between - -
celerator pedal, low respond to throt- control unit and compo-
frequency. tle. nent.
Check the component.
91/8 PID091/8 Electrical error, ac- Engine does not Check cabling between - -
celerator pedal, high respond to throt- control unit and compo-
frequency. tle. nent.
Check the component.
91/19 SID091/2 Communication er- Engine will only Use diagnostic menu to - CAN/
ror with cab control idle. find incorrect segment. POWER,
unit (D790-1), electri- menu 3
cal error, accelerator
pedal.
97/3 PID097/3 Electrical error, wa- No limitation. Check cabling between D794/Sen- -
ter-in-fuel sensor, control unit and compo- sor:09
cable short circuited nent.
to supply voltage. Check the component.
97/15 PID097/ Water in fuel. Risk of white ex- Drain water from the fuel - -
15 haust smoke and filter.
reduced engine
output.
100/1 PID100/1 Low engine oil pres- Engine output is Check the engine oil lev- - ENGINE,
sure. reduced gradually. el; fill as necessary. menu 6
The engine is
switched off after
30 seconds.
100/2 PID100/2 Oil pressure sensor, No warning of low Check the sensor. D794/Sen- ENGINE,
data error. engine oil pres- sor:44 menu 6
sure.
100/3 PID100/3 Sensor oil pressure, No warning of low Check cabling between D794/Sen- ENGINE,
cable short circuited engine oil pres- control unit and compo- sor:44 menu 6
to supply voltage. sure. nent.
Check the sensor.
100/4 PID100/4 Oil pressure sensor, No warning of low Check cabling between D794/ ENGINE,
open circuit or short engine oil pres- control unit and compo- Black:14 menu 6
circuit to ground. sure. nent.
Check the sensor.
100/18 PID100/1 Low engine oil pres- No limitation. Check oil level in the en- - ENGINE,
sure. gine, top up as needed. menu 6
Check the sensor.
102/2 PID102/2 Boost pressure sen- Reduced engine Check cabling between D794/Sen- ENGINE,
sor indicates high power. control unit and compo- sor:39 menu 7
boost pressure but nent.
other engine data in- Check the sensor.
dicates that pressure
should be normal.
102/3 PID102/3 Sensor boost pres- Reduced engine Check cabling between D794/Sen- ENGINE,
sure, cable short- power. control unit and compo- sor:39 menu 7
circuited to voltage. nent.
Check the sensor.
105/0 PID105/0 Intake air too hot. Engine output is Check the coolant level in - ENGINE,
reduced gradually. the engine, top up as menu 7
The engine is needed.
switched off after Check that the charge-air
30 seconds. cooler is clean, clean as
needed.
Check that the fan belts
are intact. Check the in-
take air temperature sen-
sor.
105/3 PID105/3 Charge air tempera- Risk of white ex- Check cabling between D794/Sen- ENGINE,
ture sensor, cable haust smoke. No control unit and compo- sor:38 menu 7
short circuited to warning of high nent.
supply voltage or coolant tempera- Check that the charge air
open circuit. ture. temperature sensor is
correctly installed and
connected.
Check the charge air
temperature sensor.
105/4 PID105/4 Charge air tempera- Risk of white ex- Check cabling between D794/Sen- ENGINE,
ture sensor, cable haust smoke. No control unit and compo- sor:38 menu 7
short circuited to warning of high nent.
ground or open cir- coolant tempera- Check that the sensor is
cuit. ture. correctly installed and
connected.
Check the sensor.
108/2 PID108/2 Electrical error, air Reduced engine Check the sensor. - -
pressure sensor, power.
data error.
108/3 PID108/3 Electrical error, air Reduced engine Check cabling between D794/Sen- -
pressure sensor, ca- power. control unit and compo- sor:06
ble short circuited to nent.
supply voltage. Check the sensor.
110/0 PID110/0 High coolant temper- Engine output is Check coolant level. - ENGINE,
ature. reduced gradually. Check that radiator is menu 7
The engine is clean.
switched off after
30 seconds. Check if there’s air in
coolant system.
Check the cap on the ex-
pansion tank.
Check the sensor.
Check thermostat.
110/3 PID110/3 Coolant temperature No indication of Check cabling between D794/Sen- ENGINE,
sensor, cable short engine tempera- control unit and sor:02 menu 7
circuited to supply ture. component.
voltage or open
circuit.
110/4 PID110/4 Coolant temperature No indication of Check cabling between D794/Sen- ENGINE,
sensor, cable short engine tempera- control unit and compo- sor:02 menu 7
circuited to ground. ture. nent.
Check that the sensor is
connected correctly.
Check the sensor.
111/1 PID111/1 Low coolant level. Engine output is Check the coolant level, - -
reduced gradually. top up if needed.
The engine is Check the sensor.
switched off after
30 seconds.
111/2 PID111/2 Electrical error, cool- No warning of low Check cabling between D794/Sen- -
ant level sensor, coolant level. control unit and compo- sor:09
data error. nent.
Check the sensor.
166/2 PID116/2 Output imbalance Uneven idling. Check the fuel quality. - -
between cylinders. The error code could be
generated if the fuel sys-
tem is opened, allowing
air to enter the system.
Troubleshoot the engine.
167/16 PID167/0 Low battery voltage. Warning active Check fuses. Check bat- D794/ -
until voltage is cor- teries and alternator. OEM:7, 8,
rect. 17, 18, 28
167/18 PID167/1 High battery voltage. Warning active Check batteries and al- D794/ -
until voltage is cor- ternator. OEM:7, 8,
rect. The engine 17, 18, 28
runs at increased
idle to increase
voltage.
168/16 PID168/0 High voltage supply No limitation. Check fuses. Check bat- D794/ -
to control unit. teries and alternator. OEM:7, 8,
17, 18, 28
168/18 PID168/1 Low voltage supply Uneven idling. Check fuses. Check bat- D794/ -
to control unit. teries and alternator. OEM:7, 8,
17, 18, 28
175/0 PID175/0 High engine oil tem- Engine output is Check the engine coolant - ENGINE,
perature. reduced gradually. and oil level. Top up as menu 7
The engine is necessary.
switched off after Check that the oil cooler
30 seconds. is clean; clean as need-
ed.
Check that the fan belts
are intact.
Check the sensor.
175/3 PID175/3 Oil temperature sen- No indication of Check cabling between D794/Sen- ENGINE,
sor, cable short engine oil temper- control unit and compo- sor:42 menu 7
circuited to supply ature. nent.
voltage or open cir- Check that the sensor is
cuit. connected correctly.
175/4 PID175/4 Oil temperature sen- No indication of Check cabling between D794/Sen- ENGINE,
sor, cable short engine oil temper- control unit and compo- sor:42 menu 7
circuited to ground. ature. nent.
Check the sensor.
190/0 PID190/0 Engine rpm too high. Fuel supply re- Ease off throttle or select - -
stricted until en- higher gear.
gine speed is
below permitted
value.
190/2 PID190/2 Electrical error, rpm/ Engine stops and Check cabling between D794/Sen- -
ignition mode sen- cannot be restart- control unit and compo- sor:47, 50
sor; no signal from ed. nent.
any sensors. Check the sensor.
190/10 PID190/ Electrical error, rpm/ No limitation. Check cabling between D794/Sen- -
10 ignition mode sen- control unit and compo- sor: 47, 50
sor, one of two sig- nent.
nals missing. Check the sensor.
191/16 PID191/0 Speed limitation acti- Speed is reduced. Reduce throttle applica- - -
vated. tion.
191/18 PID191/1 Speed warning for Engine will only Increase throttle applica- - -
low speed. idle. tion.
441/3 PID441/3 Auxiliary tempera- No warning of high Check cabling between D794/Sen-
ture sensor short temperature, Con- control unit and compo- sor: 12
circuited to ground. trol unit, engine nent.
(D794). Check the sensor.
441/4 PID441/4 Auxiliary tempera- No warning of high Check cabling between D794/Sen-
ture sensor short temperature, Con- control unit and compo- sor: 12
circuited to supply trol unit, engine nent.
voltage. (D794). Check the sensor.
558/2 SID230/2 Electrical error, ac- No limitation. Check cable between D794/ -
celerator pedal sen- control unit and compo- OEM: 03,
sor, idling contact, nent. 13
data error. Check component.
558/13 SID230/ Electrical error, ac- Engine will only Check cable between D794/ -
13 celerator pedal sen- idle. control unit and compo- OEM: 13
sor, idling contact, nent.
calibration error. Check component.
608/2 SID250/2 Communication er- No limitation. Check the control unit. D794/
ror with Control unit OEM: 26,
engine (D794). 27, 36, 37,
46
608/9 SID250/9 Communication er- No limitation. Check the control unit. D794/
ror with Control unit OEM: 26,
engine (D794). 27, 36, 37,
46
620/3 SID232/3 Electrical error, refer- Reduced engine Check cabling between D794/Sen- -
1080/3 ence voltage to sen- output. No warn- control unit and compo- sor: 18, 25,
sor short circuited to ing of low oil pres- nent. 45
supply voltage. sure or low Check the control unit.
coolant level.
620/4 SID232/4 Electrical error, refer- Reduced engine Check cabling between D794/Sen- -
1081/4 ence voltage to sen- output. No warn- control unit and compo- sor: 18, 25,
sor short circuited to ing of low oil pres- nent. 45
ground. sure or low Check the component.
coolant level.
626/11 SID237/ Electrical error to Preheating not Check cabling between D794/Ac- ENGINE,
11 control of preheating working. Risk of control unit and compo- tuator: 34 menu 5
relay. white smoke. nent.
Check the component.
627/2 SID251/2 Voltage supply to Reduced engine Check the fuses. D794/ -
control unit disap- output. Engine dif- Check batteries and al- OEM:7, 8,
pears but ignition not ficult to start or ternator. 17, 18, 28
off. dies.
629/12 SID254/ Internal error, Con- The engine will not Check the control unit. - -
12 trol unit, engine. start.
629/12 SID254/ Internal error, Con- No limitation. Check the control unit. - -
12 trol unit, engine.
632/3 SID017/3 Electrical error, fuel No limitation. Check cabling between D794/Ac- -
cut-off solenoid control unit and compo- tuator: 33
valve, cable short nent.
circuited to supply Check the solenoid
voltage. valve.
632/4 SID017/4 Electrical error, fuel Engine will shut Check cabling between D794/Ac- -
cut-off solenoid down. control unit and compo- tuator: 33
valve, cable short nent.
circuited to ground. Check the solenoid
valve.
639/2 SID231/2 Communication er- Functions via CAN Use diagnostic menu to - CAN/
ror with Control unit bus not working. find incorrect segment. POWER,
engine (D794). menu 2
639/9 SID231/9 Communication er- Functions via CAN Use diagnostic menu to - CAN/
ror with Control unit bus not working. find incorrect segment. POWER,
engine (D794). menu 2
639/9 SID231/9 Communication er- Functions via CAN Use diagnostic menu to - CAN/
ror with Control unit, bus not working. find incorrect segment. POWER,
engine (D794), time- menu 2
out error.
639/13 SID231/ Communication er- Functions via CAN Use diagnostic menu to - CAN/
13 ror with Engine con- bus not working. find incorrect segment. POWER,
trol unit (D794), menu 2
configuration error.
644/2 SID030/2 Electrical error, ac- Engine will shut Check cabling between - -
celerator pedal, sig- down. control unit and compo-
nal not within valid nent.
interval. Check the component.
647/4 SID033/4 Electrical error, fan Cooling fan runs Check cabling between D794/Ac- -
connection, cable constantly. control unit and compo- tuator:10,
short circuited to nent. Actuator: 9
ground. Check the component.
651/5 SID001/5 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 1 injector, open cylinders, sounds control unit and compo- tuator:10,
circuit on cable. rough and has re- nent. Actuator: 9
duced power. Check the injector.
652/5 SID002/5 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 2 injector, open cylinders, sounds control unit and compo- tuator: 7, 8
circuit on cable. rough and has re- nent.
duced power. Check the injector.
652/6 SID002/6 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 2 injector, cable cylinders, sounds control unit and compo- tuator:7, 8
short circuited to rough and has re- nent.
ground. duced power. Check the injector.
653/5 SID003/5 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 3 injector, open cylinders, sounds control unit and compo- tuator:6,
circuit on cable. rough and has re- nent. 16
duced power. Check the injector.
653/6 SID003/6 Electrical error, cylin- Engine runs on 5 Check cable between D794/Ac- -
der 3 injector, cable cylinders, sounds control unit and compo- tuator:6,
short circuited to rough and has re- nent. 16
ground. duced power. Check component.
654/5 SID004/5 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 4 injector, open cylinders, sounds control unit and compo- tuator:26,
circuit on cable. rough and has re- nent. 36
duced power. Check the injector.
654/6 SID004/6 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 4 injector, cable cylinders, sounds control unit and compo- tuator:26,
short circuited to rough and has re- nent. 36
ground. duced power. Check the injector.
655/5 SID005/5 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 5 injector, open cylinders, sounds control unit and compo- tuator: 3, 4
circuit on cable. rough and has re- nent.
duced power. Check the injector.
655/6 SID005/6 Electrical error, cylin- Engine runs on 5 Check cable between D794/Ac- -
der 5 injector, cable cylinders, sounds control unit and compo- tuator: 3, 4
short circuited to rough and has re- nent.
ground. duced power. Check component.
656/6 SID006/6 Electrical error, cylin- Engine runs on 5 Check cabling between D794/Ac- -
der 6 injector, cable cylinders, sounds control unit and compo- tuator: 1, 2
short circuited to rough and has re- nent.
ground. duced power. Check the injector.
702/3 SID040/3 Electrical error, auxil- No limitation. Check cabling between D794/Ac- -
PID154/3 iary output 2, cable control unit and compo- tuator: 14
short circuited to nent.
supply voltage. Check the component.
703/3 SID051/3 Electrical error, auxil- No limitation. Check cabling between D794/Ac- -
iary output 2, cable control unit and compo- tuator: 45
short circuited to nent.
supply voltage. Check the component.
974/3 SID029/3 Electrical error, auxil- Engine does not Check cabling between D794/ -
iary accelerator ped- respond to throt- control unit and compo- OEM: 21
al, cable short tle. nent.
circuited to supply Check the component.
voltage.
974/4 SID029/4 Electrical error, auxil- Engine does not Check cabling between D794/ -
iary accelerator ped- respond to throt- control unit and compo- OEM: 21
al, cable short tle. nent.
circuited to ground. Check the component.
974/19 SID029/2 Communication er- Engine does not Use diagnostic menu to - CAN/
ror with cab control respond to throt- find incorrect segment. POWER,
unit (D790-1), electri- tle. menu 2
cal error, accelerator
pedal.
1043/3 PID221/3 Electrical error, ac- Engine will only Check cabling between D794/ -
celerator pedal refer- idle. control unit and compo- OEM: 48
ence voltage, cable nent.
short circuited to Check the component.
supply voltage.
1043/4 PID221/4 Electrical error, ac- Engine will only Check cabling between D794/ -
celerator pedal refer- idle. control unit and compo- OEM: 48
ence voltage, cable nent.
short circuited to Check the component.
ground.
1073/11 SID029/ Electrical error, sole- Engine brake 2 Check cabling between D794/Ac- -
11 noid valve engine cannot be activat- control unit and compo- tuator: 44
brake 2. ed. nent.
Check the solenoid
valve.
1079/3 SID232/3 Electrical error, refer- Reduced engine Check cabling between D794/Sen- -
ence voltage to sen- power. control unit and compo- sor: 17, 37
sor short circuited to nent.
supply voltage. Check the sensor.
1079/4 SID232/4 Electrical error, refer- Reduced engine Check cabling between D794/Sen- -
ence voltage to sen- power. control unit and compo- sor: 17, 37
sor short circuited to nent.
ground. Check the sensor.
1188/3 SID032/3 Electrical error, Reduced engine Check cabling between D794/Ac- -
wastegate solenoid power. control unit and compo- tuator: 24
valve 1 short nent.
circuited to supply Check the solenoid
voltage. valve.
1189/3 SID088/3 Electrical error, Reduced engine Check cabling between D794/Ac-
wastegate solenoid power. control unit and compo- tuator: 23
valve 2 short nent.
circuited to supply Check the solenoid
voltage. valve.
1189/4 SID88/4 Electrical error, Reduced engine Check cabling between D794/Ac-
wastegate solenoid power. control unit and compo- tuator: 23
valve 2 short nent.
circuited to ground. Check the solenoid
valve.
1380/1 PID017/1 Low engine oil level. No limitation. Check the engine oil lev- - -
el; fill as necessary.
1383/31 SID151/ Engine shut off other No limitation. Switch of the engine with - -
11 than with start key, the start key.
causing load.
1384/31 SID029/ Engine shut off other No limitation. Switch of the engine with - -
14 than with start key, the start key.
causing load.
1387/3 PID223/3 Electrical error, auxil- No pressure guard Check cabling between D794/Sen- -
iary pressure sensor, (customer-specif- control unit and compo- sor: 19
cable short circuited ic option). nent.
to supply voltage. Check the sensor.
1387/4 PID223/4 Electrical error, auxil- No pressure guard Check cabling between D794/Sen- -
iary pressure sensor, (customer-specif- control unit and compo- sor: 19
cable short circuited ic option). nent.
to ground. Check the sensor.
1484/31 SID216/ Error codes in other No limitation. Check error codes for - -
11 control units. other machine control
units, particularly the cab
control unit (D790-1) and
transmission control unit
(D793).
2 Transmission
mm mm mm mm mm mm
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
00/50 7F09D/C Memory error in control Transmission - - -
unit transmission. locked in neutral
(Shut-down).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
20/60 7F065/1 Dana Transmission Check cabling Dana TRANSM,
Sensor oil pressure indi- locked in neutral between control D793/A2 - menu 10
cates low oil pressure (Shut-down). unit and sensor. X253
when there should be Check the
pressure. sensor.
21/00 7F069/1 Oil pressure sensor (1) Transmission Check the feed - -
has too low oil pressure. locked in neutral pressure to the
(Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
21/01 7F069/0 Oil pressure sensor (1) Transmission Check the feed - -
has too high oil pres- locked in neutral pressure to the
sure. (Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
22/00 7F06A/1 Oil pressure sensor (2) Transmission Check the feed - -
has too low oil pressure. locked in neutral pressure to the
(Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
22/01 7F06A/0 Oil pressure sensor (2) Transmission Check the feed - -
has too high oil pres- locked in neutral pressure to the
sure. (Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
23/00 7F06B/1 Oil pressure sensor (3) Transmission Check the feed - -
has too low oil pressure. locked in neutral pressure to the
(Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
23/01 7F06B/0 Oil pressure sensor (3) Transmission Check the feed - -
has too high oil pres- locked in neutral pressure to the
sure. (Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
24/00 7F06C/1 Oil pressure sensor (4) Transmission Check the feed - -
has too low oil pressure. locked in neutral pressure to the
(Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
24/01 7F06C/0 Oil pressure sensor (4) Transmission Check the feed - -
has too high oil pres- locked in neutral pressure to the
sure. (Shut-down). transmission.
Save informa-
tion about actual
pressure when
the problem oc-
curred.
30/04 7F090/1 Low battery voltage. Control unit saves Check cabling - CAN/
stored information to control unit. POWER,
to flash memory Check alterna- menu 15
and restarts to clear tor, battery and
memory. cabling between
battery and al-
ternator.
30/05 7F090/0 High battery voltage. Control unit re- Check voltage - CAN/
ceives reduced pro- feed. POWER,
portional control If auxiliary start menu 15
precision depend- equipment is
ing on reduced connected, dis-
PWM work cycle. connect it.
31/00 7F093/1 Reference voltage sen- Control unit re- Check voltage - CAN/
sor 8 V, too low. ceives reduced sen- feed. POWER,
sor signals. Check the con- menu 15
trol unit.
31/01 7F093/0 Reference voltage sen- Control unit re- Check voltage - CAN/
sor 8 V, too high. ceives reduced sen- feed. POWER,
sor signals. Check the con- menu 15
trol unit.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
34/01 7F0BC/1 Measured turbine speed Transmission Check cabling - -
during start-up is too locked in neutral between gear
low. (Shut-down). control and sen-
sor.
Check the
sensor.
Check the feed
pressure to the
transmission.
40/06 7F05E/2 Incorrect direction from Control unit locks Check cabling - TRANSM,
gear selector. transmission in to gear selector menu 2
neutral. with regards to
forward and re-
verse signal.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
40/08 7F041/1F Seat direction was Transmission Check seat di- - -
changed when the park- locked in neutral rection or show
ing brake was not acti- (Shut-down). the driver how
vated and/or the gear the seat is
control was not in neu- turned as per
tral position, and/or the the correct pro-
machine was not sta- cedure.
tionary.
41/06 7F05F/2 Incorrect gear selection Control unit doesn’t Check cabling - TRANSM,
from gear selector. allow change of to gear selector menu 2
range, however, op- with regards to
eration of machine signal range.
is possible.
42/04 7F080/1 Actual gear ratio too Control unit indi- Check transmis- - TRANSM,
low. cates that one or sion with pur- menu 6
several clutches are pose to
slipping. understand if
and, if that is the
case, which
clutch is slip-
ping.
Check the set
gear ratio for the
control unit.
42/05 7F080/0 Actual gear ratio too Control unit indi- Check transmis- - TRANSM,
high. cates that one or sion with pur- menu 6
several clutches are pose to
slipping. understand if
and, if that is the
case, which
clutch is slip-
ping.
Check the set
gear ratio for the
control unit.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
43/03 7F063/0 Dana Control unit indi- Check cabling Dana TRANSM,
Signal from Sensor en- cates the error. between control D793/H3 - menu 10
gine rpm and oil temper- unit and compo- B758/766
ature transmission nent.
(B758/766) outside valid Check the sen-
interval. sor.
43/07 7F063/10 Torque converter tem- Control unit indi- Check transmis- Dana TRANSM,
perature exceeds cates the error to sion oil cooler, D793/H3 - menu 10
100 °C. make operator clean as need- B758/766
aware of the warn- ed.
ing’s level. Dana full flow
Check the ther-
mostat in the D793/H3 -
transmission oil B7660
cooler.
43/08 7F063/0 Torque converter tem- The control unit pro- Check transmis- Dana TRANSM,
perature exceeds tects the transmis- sion oil cooler, D793/H3 - menu 10
120 °C. sion and does not clean as need- B758/766
allow the tempera- ed.
ture in the torque Dana full flow
Check the ther-
converter to exceed mostat in the D793/H3 -
the limit value. transmission oil B7660
The control unit cooler.
locks the transmis-
sion in neutral posi-
tion, the engine is
restricted to 50% of
max. rpm.
45/06 7F048/2 Invalid combination for The control unit lim- Check the - -
redundant digital speed its machine speed speed sensors.
inputs. to the reduced
speed.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
47/01 7F07B/10 The transmission has Control unit indi- Release the ac- - -
exceeded the limit value cates the error. celerator pedal
for top speed. and slow down
the machine.
48/00 7F0B3/0 Disengaged 4WD/2WD Control unit indi- Check the 4WD/ - -
selector stuck in en- cates the error. 2WD selector.
gaged mode, or the Check whether
feedback signal is incor- digital feedback
rect. is switched on
and connected
to the control
unit.
48/01 7F0B3/1 Engaged 4WD/2WD se- Control unit indi- Check the 4WD/ - -
lector stuck in engaged cates the error. 2WD selector.
mode, or the return sig- Check whether
nal is incorrect. digital feedback
is switched on
and connected
to the control
unit.
49/00 7F0B4/0 Disengaged Low/High Control unit indi- Check the Low/ - -
selector stuck in en- cates the error. High gear selec-
gaged mode, or the tor.
feedback signal is incor- Check whether
rect. digital feedback
is switched on
and connected
to the control
unit.
49/01 7F0B4/1 Engaged Low/High se- Control unit indi- Check the Low/ - -
lector stuck in engaged cates the error. High gear
mode, or the return sig- selector.
nal is incorrect. Check whether
digital feedback
is switched on
and connected
to the control
unit.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
50/00 7F010/4 Dana Transmission Check cabling Dana TRANSM,
Sensor oil pressure, locked in gear 1 and between control D793/A2 - menu 10
short circuited to 2 (Limp-home). unit and sensor. X253
ground. Check the sen-
sor.
Dana full flow Dana full flow
Sensor gear 1/3 D793/A2 -
(B6067), short circuited B6067
to ground.
50/04 7F010/11 Sensor gear 1/3 The control unit Check cabling D793/A2 - TRANSM,
(B6067), the value is be- identifies the error between control B6067 menu 10
low the lowest calibrated and use the lowest unit and compo-
value. value in its settings. nent.
Check the sen-
sor.
50/05 7F010/F Sensor gear 1/3 The control unit Check cabling D793/A2 -
(B6067), the value is identifies the error between control B6067
above the highest cali- and use the highest unit and compo-
brated value. value in its settings. nent.
Check the sen-
sor.
51/00 7F011/4 Dana The control unit lim- Check cabling Dana TRANSM,
Sensor engine rpm and its the transmis- between control D793/H3 - menu 10
oil temperature trans- sion’s temperature unit and sensor. B758/766
mission (B758/766) measurement to the Check the sen-
short-circuited to lowest value in its sor.
ground. settings, which re-
sults in poor tem-
Dana full flow perature Dana full flow
Oil temperature sensor compensation. D793/H3 -
(B7660) short circuited B7660
to ground.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
51/01 7F011/3 Dana The control unit lim- Check cabling Dana TRANSM,
Sensor engine rpm and its the transmis- between control D793/H3 - menu 10
oil temperature trans- sion’s temperature unit and sensor. B758/766
mission (B758/766) not measurement to the Check the sen-
connected or open cir- highest value in its sor.
cuit. settings, which re-
sults in poor tem-
Dana full flow perature Dana full flow
Sensor oil temperature compensation. D793/H3 -
(7660), not connected or B7660
open circuit.
51/04 7F011/11 Sensor oil temperature The control unit lim- Check cabling D793/H3 - TRANSM,
(B7660), the value is be- its the transmis- between control B7660 menu 10
low the lowest calibrated sion’s temperature unit and compo-
value. measurement to the nent.
lowest value in its Check the sen-
settings. sor.
51/05 7F011/F Sensor oil temperature The control unit lim- Check cabling D793/H3 - TRANSM,
(B7660), the value is its the transmis- between control B7660 menu 10
above the highest cali- sion’s temperature unit and compo-
brated value. measurement to the nent.
highest value in its Check the sen-
settings. sor.
52/00 7F012/4 Dana The control unit lim- Check cabling Dana TRANSM,
Sensor oil temperature its the transmis- between control D793/J3 - S221 menu 10
(S221) short-circuited to sion’s temperature unit and sensor.
ground. measurement to the Check the sen-
highest value in its sor.
Dana full flow settings, which re- Dana full flow
Temperature switch sults in poor tem- D793/J3 -
torque converter perature S2210
(S2210) short circuited compensation.
to ground.
52/01 7F012/3 Dana The control unit lim- Check cabling Dana TRANSM,
Sensor oil temperature its the transmis- between control D793/J3 - S221 menu 10
(S221) open circuit. sion’s temperature unit and sensor.
measurement to the Check the sen-
Dana full flow highest value in its Dana full flow
sor.
Temperature switch settings, which re- D793/J3 -
torque converter sults in poor tem- S2210
(S2210) is not perature
connected. compensation.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
52/04 7F012/11 Temperature switch The control unit lim- Check cabling D793/J3B - TRANSM,
torque converter its the transmis- between control S2210 menu 10
(S2210), the value is be- sion’s temperature unit and compo-
low the lowest calibrated measurement to the nent.
value. lowest value in its Check the sen-
settings, which re- sor.
sults in poor tem-
perature
compensation.
52/05 7F012/F Temperature switch The control unit lim- Check cabling D793/J3B - TRANSM,
torque converter its the transmis- between control S2210 menu 10
(S2210), the value is sion’s temperature unit and compo-
above the highest cali- measurement to the nent.
brated value. highest value in its Check the sen-
settings, which re- sor.
sults in poor tem-
perature
compensation.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
53/01 7F013/3 Analogue input signal 3, Depending on func- Check cabling - -
is not connected. tion assigned to the between control
pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral
position.
Other: The control
unit uses the lowest
value in its settings.
53/04 7F013/11 Analogue input signal 3, The control unit Check cabling - -
the value is below the identifies the error between control
lowest calibrated value. and use the lowest unit and compo-
value in its settings. nent.
Check the com-
ponent.
53/05 7F013/F Analogue input signal 3, The control unit Check cabling - -
the value is above the identifies the error between control
highest calibrated value. and use the highest unit and compo-
value in its settings. nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
55/00 7F015/4 Analogue input signal 5, Depending on the Check cabling - -
short circuited to function that is as- between control
ground. signed to the pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral posi-
tion.
Other: The control
unit uses the lowest
value in its settings.
55/04 7F015/11 Analogue input signal 5, The control unit Check cabling - -
the value is below the identifies the error between control
lowest calibrated value. and use the lowest unit and compo-
value in its settings. nent.
Check the com-
ponent.
55/05 7F015/F Analogue input signal 5, The control unit Check cabling - -
the value is above the identifies the error between control
highest calibrated value. and use the highest unit and compo-
value in its settings. nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
56/00 7F016/4 Pressure sensor gear 2/ Depending on the Check cabling D793/S1 - TRANSM,
4 (B6069), short function that is as- between control B6069 menu 10
circuited to ground. signed to the pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral posi-
tion.
Other: The control
unit uses the lowest
value in its settings.
56/01 7F016/3 Pressure sensor gear 2/ Depending on the Check cabling D793/S1 - TRANSM,
4 (B6069), is not con- function that is as- between control B6069 menu 10
nected. signed to the pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral posi-
tion.
Other: The control
unit uses the lowest
value in its settings.
56/04 7F016/11 Pressure sensor gear 2/ The control unit Check cabling D793/S1 - TRANSM,
4 (B6069), the value is identifies the error between control B6069 menu 10
below the lowest cali- and use the lowest unit and compo-
brated value. value in its settings. nent.
Check the com-
ponent.
56/05 7F016/F Pressure sensor gear 2/ The control unit Check cabling D793/S1 - TRANSM,
4 (B6069), the value is identifies the error between control B6069 menu 10
above the highest cali- and use the highest unit and compo-
brated value. value in its settings. nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
57/00 7F017/4 Analogue input signal 7, Depending on the Check cabling - -
short circuited to function that is as- between control
ground. signed to the pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral posi-
tion.
Other: The control
unit uses the lowest
value in its settings.
57/04 7F017/11 Analogue input signal 7, The control unit Check cabling - -
the value is below the identifies the error between control
lowest calibrated value. and use the lowest unit and compo-
value in its settings. nent.
Check the com-
ponent.
57/05 7F017/F Analogue input signal 7, The control unit Check cabling - -
the value is above the identifies the error between control
highest calibrated value. and use the highest unit and compo-
value in its settings. nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
58/00 7F018/4 Analogue input signal 8, Depending on the Check cabling - -
short circuited to function that is as- between control
ground. signed to the pin: unit and compo-
Pressure feedback: nent.
Transmission Check the com-
locked in gear 1 and ponent.
2 (Limp-home).
Oil pressure sensor:
The control unit
locks the transmis-
sion in neutral posi-
tion.
Other: The control
unit uses the lowest
value in its settings.
58/04 7F018/11 Analogue input signal 8, The control unit Check cabling - -
the value is below the identifies the error between control
lowest calibrated value. and use the lowest unit and compo-
value in its settings. nent.
Check the com-
ponent.
58/05 7F018/F Analogue input signal 8, The control unit Check cabling - -
the value is above the identifies the error between control
highest calibrated value. and use the highest unit and compo-
value in its settings. nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
60/00 7F01A/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm drum signal that is not the tween control D793/C3 - menu 6
(B752) short-circuited to engine rpm signal is unit and sensor. B752
ground. incorrect, the con- Check the sen-
trol unit calculates sor.
Dana full flow the missing rpm. Dana full flow
Sensor rpm drum If several rpm sig- D793/C3 -
(B7520) short-circuited nals or if the engine B7520
to ground. speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
60/01 7F01A/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm drum signal that is not the tween control D793/C3 - menu 6
(B752) not connected. engine rpm signal is unit and sensor. B752
incorrect, the con- Check the sen-
Dana full flow trol unit calculates Dana full flow
sor.
Sensor rpm drum the missing rpm. D793/C3 -
(B7520) not connected. If several rpm sig- B7520
nals or if the engine
speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
60/03 7F01A/A Sensor rpm drum Control unit indi- Check cable be- D793/C3 - TRANSM,
(B7520), value outside cates the error. tween control B7520 menu 6
limit values. unit and compo-
nent.
Check compo-
nent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
60/04 7F01A/1 Sensor rpm drum This message is Check the trans- D793/C3 - TRANSM,
(B7520), pulse count too provided as supple- mission to find B7520 menu 6
low. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
60/05 7F01A/0 Sensor rpm drum This message is Check the trans- D793/C3 - TRANSM,
(B7520), pulse count too provided as supple- mission to find B7520 menu 6
high. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
61/00 7F01B/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm output shaft signal that is not the tween control D793/E3 - menu 6
(B758) short-circuited to engine rpm signal is unit and sensor. B758
ground. incorrect, the con- Check the sen-
trol unit calculates sor.
Dana full flow the missing rpm. Dana full flow
Sensor rpm output shaft If several rpm sig- D793/E3 -
(B7580) short-circuited nals or if the engine B7580
to ground. speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
61/01 7F01B/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm output shaft signal that is not the tween control D793/E3 - menu 6
(B758) not connected. engine rpm signal is unit and sensor. B758
incorrect, the con- Check the sen-
Dana full flow trol unit calculates Dana full flow
sor.
Sensor rpm output shaft the missing rpm. D793/E3 -
(B7580) not connected. If several rpm sig- B7580
nals or if the engine
speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
61/03 7F01B/A Sensor rpm output shaft Control unit indi- Check cable be- D793/E3 - TRANSM,
(B7580), value outside cates the error. tween control B7580 menu 6
limit values. unit and compo-
nent.
Check the sen-
sor.
61/04 7F01B/1 Sensor rpm output shaft This message is Check the trans- D793/E3 - TRANSM,
(B7580), pulse count too provided as supple- mission to find B7580 menu 6
low. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
61/05 7F01B/0 Sensor rpm output shaft This message is Check the trans- D793/E3 - TRANSM,
(B7580), pulse count too provided as supple- mission to find B7580 menu 6
high. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
62/00 7F01C/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor engine rpm signal that is not the tween control D793/F3 - menu 6
(B758/766), short- engine rpm signal is unit and sensor. B758/766
circuited to ground. incorrect, the con- Check the sen-
trol unit calculates sor.
Dana full flow the missing rpm. Dana full flow
Sensor engine speed If several rpm sig- D793/F3 -
(B7530), short circuited nals or if the engine B7530
to ground. speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
62/01 7F01C/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor engine rpm signal that is not the tween control D793/F3 - menu 6
(B758/766), not con- engine rpm signal is unit and sensor. B758/766
nected or has open cir- incorrect, the con- Check the sen-
cuit. trol unit calculates sor.
the missing rpm.
Dana full flow Dana full flow
If several rpm sig-
Sensor engine speed nals or if the engine D793/F3 -
(B7530), not connected speed signal are B7530
or has open circuit. defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
62/04 7F01C/1 Sensor engine speed This message is Check the trans- D793//F3 - TRANSM,
(B7530), pulse count is provided as supple- mission to find B7530 menu 6
too low. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
62/05 7F01C/0 Sensor engine speed This message is Check the trans- D793/F3 - TRANSM,
(B7530), pulse count is provided as supple- mission to find B7530 menu 6
too high. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
62/06 7F07A/1 Incorrect engine speed Transmission in Check sensor D793/F3 - TRANSM,
information when tur- Limp-home. for engine rpm B7530 menu 6
bine speed is calculated speed.
Check the com-
ponent’s posi-
tion.
63/00 7F01D/6 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm turbine signal that is not the tween control D793/R2 - menu 6
(B751) short-circuited to engine rpm signal is unit and sensor. B751
ground. incorrect, the con- Check the sen-
trol unit calculates sor.
Dana full flow the missing rpm. Dana full flow
Sensor rpm turbine If several rpm sig- D793/G3 -
(B7510) short-circuited nals or if the engine B7510
to ground. speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
63/01 7F01D/5 Dana When only one rpm Check cable be- Dana TRANSM,
Sensor rpm turbine signal that is not the tween control D793/R2 - menu 6
(B751) not connected. engine rpm signal is unit and sensor. B751
incorrect, the con- Check the sen-
Dana full flow trol unit calculates Dana full flow
sor.
Sensor rpm turbine the missing rpm. D793/G3 -
(B7510) not connected. If several rpm sig- B7510
nals or if the engine
speed signal are
defective, the con-
trol unit locks the
transmission control
unit to gear 1-2
(Limp-home).
63/03 7F01D/A Sensor rpm turbine Control unit indi- Check cable be- D793/G3 - TRANSM,
(B7510), value outside cates the error. tween control B7510 menu 6
limit values. unit and compo-
nent.
Check compo-
nent.
63/04 7F01D/1 Sensor rpm turbine This message is Check the trans- D793/G3 - TRANSM,
(B7510), pulse count too provided as supple- mission to find B7510 menu 6
low. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
63/05 7F01D/0 Sensor rpm turbine This message is Check the trans- D793/G3 - TRANSM,
(B7510), pulse count too provided as supple- mission to find B7510 menu 6
high. mentary information out if, and
for errors in the which, clutch is
transmission. slipping.
Check the trans-
mission’s set-
tings for the ratio
in the control
unit.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
70/00 7F020/4 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS locked in gear 1 and between control D793/B1 - menu 8
front (Y630), short- 2 (Limp-home). unit and sole- Y630, D793/C1
circuited to each other, noid valve. - Y630
signal cable short- Check the sole-
circuited to voltage, or noid valve.
plus-cable short-
circuited to frame
ground.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
70/03 7F020/8 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS for- locked in gear 1 and between control D793/B1 - menu 9
ward (Y630), control 2 (Limp-home). unit and sole- Y630, D793/C1
current outside ap- noid valve. - Y630
proved interval. Incor- Check the sole-
rect impedance. noid valve.
70/09 7F020/5 Servo valve gear for- Transmission Check cabling D793/B1 - TRANSM,
ward and reverse locked in gear 1 and between control Y6300, D793/ menu 9
(Y6300), not connected. 2 (Limp-home). unit and compo- C1 - Y6300
nent.
Check the sole-
noid valve.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
71/01 7F021/3 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS 2/4 locked in gear 1 and between control D793/D1 - menu 8
(Y6069) open circuit or 2 (Limp-home). unit and sole- Y6069, D793/
short-circuited voltage. noid valve. E1 - Y6069
Check the sole-
Dana full flow Dana full flow
noid valve.
Solenoid valve gear se- D793/D1 -
lection 1/3 (Y6067), Y6067, D793/
open circuit or short- E1 - Y6067
circuited voltage.
71/09 7F021/5 Solenoid valve gear se- Transmission Check cabling D793/D1 - TRANSM,
lection 1/3 (Y6067), not locked in gear 1 and between control Y6067, D793/ menu 9
connected. 2 (Limp-home). unit and compo- E1 - Y6067
nent.
Check the sole-
noid valve.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
72/00 7F022/4 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS re- locked in gear 1 and between control D793/F1 - menu 8
verse (Y631), cables 2 (Limp-home). unit and sole- Y631, D793/G1
short-circuited to each noid valve. - Y631
other, signal cable Check the sole-
short-circuited to volt- noid valve.
age, or plus-cable short-
circuited to frame
ground.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
72/03 7F022/8 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS re- locked in gear 1 and between control D793/F1 - menu 9
verse (Y631), control 2 (Limp-home). unit and sole- Y631, G1 -
current outside ap- noid valve. Y631
proved interval (incor- Check the sole-
rect impedance). noid valve.
72/09 7F022/5 Solenoid valve gear se- Transmission Check cabling Dana full flow -
lection 2/4 (Y6069), not locked in gear 1 and between control D793/F1 -
connected. 2 (Limp-home). unit and compo- Y6069, D793/
nent. G1 - Y6069
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
73/01 7F023/3 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS 1/3 locked in gear 1 and between control D793/H1 - menu 8
(Y6067) open circuit or 2 (Limp-home). unit and sole- Y6067, J1 -
short-circuited voltage. noid valve. Y6067
Check the sole-
Dana full flow Dana full flow
noid valve.
Analogue output signal -
3, open circuit or short-
circuited voltage.
74/00 7F024/4 Analogue output signal Control unit indi- Check cabling - -
4, short circuited to cates the error. between control
ground. unit and compo-
nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
74/01 7F024/3 Analogue output signal Control unit indi- Check cabling - -
4 not connected or cates the error. between control
short-circuited voltage. unit and compo-
nent.
Check the com-
ponent.
75/00 7F025/4 Analogue output signal Control unit indi- Check cabling - -
5, short circuited to cates the error. between control
ground. unit and compo-
nent.
Check the com-
ponent.
75/01 7F025/3 Analogue output signal Control unit indi- Check cabling - -
5 not connected or cates the error. between control
short-circuited voltage. unit and compo-
nent.
Check the com-
ponent.
76/00 7F026/4 Analogue output signal Control unit indi- Check cabling - -
6, short circuited to cates the error. between control
ground. unit and compo-
nent.
Check the com-
ponent.
76/01 7F026/3 Analogue output signal Control unit indi- Check cabling - -
6, not connected or cates the error. between control
short-circuited voltage. unit and compo-
nent.
Check the com-
ponent.
76/02 7F026/6 Analogue output signal Control unit indi- Check cabling - -
6, control current over cates the error. between control
1400 mA. unit and compo-
nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
76/03 7F026/8 Analogue output signal Control unit indi- Check cabling - -
6, output signal outside cates the error. between control
the approved interval unit and compo-
(incorrect impedance). nent.
Check the com-
ponent.
76/09 7F026/5 Analogue output signal Control unit indi- Check cabling - -
3, not connected. cates the error. between control
unit and compo-
nent.
Check the com-
ponent.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
80/09 7F027/5 Solenoid valve drive for- Transmission Check cabling D793/K1 - TRANSM,
ward (Y6066F), not con- locked in gear 1 and between control Y6066F menu 7
nected. 2 (Limp-home). unit and compo-
nent.
Check the sole-
noid valve.
81/09 7F027/5 Solenoid valve drive re- Transmission Check cabling D793/E2 - TRANSM,
verse (Y6066R), not locked in gear 1 and between control Y6066R menu 7
connected. 2 (Limp-home). unit and compo-
nent.
Check the sole-
noid valve.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
82/00 7F029/4 Dana Transmission Check cabling Dana TRANSM,
Solenoid valve VFS 1/3 locked in gear 1 and between control D793/F2 - menu 7
(Y6075), cable short- 2 (Limp-home). unit and sole- Y6075
circuited to frame noid valve.
ground. Check the sole-
noid valve.
Dana full flow Dana full flow
Solenoid valve gear se- D793/F2 -
lection 1/3 (Y6075), ca- Y6075
ble short-circuited to
frame ground.
82/09 7F029/5 Solenoid valve gear se- Transmission Check cabling D793/F2 - TRANSM,
lection 1/3 (Y6075), not locked in gear 1 and between control Y6075 menu 7
connected. 2 (Limp-home). unit and sole-
noid valve.
Check the sole-
noid valve.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
83/01 7F02A/4 Dana Transmission Check cabling Dana Dana
Solenoid valve RSP locked in neutral between control D793/K2 - TRANSM,
Drive (Y6066), cable is (Shut-down). unit and compo- Y6066 menu 7
not connected or short- nent.
circuited to voltage. Check the com-
ponent.
Dana full flow Transmission Dana full flow
Solenoid valve gear se- locked in neutral D793/K2 -
lection 2/4 (Y6074), ca- (Shut-down). Y6074
ble short-circuited to
voltage.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
90/12 7F0F0/C Software error Control - - - -
unit, transmission
(D793).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
91/10 7F0F1/6 Software error Control - - - -
unit, transmission
(D793).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
91/61 7F0F7/15 Software error Control - - - -
unit, transmission
(D793).
92/09 7F0F2/9 Digital input signal dupli- Transmission Note the time - -
cated assignment. locked in neutral and contact
(Shut-down). Cargotec sup-
port.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
92/10 7F0F2/A Digital output signal du- Transmission Note the time - -
plicated assignment. locked in neutral and contact
(Shut-down). Cargotec sup-
port.
92/11 7F0F2/B Digital output signal se- Transmission Note the time - -
lected on unconfigured locked in neutral and contact
output. (Shut-down). Cargotec sup-
port.
92/12 7F0F2/C Digital output signal in- Transmission Note the time - -
correct. locked in neutral and contact
(Shut-down). Cargotec sup-
port.
92/13 7F0F2/D Digital output signal se- Transmission Note the time - -
lected on transmission locked in neutral and contact
cable. (Shut-down). Cargotec sup-
port.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
92/20 7F0F2/14 Incorrect configuration Transmission Note the time - -
regarding servo motor locked in neutral and contact
or brake valve (ana- (Shut-down). Cargotec sup-
logue output signal 4-5- port.
6).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
93/04 7F0F3/4 Failed initialisation of Transmission Switch off the - -
the necessary control locked in neutral machine and
unit data in flash memo- (Shut-down). the main electri-
ry, caused by a memory cal power.
conflict.
93/10 7F0F3/A Initiation of statistical Control unit indi- Switch off the - -
data in flash memory, cates the error. machine and
caused by firmware up- the main electri-
date or a memory con- cal power.
flict.
93/11 7F0F3/B Initiation of stored incor- Control unit indi- Switch off the - -
rect data in flash memo- cates the error. machine and
ry, caused by firmware the main electri-
update or a memory cal power.
conflict.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
94/03 7F0F4/3 Failed initialisation of Transmission Note the time - -
the necessary control locked in neutral and contact
unit data in flash memo- (Shut-down). Cargotec sup-
ry, caused by a memory port.
conflict.
95/00 7F0F5/0 - - - - -
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
99/92 7F0F6/2 Software error Control - - - -
unit, transmission
(D793).
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E4/01 7F0E5/F Abnormal acceleration. The transmission - - -
disengages auto-
matic gearing for a
time.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.1.06 7F0FA - Calibration of drive The control unit Measure the - -
7F0FD/6 mode pressure, during identifies the error clutch pressure
calibration the turbine and the calibration in order to de-
speed signal does not is stopped. tect leaks.
reach down to the low- Check the sig-
est value. nal from the tur-
bine speed
sensor.
Check the stall
speed in order
to detect slip-
ping clutch.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.1.14 7F0FA - Calibration of drive The control unit Measure the - -
7F0FD/E mode pressure, during identifies the error clutch pressure
calibration the turbine and the calibration in order to de-
speed does not de- is stopped. tect leaks.
crease. Check the sig-
nal from the tur-
bine speed
sensor.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.1.25 7F0FA - Calibration of drive The control unit Calibrating at - -
7F0FD/19 mode pressure, the identifies the error higher tempera-
starting point of engage- and the calibration tures (90-
ment is too early during is stopped. 100 C).
calibration. Too much Check the
traction. speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.1.29 7F0FA - Calibration of drive The control unit Calibrating at - -
7F0FD/1D mode pressure, turbine identifies the error higher tempera-
speed does not reach and the calibration tures (90-
the correct value during is stopped. 100 C).
the release phase of the Check the
engagement’s starting speed sensors
point during calibration. (error code 42/
04 or 42/05).
Check the servo
valves.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.2.10 7F0FA - Calibration optimisation The calibration is Determine the - -
7F0FD/A of filling time, transmis- stopped. reason why cali-
sion error during calibra- bration was
tion. stopped.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.2.17 7F0FA - Calibration optimisation The calibration is Download the - -
-24 7F0FD of filling time, unexpect- stopped. correct parame-
ed algorithm response. ters and resume
calibration.
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.2.28 7F0FA - Calibration optimisation The control unit Measure the - -
7F0FD/1C of filling time, turbine identifies the error clutch pressure
speed does not reach a and the calibration in order to de-
value of 0 rpm during the is stopped. tect leaks.
closing phase of calibra- Check the sig-
tion. nal from the tur-
bine speed
sensor.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.3.07 7F0FA - Calibration of control The calibration is Download the - -
-09 7F0FD current for pressure, un- stopped. correct parame-
expected algorithm re- ters and repeat
sponse. calibration.
Make sure that
the machine
does not move.
Check engine
speed re-
sponse.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.3.16 7F0FA - Calibration of control The control unit Measure the - -
7F0FD/10 current for pressure, the identifies the error clutch pressure
turbine speed is too low and the calibration in order to de-
to start calibration. is stopped. tect leaks.
Check the sig-
nal from the tur-
bine speed
sensor.
Connec- Diag-
Description Limitation Action tions and nostic
components menu
Code SPN/FM1
E.3.27 7F0FA - Calibration of control The calibration is Download the - -
7F0FD current for pressure, un- stopped. correct parame-
expected algorithm re- ters and resume
sponse. calibration.
Check if the ma-
chine starts to
move.
Check engine
speed re-
sponse.
8 Control system
mm mm mm mm mm mm
2 Communication error Levelling, tilt, Use diagnostic menu to D791-2 CAN/ 11.6.2 Re-
with Control unit, at- overheight find incorrect segment. POWER, dundant
tachment option extension not menu 2 CAN-bus
(D791-2). working.
3 Communication error Left side of Use diagnostic menu to D791-3 CAN/ 11.6.2 Re-
with Control unit, at- bottom lift not find incorrect segment. POWER, dundant
tachment left jack working. menu 2 CAN-bus
pair (D791-3).
4 Communication error Right side of Use diagnostic menu to D791-4 CAN/ 11.6.2 Re-
with Control unit, at- bottom lift not find incorrect segment. POWER, dundant
tachment right jack working. menu 2 CAN-bus
pair (D791-4).
5 Communication error Lighting rear, Use diagnostic menu to D797-R CAN/ 11.6.2 Re-
with Control unit, hydraulic oil find incorrect segment. POWER, dundant
frame rear (D797-R). cooling, over- menu 2 CAN-bus
load system,
extension not
working.
6 Communication error Front light- Use diagnostic menu to D797-F CAN/ 11.6.2 Re-
with Control unit, ing, lift, exten- find incorrect segment. POWER, dundant
frame front (D797-F). sion, brake menu 2 CAN-bus
lights, brake
cooling not
working.
7 Communication error Sliding cab, Use diagnostic menu to D797-O CAN/ 11.6.2 Re-
with Control unit, support jacks, find incorrect segment. POWER, dundant
frame option (D797- joystick con- menu 2 CAN-bus
O). trol mini-
wheel, cab lift
and cab tilt
not working.
8 Communication error Controls in Use diagnostic menu to D795 CAN/ 11.6.2 Re-
with KID control unit steering find incorrect segment. POWER, dundant
(D795) wheel panel menu 2 CAN-bus
and display
not working.
11 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 1. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
12 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 2. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
13 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 3. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
14 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 4. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
15 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 5. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
16 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 6. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
17 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 7. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
18 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 8. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
20 Accelerator pedal Poor sensitiv- Calibrate the gas ped- D790-1/K6:11 CALIBRA- 1. Engine
(B690) not calibrated. ity in acceler- al, see the section 8 – B690 TION:
ator pedal. Control system, group DRIVE-
8.5.2.3 Calibrate TRAIN,
DRIVE-TRAIN. menu 1
and 2
11 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 1. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
12 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 2. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
13 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 3. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
14 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 4. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
15 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 5. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
16 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 6. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
17 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 7. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
18 Wiring fault CAN bus No limitation. Use diagnostic menu to Varies de- CAN/ 11.6.2 Re-
segment 8. find incorrect segment. pending on POWER, dundant
machine con- menu 1 CAN-bus
figuration. and 21
20 Accelerator pedal Poor sensitiv- Calibrate the gas ped- D790-1/K6:11 CALIBRA- 1. Engine
(B690) not calibrated. ity in acceler- al, see the section 8 – B690 TION:
ator pedal. Control system, group DRIVE-
8.5.2.3 Calibrate TRAIN,
DRIVE-TRAIN. menu 1
and 2
22 Communication error Engine does Use diagnostic menu to Volvo: D790- CAN/ 11.6.3 CAN-
with Control unit en- not react to check communication. 1/K13:1, POWER, bus drivetrain
gine (D794). commands Check the wiring be- K13:2 – D794/ menu 3
from cab. tween cab control unit 2, 1
(D790-1) and engine Cummins:
control unit (D794) D790-1/
K13:1, K13:2
– D794/46, 37
23 Setup file cannot be No controls Contact Cargotec sup- D790-1 - 11.5.3.1 Con-
read in cab control working in port. trol unit cab
unit (D790-1). cab.
24 Electric power feed to Cab fan not Check fuse F58-5/3. D790-1/K2:8 - 9.4.3 Cab fan
cab fan less than 18 working. – 58-5/3:2
V.
25 Interference during Error code Switch the ignition off D794 ENGINE, 11.5.3.10
software download. stored in en- and on. menu 8 Control unit
26
Buffer for error codes gine control Repeat software down- engine
27 from Control unit, en- unit (D794). load.
gine (D794), active
28
error code when
29 downloading.
30
31 Incorrect power sup- Control in cab Check fuse F58-5/1. D790-1/K1:2, CAN/ 11.5.1.3 Igni-
ply to cab control unit not working. Check cabling between K1:3, K1:4 – POWER, tion voltage
(D790-1). Voltage un- the control unit and the F58-5/1:1, 1:2 menu 6 (15)
der 18 V or over 32 V. component with diag-
nostic menu.
Check the control unit.
33 No feedback signal The emer- Check fuse F58-3/8. D790-1/ CAN/ 11.5.1.4
for emergency stop gency stop Check cabling between K11:13 – POWER, Emergency
switch voltage from switch can- the control unit and the K3009-1/87 menu 5 stop switch
emergency stop not be disen- component with diag- voltage (15E)
switch voltage relay gaged. All nostic menu.
(K3009-1). hydraulic
functions are
blocked.
34 Faulty signal from Parking brake Check cabling between D791-1/K8:5 HYD, 4.5 Parking
parking brake switch cannot be re- the control unit and the – S107/7 menu 5 brake
(S107); indicates re- leased. component with diag- D791-1/K8:13
leased and applied at nostic menu. – S107/1
same time or nothing Check the switch.
at all.
35 Interference during Error code Switch the ignition off D793 TRANSM, 11.5.3.9 Con-
software download. stored in and on. menu 13 trol unit trans-
36
Buffer for error codes transmission Repeat software down- mission
37 from Control unit, control unit load.
transmission (D793), (D793).
38
active error code
39 when downloading.
40
41 The transistor has Windscreen Check cabling between D790-1/K2:4 CAB, 9.5.7 Wiper
been triggered due to wiper rear not the control unit and the – M650-2/53 menu 3 motor rear
short circuit in the cir- working. component with diag-
cuit for Wiper motor, nostic menu.
rear (M650-2). Check the motor.
42 The transistor has Rotating bea- Check cabling between D790-1/K2:5 LIGHTS, 9.6.8 Rotat-
been triggered due to con not work- the control unit and the – H428 menu 9 ing beacon
short circuit in the cir- ing. component with diag-
cuit for Revolving nostic menu.
beacon (H428). Check the component.
44 The transistor has Working light, Check bulb. D790-1/K2:7 LIGHTS, 9.6.9 Work-
been triggered due to cab right not Check cabling between – E404-1R menu 1 ing light, cab
short circuit in the cir- working. the control unit and the
cuit for Working light, component with diag-
cab right (E404-1R). nostic menu.
45 The transistor has Windscreen Check cabling between D790-1/K2:1 CAB, 9.5.1 Wiper
been triggered due to wiper front the control unit and the – M650-1/53 menu 2 front
short circuit in the cir- not working. component with diag-
cuit for Wiper motor, nostic menu.
front (M650-1). Check the motor.
46 The transistor has Cab fan not Check cabling between D790-1/K2:2 CLI- 9.4.3 Cab fan
been triggered due to working. the control unit and the – M657-1/2 MATE,
short circuit in the cir- component with diag- menu 6
cuit for Fan motor nostic menu.
(M657-1). Check the motor.
47 The transistor has Recirculation Check cabling between D790-1/K2:3 CLI- 9.4.2 Fresh
been triggered due to damper to the control unit and the – M612/3 MATE, air and recir-
short circuit in the cir- ventilation not component with diag- menu 6 culation
cuit for Actuator mo- working. nostic menu. damper
tor, recirculation Check the motor.
(M612).
48 The transistor has Heat in cab Check cabling between D790-1/K4:1 CLI- 9.4.5 Water
been triggered due to cannot be ad- the control unit and the – Y673/5 MATE, valve
short circuit in the cir- justed. component with diag- menu 7
cuit for Water valve nostic menu.
(Y673). Check the motor.
49 The transistor has Heat in cab Check cabling between D790-1/K4:2 CLI- 9.4.5 Water
been triggered due to cannot be ad- the control unit and the – Y673/6 MATE, valve
short circuit in the cir- justed. component with diag- menu 7
cuit for Water valve nostic menu.
(Y673). Check the motor.
50 The transistor has Air distribu- Check cabling between D790-1/K4:3 CLI- 9.4.14 Air dis-
been triggered due to tion in cab the control unit and the – Y672/5 MATE, tributor
short circuit in the cir- cannot be ad- component with diag- menu 8
cuit for Damper motor justed. nostic menu.
(Y672) Check the motor.
53 The transistor has Windscreen Check cabling between D790-1/K5:4 CAB, 9.5.4 Wash-
been triggered due to washer rear the control unit and the – M651-2 menu 1 er motor and
short circuit in the cir- and roof not component with diag- reservoir
cuit for Washer mo- working. nostic menu.
tor, roof and rear Check the motor.
(M651-2).
54 The transistor has Flashing haz- Check cabling between D790-1/K5:5 LIGHTS, 9.6.7 Flash-
been triggered due to ard lights not the control unit and the – S109/9 menu 7 ing hazard
short circuit or open working. component with diag- lights
circuit in circuit for in- nostic menu.
dicator lamp Switch, Check the switch.
flashing hazard lights
(S109).
55 The transistor has Reduced or Check bulbs for back- D7901/K6:1, LIGHTS, 9.1 Controls
been triggered due to no back- ground lighting, change K 8:15, K 9:2, menu 13 and instru-
short circuit in the cir- ground light- if needed. K 10:5, all in- ments
cuit for background ing in Check cable harness to puts of type A
lighting in switches switches and background lighting. Digital in
and instruments. instruments
56 The transistor has Indication for Check cabling between D790-1/K7:8 - 7.1.1 Control
been triggered due to tilt lock in con- the control unit and the – S815/5 lever
short circuit or open trol lever not component with diag-
circuit in the circuit for illuminated. nostic menu.
LED indication for tilt Check the switch.
lock in control lever
(S815).
57 The transistor has Indication for Check cabling between D790-1/K7:9 - 7.1.1 Control
been triggered due to levelling lock the control unit and the – S815/7 lever
short circuit or open in control le- component with diag-
circuit in the circuit for ver not illumi- nostic menu.
LED indication for nated. Check the switch.
levelling lock in con-
trol lever (S815).
60 The transistor has Seat heating Check cabling between D790-1/K10:7 CAB, 9.3.3 Heat-
been triggered due to not working. the control unit and the – K383/86 menu 8 ing coils
short circuit or open component with diag-
circuit in the circuit for nostic menu.
Relay seat heater Check the component.
(K383).
62 The transistor has Hour meter Check cabling between D790-1/K10:9 CAN/ 9.3.5 Air sus-
been triggered due to and air sus- the control unit and the – P708, K358/ POWER, pension
short circuit or open pension seat component with diag- 86 menu 7
circuit for simulated not working. nostic menu.
D+ feed for hour me- Check the component.
ter (P708) and Relay
compressor air sus-
pension seat (K358).
63 The transistor has No ignition Check cabling between D790-1/ CAN/ 11.5.1.3 Igni-
been triggered due to voltage to the the control unit and the K10:10 – POWER, tion voltage
short circuit or open machine’s component with diag- K315-1/86 menu 4 (15)
circuit in the circuit for Control units. nostic menu.
Relay ignition voltage Check the component.
(K315-1).
64 The transistor has No emergen- Check cabling between D790-1/ CAN/ 11.5.1.4
been triggered due to cy stop switch the control unit and the K10:11 – POWER, Emergency
short circuit or open voltage to the component with diag- K3009-1/86 menu 5 stop switch
circuit in circuit for re- machine’s nostic menu. voltage
lay for emergency control units. Check the component.
stop switch voltage
(K3009-1).
65 The transistor has No emergen- Check cabling between D790-1/ CAN/ 11.5.1.4
been triggered due to cy stop switch the control unit and the K10:11 – POWER, Emergency
short circuit or open voltage to the component with diag- K3009-1/86 menu 5 stop switch
circuit in circuit for re- machine’s nostic menu. voltage
lay for emergency control units. Check the component.
stop switch voltage
(K3009-2).
66 The transistor has Windscreen Check cabling between D790-1/ CAB, 9.5.4 Wash-
been triggered due to washer not the control unit and the K10:13 – menu 1 er motor and
short circuit in the cir- working. component with diag- M651-1 reservoir
cuit for Washer mo- nostic menu.
tor, windscreen Check the component.
(M651-1).
68 The transistor has Pause heater Check cabling between D790-1/ - 9.4 Heating,
been triggered due to not working. the control unit and the K10:15 – ventilation
short circuit or open component with diag- M667 and air condi-
circuit in circuit for nostic menu. tioning
pause heater circula- Check the motor.
tion pump (M667).
69 The transistor has No voltage Check cabling between D790-1/ CAN/ 11.5.1.3 Igni-
been triggered due to feed to en- the control unit and the K10:16 – POWER, tion voltage
short circuit or open gine and component with diag- K315-2/86 menu 4 (15)
circuit in the circuit for transmission. nostic menu.
Relay ignition voltage Check the component.
drivetrain (K315-2).
71 The transistor has Interior light- Check bulb. D790-1/K11:6 LIGHTS, 9.6.12 Interi-
been triggered due to ing in cab not Check cabling between – E434-1 menu 12 or lighting
short circuit in the cir- working. the control unit and the cab
cuit for Interior light- component with diag-
ing, cab (E434-1). nostic menu.
74 The transistor has Horn/loud Check cabling between D790-1/ CAB, 9.7.1 Horn
been triggered due to horn not the control unit and the K11:11 – menu 5
short circuit in the cir- working. component with diag- H850/1,
cuit for horn (H850) nostic menu. K3016/86
or Relay loud horn Check the component.
(K3016)
75 Relay ignition voltage The cab con- Check cabling between - CAN/ 11.5.1.3 Igni-
(K315-1) has jammed trol unit the control unit and the POWER, tion voltage
in position on. (D790-1) is component with diag- menu 4
still ener- nostic menu.
gised and is Check the component.
thereby ac-
tive.
81 Faulty signal from Ac- Air distribu- Check cabling between D790-1/K4:7 CLI- 9.4.6 Fresh
tuating motor (Y672). tion cannot be the control unit and the – Y672/9 MATE, air and recir-
Signal voltage under changed. component with diag- menu 4 culation
0.2 V or over 4.8 V. nostic menu. damper
Check the motor.
85 Faulty signal from ac- Engine speed Check cabling between D790-1/K6:11 ENGINE, 1 Engine
celerator pedal limited to idle. the control unit and the – R690/2 menu 1
(R690). Signal volt- component with diag-
age under 0.2 V or nostic menu.
over 4.8 V. Check the component.
87 Faulty signal from Lifting/lower- Check cabling between D790-1/K7:3 BOOM, 7.1.1 Control
Control lever (S815- ing not work- the control unit and the – S815-P1/8 menu 1 lever
P1) for lifting/lower- ing. component with diag-
ing. Signal voltage nostic menu.
under 0.2 V or over Check the switch.
4.8 V.
88 Faulty signal from Extension not Check cabling between D790-1/K7:4 BOOM, 7.1.1 Control
Control lever (S815- working. the control unit and the – S815-P2/4 menu 1 lever
P2) for extension. component with diag-
Signal voltage under nostic menu.
0.2 V or over 4.8 V. Check the switch.
89 Faulty signal from Rotation not Check cabling between D790-1/K7:5 ATTACH, 7.1.1 Control
Control lever (S815- working. the control unit and the – S815-P3/11 menu 1 lever
P3) for rotation. Sig- component with diag-
nal voltage under 0.2 nostic menu.
V or over 4.8 V. Check the switch.
90 Faulty signal from Controllable Check cabling between D790-1/K7:6 ATTACH, 7.1.1 Control
Control lever (S815- tilt not work- the control unit and the – S815-P4/1 menu 1 lever
P4) for tilt. Signal ing. component with diag-
voltage under 0.2 V nostic menu.
or over 4.8 V. Check the switch.
93 Faulty signal from Joystick Check cabling between D790-1/K9:9 STEER- 5.1.2 Mini-
Mini-wheel (R825-2). steering or the control unit and the – R825-2/H2 ING, menu wheel
Signal voltage under mini-wheel component with diag- 1
0.2 V or over 4.8 V. not working. nostic menu.
Check the switch.
94 Faulty signal from Cab heat can- Check cabling between D790-1/K10:4 CLI- 9.4.5 Water
Water valve, cab not be adjust- the control unit and the – Y673/9 MATE, valve
heating (Y673). Sig- ed. component with diag- menu 4
nal voltage under 0.2 nostic menu.
V or over 4.8 V. Check the motor.
96 Faulty signal from Air condition- Check cabling between D790-1/K4:8 CLI- 9.4.17 Sen-
cab temperature sen- ing not work- the control unit and the – B775-1/2 MATE, sor cab tem-
sor (B775-1) Sensor ing. component with diag- menu 1 perature
indicates tempera- nostic menu.
ture under -43 °C or Check the sensor.
over 105 °C.
97 Faulty signal from Air condition- Check cabling between D790-1/K4:9 CLI- 9.4.18 Sen-
outside temperature ing not work- the control unit and the – B774/2 MATE, sor outdoor
sensor (B774). Tem- ing. component with diag- menu 2 temperature
perature signal over nostic menu.
105 °C. Check the sensor.
98 Faulty signal from Air condition- Check cabling between D790-1/K4:10 CLI- 9.4.16 Sen-
outlet fan tempera- ing not work- the control unit and the – B775-2/2 MATE, sor tempera-
ture sensor (B775-2) ing. component with diag- menu 2 ture outlet fan
Sensor indicates nostic menu.
temperature under - Check the sensor.
43 °C or over 105 °C.
99 Faulty signal from re- Air condition- Check cabling between D790-1/K4:11 CLI- 9.4.12 Sen-
frigerant temperature ing not work- the control unit and the – B775-3/2 MATE, sor tempera-
sensor (B775-3) Sen- ing. component with diag- menu 2 ture
sor indicates temper- nostic menu. refrigerant
ature under -43 °C or Check the sensor.
over 105 °C.
102 Redundant voltage - Check cabling between D797-F/K2:8 CAN/ 11.5.1.2 Re-
feed right to Control the control unit and the POWER, dundant volt-
unit, frame front component with diag- menu 8 age feed of
(D797-F) does not nostic menu. Control units
reach destination. Check the control unit.
103 Incorrect power sup- No electric Check fuse F58-2/1, D797-F/K2:1, CAN/ 11.5.1.3 Igni-
ply to Control unit, power feed to change if needed. K2:9, K2:10 – POWER, tion voltage
frame front (D797-F). components. Check cabling between F58-2/1:1, 1:2 menu 8 (15)
Voltage under 18 V or the control unit and the
over 32 V. component with diag-
nostic menu.
104 Faulty emergency Functions Check fuse F58-3/2, D797-F/K2:11 CAN/ 11.5.1.4
stop voltage to Con- normally sup- change if needed. – F58-3/2:1 POWER, Emergency
trol unit, frame front plied emer- Check cabling between menu 8 stop switch
(D797-F). gency stop the control unit and the voltage
switch volt- component with diag-
age have no nostic menu.
feed. All hy-
draulic func-
tions blocked.
105 Incorrect 5 V refer- Regenera- Check cabling between D797-F/K1:8 CAN/ 8.2.1.7 Sen-
ence voltage to pres- tion lifting, the control unit and the – B768-R1/1, POWER, sor hydraulic
sure sensor. Voltage weight indica- component with diag- B768-R2/1, menu 9 pressure lift
under 4.9 V or over tor and over- nostic menu. B768-L1/1, cylinder
5.1 V. load system Check the sensor. B768-L2/1
not working.
106 The transistor has Cooling fan Check cabling between D797-F/K1:14 HYD, 4.8.8 Cooling
been triggered due to brake oil not the control unit and the – M674/1 menu 2 fan
short circuit in the cir- working. component with diag-
cuit for Cooling fan, nostic menu.
brake fluid (M674). Check the motor.
107 The transistor has Left high Check bulb. D797-F/K1:1 LIGHTS, 9.6.1 Head-
been triggered due to beam not Check the lamp holder. – E402L/1 menu 6 lights
short circuit or open working.
Check cabling between
circuit in the circuit for
High beam lamp, left the control unit and the
(E402L). component with diag-
nostic menu.
110 The transistor has Low beams Check bulb. D797-F/K1:42 LIGHTS, 9.6.1 Head-
been triggered due to not working. Check the lamp holder. – E400L/1, menu 6 lights
short circuit or open E400R/1
circuit in the circuit for Check cabling between
Low beam lamp the control unit and the
component with diag-
(E400L/E400R).
nostic menu.
111 The transistor has Lift not work- Check cabling between D797-F/K1:2 BOOM, 7.2.5 Control
been triggered due to ing. the control unit and the – Y6005/1 menu 4 valve lift, low-
short circuit in the cir- component with diag- er and exten-
cuit for Solenoid nostic menu. sion
valve, boom up Check the solenoid
(Y6005). valve.
112 The transistor has Lower not Check cabling between D797-F/K1:3 BOOM, 7.2.5 Control
been triggered due to working. the control unit and the – Y6004/1 menu 5 valve lift, low-
short circuit in the cir- component with diag- er and exten-
cuit for Solenoid nostic menu. sion
valve, boom down Check the solenoid
(Y6004). valve.
113 The transistor has Extension out Check cabling between D797-F/K1:4 BOOM, 7.3.5 Control
been triggered due to not working. the control unit and the – Y6006/1 menu 7 valve lift, low-
short circuit in the cir- component with diag- er and exten-
cuit for Solenoid nostic menu. sion
valve, boom out Check the solenoid
(Y6006). valve.
114 The transistor has Extension in Check cabling between D797-F/K1:5 BOOM, 7.3.5 Control
been triggered due to not working. the control unit and the – Y6007/1 menu 6 valve lift, low-
short circuit in the cir- component with diag- er and exten-
cuit for Solenoid nostic menu. sion
valve, boom in Check the solenoid
(Y6007). valve.
116 The transistor has Lifting/lower- Check cabling between D797-F/K1:31 BOOM, 7.2.7 Valve
been triggered due to ing not work- the control unit and the – Y6001/1 menu 2 block lift cyl-
short circuit or open ing. component with diag- inder
circuit in the circuit for nostic menu.
Solenoid valve, Check the solenoid
blocking lift, right valve.
(Y6001).
117 The transistor has Regenera- Check cabling between D797-F/K1:32 BOOM, 7.2.7 Valve
been triggered due to tion lift not the control unit and the – Y6051/1 menu 3 block lift cyl-
short circuit or open working. component with diag- inder
circuit in the circuit for nostic menu.
Solenoid valve, re- Check the solenoid
generation lift, right valve.
(Y6051).
118 The transistor has Regenera- Check cabling between D797-F/K1:33 BOOM, 7.2.7 Valve
been triggered due to tion lift not the control unit and the – Y6052/1 menu 3 block lift cyl-
short circuit or open working. component with diag- inder
circuit in the circuit for nostic menu.
Solenoid valve re- Check the solenoid
generation lift, left valve.
(Y6052).
119 The transistor has Parking brake Check cabling between D797-F/K1:7 HYD, 4.5.3 Sole-
been triggered due to cannot be re- the control unit and the – Y642/1 menu 5 noid valve
short circuit or open leased. component with diag- parking brake
circuit in the circuit for nostic menu.
Solenoid valve, park- Check the solenoid
ing brake (Y642). valve.
120 The transistor has Direction indi- Check bulb. D797-F/K1:9 LIGHTS, 9.6.6 Direc-
been triggered due to cator front left Check the lamp holder. – H422/1 menu 8 tion indica-
short circuit or open not working. tors
circuit in the circuit for Check cabling between
the control unit and the
Lamp, direction indi-
component with diag-
cator, left front
nostic menu.
(H422).
122 The transistor has Position light Check bulb. D797-F/K1:25 LIGHTS, 9.6.2 Run-
been triggered due to front left not Check the lamp holder. – H416-1/1 menu 5 ning lights
short circuit or open working.
Check cabling between
circuit in the circuit for
the control unit and the
Lamp, position light,
left front (H416-1). component with diag-
nostic menu.
123 The transistor has Position light Check bulb. D797-F/K1:29 LIGHTS, 9.6.2 Run-
been triggered due to front right not Check the lamp holder. – H417-1/1 menu 5 ning lights
short circuit or open working.
Check cabling between
circuit in the circuit for
the control unit and the
Lamp, position light,
component with diag-
right front (H417-1).
nostic menu.
124 Incorrect 24 V refer- Indicator light Check cabling between D797-F/K1:39 CAN/ 4.5.5 Parking
ence voltage to NC parking brake the control unit and the – S200/1, POWER, brake NC
switch parking brake and warning component with diag- S204/1, S216/ menu 9 switch
(S200), NC switch for low brake nostic menu. 1, S220/1 4.3.8 NO
low brake pressure pressure not Check the sensor. (normally
(S204), NO switch switching off. open) switch,
brake lights (S216) Brake lights brake lights
and NC switch de- and declutch
clutch (S220-2). not working. 4.3.7 NC
Gear cannot (normally
closed)
be engaged
switch, brake
because the
signal re- pressure
leased park-
ing brake is
not working.
133 Faulty signal from Overload sys- Check cabling between D797-F/K1:21 OP, menu 7.2.9 Sensor
Sensor hydraulic tem not work- the control unit and the – B768-L1/3 3 [V] hydraulic
pressure lift cylinder ing. All lift component with diag- HYD, pressure lift
left (B768-L1). Signal functions op- nostic menu. menu 6 cylinder
voltage under 0.2 V erate at re- Check the sensor. [bar]
or over 4.8 V. duced speed.
Error code
150 is activat-
ed.
135 Faulty signal from Overload sys- Check cabling between D797-F/K1:23 OP, menu 7.2.9 Sensor
Sensor hydraulic tem not work- the control unit and the – B768-R1/3 3 [V] hydraulic
pressure lift cylinder ing. All lift component with diag- HYD, pressure lift
right (B768-R1). Sig- functions op- nostic menu. menu 6 cylinder
nal voltage under 0.2 erate at re- Check the sensor. [bar]
V or over 4.8 V. duced speed.
Error code
150 is activat-
ed.
136 Faulty signal from Overload sys- Check cabling between D797-F/K1:24 OP, menu 7.2.9 Sensor
Sensor hydraulic tem not work- the control unit and the – B768-R2/3 3 [V] hydraulic
pressure lift cylinder ing. All lift component with diag- HYD, pressure lift
right (B768-R2). Sig- functions op- nostic menu. menu 6 cylinder
nal voltage under 0.2 erate at re- Check the sensor. [bar]
V or over 4.8 V. duced speed.
Error code
150 is activat-
ed.
137 Faulty signal from Lift not work- Check cabling between D797-F/K1:16 BOOM, 7.2.5 Control
Solenoid valve, boom ing. the control unit and the – Y6005/2 menu 4 valve lift, low-
up (Y6005). Return component with diag- er and exten-
current does not nostic menu. sion
match control cur- Check the solenoid
rent. valve.
138 Faulty signal from Lower not Check cabling between D797-F/K1:17 BOOM, 7.2.5 Control
Solenoid valve, boom working. the control unit and the – Y6004/2 menu 5 valve lift, low-
down (Y6004). Re- component with diag- er and exten-
turn current does not nostic menu. sion
match control cur- Check the solenoid
rent. valve.
140 Faulty signal from Extension in Check cabling between D797-F/K1:19 BOOM, 7.3.5 Control
Solenoid valve, boom not working. the control unit and the – Y6007/2 menu 6 valve lift, low-
in (Y6007). Return component with diag- er and exten-
current does not nostic menu. sion
match control cur- Check the solenoid
rent. valve.
145 Faulty signal from Overload sys- Check sensor arm - OP, menu 8.2.1.5 Sen-
Sensor, boom angle tem not work- mounting. 4 sor, boom an-
(B771). Logical error, ing. All lift Check the sensor. gle
the signal does not functions op-
Check cabling between
change when lifting erate at re-
the control unit and the
or lowering is activat- duced speed.
component with diag-
ed. Error code
150 is activat- nostic menu.
ed.
146 Faulty signal from Overload sys- Check the cable to the - OP, menu 8.2.1.6 Sen-
Sensor, boom length tem not work- sensor. 4 sor, boom
(B777). Logical error, ing. All lift Check the sensor. length
the signal does not functions op-
change when exten- erate at re- Check cabling between
sion is activated. duced speed. the control unit and the
component with diag-
Error code
nostic menu.
150 is activat-
ed.
147 High brake oil tem- Reduced Check that cooling fan D797-F/K2:13 HYD, 4.8 Tempera-
perature. braking abili- is working. – B762/1 menu 2 ture control,
ty. Check that cooler isn’t cleaning and
clogged. brake oil
148 Faulty signal from Model year Check the sensor. D797-F/K2:13 HYD, 4.8.10 Sen-
brake oil temperature 2009-: Ma- Check cabling between – B762/1 menu 2 sor brake oil
sensor (Y672). Signal chine speed the control unit and the temperature
voltage under 0.2 V limited to 5 component with diag-
or over 4.8 V. km/h. nostic menu.
150 Defective overload Overload sys- Check if there are error - OP, menu 8.2.1 Over-
protection. tem not work- codes for sensors in 1–5 load system
This error code can- ing. All lift the overload system.
not be removed with functions op-
Reset. erate at re-
duced speed.
151 Redundant voltage - Check cabling between D797-R/K2:7 CAN/ 11.5.1.2 Re-
feed left to Control the control unit and the POWER, dundant volt-
unit, frame rear component with diag- menu 10 age feed of
(D797-R) does not nostic menu. Control units
reach destination. Check the control unit.
152 Redundant voltage - Check cabling between D797-R/K2:8 CAN/ 11.5.1.2 Re-
feed right to Control the control unit and the POWER, dundant volt-
unit, frame rear component with diag- menu 10 age feed of
(D797-R) does not nostic menu. Control units
reach destination. Check the control unit.
153 Incorrect power sup- - Check fuse F58-2/3, D797-R/K2:1, CAN/ 11.5.1.3 Igni-
ply to Control unit, change if needed. K2:9, K2:10 – POWER, tion voltage
frame rear (D797-R). Check cabling between F58-2/3:1 menu 10 (15)
Voltage under 18 V or the control unit and the
over 32 V. component with diag-
nostic menu.
154 Incorrect power sup- - Check fuse F58-2/3, D797-R/ CAN/ 11.5.1.4
ply to Control unit, change if needed. K2:11 – F58- POWER, Emergency
frame rear (D797-R). Check cabling between 2/3:2 menu 10 stop switch
the control unit and the voltage
component with diag-
nostic menu.
155 Incorrect 5 V refer- Overload sys- Check cabling between D797-R/K1:8 CAN/ 8.2.1.5 Sen-
ence voltage to ana- tems and the control unit and the – B771/1, POWER, sor, boom an-
logue sensors. weight indica- component with diag- B777/1 menu 11 gle
Voltage under 4.9 V tor not work- nostic menu. 8.2.1.6 Sen-
or over 5.1 V. ing. Check the sensor. sor, boom
length, (ana-
logue sensor)
157 The transistor has Working light, Check bulb. D797-R/K1:1 LIGHTS, 9.6.10 Work-
been triggered due to boom left not Check the lamp holder. – E404-3L menu 3 ing lights,
short circuit or open working. boom
Check cabling between
circuit in the circuit for
the control unit and the
Lamp, working lights,
boom, left front component with diag-
(E404-3L). nostic menu.
158 The transistor has Working light, Check bulb. D797-R/ LIGHTS, 9.6.10 Work-
been triggered due to boom right Check the lamp holder. K1:15 – E404- menu 3 ing lights,
short circuit or open not working. 3R boom
circuit in the circuit for Check cabling between
Lamp, working lights, the control unit and the
boom, right front component with diag-
nostic menu.
(E404-3R).
159 The transistor has Left revers- Check bulb. D797-R/ LIGHTS, 9.6.5 Back-
been triggered due to ing light not Check the lamp holder. K1:28 – menu 11 up light
short circuit or open working. E405L
circuit in the circuit for Check cabling between
the control unit and the
Lamp, reversing light,
component with diag-
left (E405L).
nostic menu.
160 The transistor has Right revers- Check bulb. D797-R/ LIGHTS, 9.6.5 Back-
been triggered due to ing light not Check the lamp holder. K1:42 – menu 11 up light
short circuit or open working. E405R
circuit in the circuit for Check cabling between
Lamp, reversing light, the control unit and the
component with diag-
right (E405R).
nostic menu.
161 The transistor has Overload sys- Check cabling between D797-R/K1:2 OP, menu 8.2.1.4 Sen-
been triggered due to tems indi- the control unit and the – B7221L/A, 1 sor, steering
short circuit or open cates component with diag- B7221R/A axle load
circuit in the circuit for overload. nostic menu.
Sensor, steering axle Check the sensor.
load (B7221L and
B7221R).
163 The transistor has Regenera- Check cabling between D797-R/K1:4 BOOM, 7.3.7 Valve
been triggered due to tion extension the control unit and the – Y6046/1 menu 3 block, exten-
short circuit or open not working. component with diag- sion cylinder
circuit in the circuit for nostic menu.
Solenoid valve, re- Check the solenoid
generation extension, valve.
(Y6046).
164 The transistor has Extension not Check cabling between D797-R/K1:5 BOOM, 7.3.7 Valve
been triggered due to working. the control unit and the – Y6050/1 menu 2 block, exten-
short circuit or open component with diag- sion cylinder
circuit in the circuit for nostic menu.
Solenoid valve, Check the solenoid
blocking extension, valve.
(Y6050).
165 The transistor has Back-up Check cabling between D797-R/ LIGHTS, 9.7.5 Back-
been triggered due to alarm not the control unit and the K1:30 – H965/ menu 11 up alarm
short circuit or open working. component with diag- 1
circuit in circuit for re- nostic menu.
versing warning de- Check the component.
vice (H965).
166 The transistor has Attachment Check cabling between D797-R/ HYD, 7.4.2 Valve
been triggered due to functions not the control unit and the K1:31 – menu 6 block, top lift
short circuit or open working. component with diag- Y6003/1 hydraulics
circuit in the circuit for nostic menu.
Solenoid valve, top Check the solenoid
hydraulics (Y6003). valve.
167 The transistor has Brake light Check bulb. D797-R/ LIGHTS, 9.6.4 Brake
been triggered due to left not work- Check the lamp holder. K1:32 – menu 11 lights
short circuit or open ing. H411L/1
circuit in the circuit for Check cabling between
Lamp, brake light, left the control unit and the
(H411L). component with diag-
nostic menu.
169 The transistor has Position light Check bulb. D797-R/K1:7 LIGHTS, 9.6.2 Run-
been triggered due to left rear not Check the lamp holder. – H416-2/1 menu 5 ning lights
short circuit or open working.
circuit in the circuit for Check cabling between
Lamp, position light, the control unit and the
component with diag-
left (H416-2).
nostic menu.
170 The transistor has Position light Check bulb. D797-R/K1:9 LIGHTS, 9.6.2 Run-
been triggered due to right rear not Check the lamp holder. – H417-2/1 menu 5 ning lights
short circuit or open working.
circuit in the circuit for Check cabling between
Lamp, position light, the control unit and the
right (H417-2). component with diag-
nostic menu.
171 The transistor has Left rear light Check bulb. D797-R/ LIGHTS, 9.6.3 Rear
been triggered due to not working. Check the lamp holder. K1:10 – menu 5 lights
short circuit or open H412L/1
Check the lamp holder.
circuit in the circuit for
Lamp, rear light, left
(E421L).
172 The transistor has Left rear light Check bulb. D797-R/ LIGHTS, 9.6.3 Rear
been triggered due to not working. Check the lamp holder. K1:25 – menu 5 lights
short circuit or open H412R/1
circuit in the circuit for Check cabling between
Lamp, rear light, right the control unit and the
(E421R). component with diag-
nostic menu.
173 The transistor has Direction indi- Check bulb. D797-R/ LIGHTS, 9.6.6 Direc-
been triggered due to cator rear left Check the lamp holder. K1:29 – H426/ menu 8 tion indica-
short circuit or open not working. 1 tors
circuit in the circuit for Check cabling between
Lamp, direction indi- the control unit and the
cator, left rear component with diag-
nostic menu.
(H426).
175 Different signal from Overload sys- Check sensor adjust- D797-R/ OP, menu 8.2.1.4 Sen-
Sensor, steering axle tems indi- ment. K1:11 – 1 sor, steering
load (B7221L and cates Check the sensor. B7221L/C axle load
B722R) for more than overload. D797-R/
10 seconds. K1:12 –
B7221R/C
178 The transistor has Unloading of Check cabling between D797-R/ BOOM, 7.3.8 Valve
been triggered due to hydraulic oil the control unit and the K1:40 – menu 2 block, pump
short circuit or open pumps at component with diag- Y6062/1 unloading
circuit in the circuit for boom not nostic menu.
Solenoid valve, pump working. Check the solenoid
unloading (Y6062). valve.
183 Faulty signal from Overload sys- Check cabling between D797-R/ OP, menu 8.2.1.5 Sen-
Sensor, boom angle tem not work- the control unit and the K1:21 – B771/ 4 sor, boom an-
(B771). Signal volt- ing. All lift component with diag- 3 gle
age under 0.2 V or functions op- nostic menu.
over 4.8 V. erate at re- Check the sensor.
duced speed.
Error code
150 is activat-
ed.
184 Faulty signal from Overload sys- Check cabling between D797-R/ OP, menu 8.2.1.6 Sen-
Sensor, boom length tem not work- the control unit and the K1:22 – B777/ 4 sor, boom
(B777). Signal volt- ing. All lift component with diag- 3 length
age under 0.2 V or functions op- nostic menu.
over 4.8 V. erate at re- Check the sensor.
duced speed.
Error code
150 is activat-
ed.
193 Only engine alterna- Starter motor Check cabling between D797-R/ ENGINE, 1 Engine
tive Cummins not working. the control unit and the K1:36 – K360/ menu 5
QSM11: component with diag- 86
The transistor has nostic menu.
been triggered due to Check the component.
short circuit or open
circuit in the circuit for
Relay starter motor
(K360).
197 High hydraulic oil No limitation. Check that cooling fan D797-R/ HYD, 10.6 Temper-
temperature. is working. K2:13 – B776/ menu 1 ature control,
Check that cooler isn’t 1 cleaning and
clogged. hydraulic oil
198 Faulty signal from Incorrect tem- Check the sensor. D797-R/ HYD, 10.6.4 Sen-
Sensor, hydraulic oil perature dis- Check cabling between K2:13 – B776/ menu 1 sor, hydrau-
temperature (B776). play. the control unit and the 1 lic oil
component with diag- temperature
nostic menu.
199 Faulty signal from Incorrect dis- Check the sensor. D797-R/ CAB, 1.2.2 Sensor
fuel level sensor play of fuel Check cabling between K2:15 – B757 menu 7 fuel level
(B757). Resistance amount (emp- the control unit and the
over 180 Ω. ty or full). component with diag-
nostic menu.
201 Redundant voltage - Check cabling between D797-O/K2:7 CAN/ 11.5.1.2 Re-
feed left to Control the control unit and the POWER, dundant volt-
unit, frame option component with diag- menu 12 age feed of
(D797-O) does not nostic menu. Control units
reach destination. Check the control unit.
203 Incorrect power sup- - Check fuse F58-2/4, D797-O/ CAN/ 11.5.1.3 Igni-
ply to Control unit, change if needed. K2:10 – F58- POWER, tion voltage
frame option (D797- Check cabling between 2/4:1 menu 12 (15)
O). Voltage under 18 the control unit and the
V or over 32 V. component with diag-
nostic menu.
204 Incorrect emergency Functions Check fuse F58-3/4, D797-O/ CAN/ 11.5.1.4
stop switch voltage to normally sup- change if needed. K2:11 – F58- POWER, Emergency
Control unit frame op- plied emer- Check cabling between 3/4:1 menu 12 stop switch
tion (D797-O). gency stop the control unit and the voltage
switch volt- component with diag-
age have no nostic menu.
feed. All hy-
draulic func-
tions blocked.
211 The transistor has Hydraulic cab Check cabling between D797-O/K1:2 SLIDING- 9.10.4.3 Con-
been triggered due to sliding or lifta- the control unit and the – Y6016/1 CAB, trol valve op-
short circuit in the cir- ble cab not component with diag- menu 3 tion frame
cuit for Solenoid working. nostic menu. 9.10.5.2 Con-
valve, cab forward/up Check the solenoid trol valve op-
(Y6016). valve. tion frame
212 The transistor has Hydraulic cab Check cabling between D797-O/K1:3 SLIDING- 9.10.4.3 Con-
been triggered due to sliding or lifta- the control unit and the – Y6017/1 CAB, trol valve op-
short circuit in the cir- ble cab not component with diag- menu 4 tion frame
cuit for Solenoid working. nostic menu. 9.10.5.2 Con-
valve, cab backward/ Check the solenoid trol valve op-
down (Y6017). valve. tion frame
213 The transistor has Joystick Check cabling between D797-O/K1:4 EL- 5.2.10 Con-
been triggered due to steering or the control unit and the – Y636L1/1 STEER- trol valve joy-
short circuit in the cir- mini-wheel component with diag- ING, menu stick
cuit for Solenoid not working. nostic menu. 4 steering/mini-
valve, steering left Check the solenoid wheel
(Y636L). valve.
215 The transistor has Support jacks Check cabling between D797-O/ SUP- 7.10.1.2 Con-
been triggered due to not working. the control unit and the K1:30 – PORT- trol valve op-
short circuit or open component with diag- Y6063/1 JACKS, tion frame
circuit in the circuit for nostic menu. menu 3
Solenoid valve, sup- Check the solenoid
port jacks up, valve.
(Y6053).
216 The transistor has Support jacks Check cabling between D797-O/ SUP- 7.10.1.2 Con-
been triggered due to not working. the control unit and the K1:31 – PORT- trol valve op-
short circuit or open component with diag- Y6064/1 JACKS, tion frame
circuit in the circuit for nostic menu. menu 3
Solenoid valve, sup- Check the solenoid
port jacks down, valve.
(Y6064).
217 Solenoid valve, cab Tiltable cab Check cabling between D797-O/ SLIDING- MISSING
tilt up (Y6047). not working. the control unit and the K1:32 – CAB,
component with diag- Y6047/1 menu 3
nostic menu.
Check the solenoid
valve.
218 Solenoid valve, cab Tiltable cab Check cabling between D797-O/ SLIDING- MISSING
tilt down (Y6048). not working. the control unit and the K1:33 – CAB,
component with diag- Y6048/1 menu 4
nostic menu.
Check the solenoid
valve.
219 Solenoid valve, dis- Disengage- Check cabling between D797-O/K1:7 HYD, MISSING
engagement of hy- ment of hy- the control unit and the – Y6057/1 menu 6
draulic oil pumps draulic oil component with diag-
(Y6057). pump when nostic menu.
lowering of Check the solenoid
tiltable cab is valve.
not working.
221 Incorrect 24 V refer- Indication for Check cabling between D797-O/ SLIDING- 9.10.5.8 Sen-
ence voltage to Posi- Lowered cab the control unit and the K1:10 – B777- CAB, sor lowered
tion sensor cab lift not working. component with diag- 2/1 menu 4 cab
(B777-2). Door must be nostic menu.
closed so that Check the sensor.
the boom can
be lowered.
Speed limita-
tion is activat-
ed.
237 Faulty signal from Hydraulic cab Check cabling between D797-O/ SLIDING- 9.10.4.3 Con-
Solenoid valve, cab sliding or lifta- the control unit and the K1:16 – CAB, trol valve op-
forward/up (Y6016). ble cab not component with diag- Y6016/2 menu 3 tion frame
Return current does working. nostic menu. 9.10.5.2 Con-
not match control cur- Check the solenoid trol valve op-
rent. valve. tion frame
238 Faulty signal from Hydraulic cab Check cabling between D797-O/ SLIDING- 9.10.4.3 Con-
Solenoid valve, cab sliding or lifta- the control unit and the K1:17 – CAB, trol valve op-
backward/down ble cab not component with diag- Y6017/2 menu 4 tion frame
(Y6017). Return cur- working. nostic menu. 9.10.5.2 Con-
rent does not match Check the solenoid trol valve op-
control current. valve. tion frame
239 Faulty signal from Joystick Check cabling between D797-O/ EL- 5.2.10 Con-
Solenoid valve, steer- steering or the control unit and the K1:18 – STEER- trol valve joy-
ing left (Y636L). Re- mini-wheel component with diag- Y636L/2 ING, menu stick
turn current does not not working. nostic menu. 4 steering/mini-
match control cur- Check the solenoid wheel
rent. valve.
240 Faulty signal from Joystick Check cabling between D797-O/ EL- 5.2.10 Con-
Solenoid valve, steer- steering or the control unit and the K1:19 – STEER- trol valve joy-
ing right (Y636R). mini-wheel component with diag- Y636R/2 ING, menu stick
Return current does not working. nostic menu. 5 steering/mini-
not match control cur- Check the solenoid wheel
rent. valve.
252 Redundant voltage - Check cabling between D791-1/K2:8 CAN/ 11.5.1.2 Re-
feed left to frame con- the control unit and the POWER, dundant volt-
trol unit (D791-1) component with diag- menu 16 age feed of
does not reach desti- nostic menu. Control units
nation.
253 Incorrect power sup- Functions Check fuse F58-3/1, D791-1/K2:1/ CAN/ 11.5.1.4
ply to attachment normally sup- change if needed. 9/10 – F52-1 POWER, Emergency
control unit (D791-1). plied emer- Check fuse F52-1, – F58-3/1:1 menu 16 stop switch
Voltage under 18 V or gency stop change if needed. voltage
over 32 V. switch volt-
Check cabling between
age have no
the control unit and the
feed. No at-
tachment component with diag-
functions op- nostic menu.
erational.
254 Incorrect emergency Functions Check fuse F58-3/1, D791-1/K2:11 CAN/ 11.5.1.4
stop switch voltage to normally sup- change if needed. – F58-3/1 POWER, Emergency
Control unit, attach- plied emer- Check fuse F52-1, menu 16 stop switch
ment (D791-1). gency stop change if needed. voltage
switch volt-
Check cabling between
age have no
the control unit and the
feed. No at-
component with diag-
tachment
functions op- nostic menu.
erational.
257 The transistor has Working Check bulb. D791-1/K1:1 LIGHTS, 9.6.11 Work-
been triggered due to lights attach- Check the lamp holder. – E406R menu 2 ing lights at-
short circuit or open ment right not tachment
circuit in the circuit for working. Check cabling between
Lamp, working lights, the control unit and the
component with diag-
attachment right
nostic menu.
(E406R).
258 The transistor has Working Check bulb. D791-1/K1:15 LIGHTS, 9.6.11 Work-
been triggered due to lights attach- Check the lamp holder. – E406L menu 2 ing lights at-
short circuit or open ment left not tachment
Check cabling between
circuit in the circuit for working.
the control unit and the
Lamp, working lights,
component with diag-
attachment left
(E406L). nostic menu.
260 The transistor has Auxiliary at- Check bulb. D791-1/K1:42 LIGHTS, 9.6.11 Work-
been triggered due to tachment Check the lamp holder. – E404-4L, menu 2 ing lights at-
short circuit or open working lights E404-4R tachment
Check cabling between
circuit in the circuit for not working.
the control unit and the
Lamp, extra working
lights, attachment component with diag-
(E404-4L and E404- nostic menu.
4R).
261 The transistor has Rotation of at- Check cabling between D791-1/K1:2 ATTACH, 7.6.3 Control
been triggered due to tachment not the control unit and the – Y6008/1 menu 11 valve attach-
short circuit in the cir- working. component with diag- ment
cuit for Solenoid nostic menu.
valve, rotation clock- Check the solenoid
wise (Y6008). valve.
262 The transistor has Rotation of at- Check cabling between D791-1/K1:3 ATTACH, 7.6.3 Control
been triggered due to tachment not the control unit and the – Y6009/1 menu 12 valve attach-
short circuit in the cir- working. component with diag- ment
cuit for Solenoid nostic menu.
valve, rotation anti- Check the solenoid
clockwise (Y6009). valve.
263 The transistor has Spreading not Check cabling between D791-1/K1:4 ATTACH, 7.5.3 Control
been triggered due to working. the control unit and the – Y6018/1 menu 13 valve attach-
short circuit in the cir- component with diag- ment
cuit for Solenoid nostic menu.
valve, spreading out Check the solenoid
(Y6018). valve.
264 The transistor has Spreading not Check cabling between D791-1/K1:5 ATTACH, 7.5.3 Control
been triggered due to working. the control unit and the – Y6019/1 menu 14 valve attach-
short circuit in the cir- component with diag- ment
cuit for Solenoid nostic menu.
valve, spreading in Check the solenoid
(Y6019). valve.
266 The transistor has Side shift of Check cabling between D791-1/K1:31 ATTACH, 7.4.3 Control
been triggered due to attachment the control unit and the – Y6020/1 menu 8 valve attach-
short circuit or open not working. component with diag- ment
circuit in the circuit for nostic menu.
Solenoid valve, side Check the solenoid
shift, left (Y6020). valve.
267 The transistor has Twistlock not Check cabling between D791-1/K1:32 ATTACH, 7.9.1.3 Con-
been triggered due to working. the control unit and the – Y6040/1 menu 9 trol valve at-
short circuit or open component with diag- tachment
circuit in the circuit for nostic menu.
Solenoid valve, lock Check the solenoid
twistlock, (Y6040). valve.
268 The transistor has Twistlock not Check cabling between D791-1/K1:33 ATTACH, 7.9.1.3 Con-
been triggered due to working. the control unit and the – Y6039/1 menu 9 trol valve at-
short circuit or open component with diag- tachment
circuit in the circuit for nostic menu.
Solenoid valve, open Check the solenoid
twistlock, (Y6039). valve.
269 The transistor has Tilt locked, tilt Check cabling between D791-1/K1:7 ATTACH, 7.7.4 Lock
been triggered due to damping and the control unit and the – Y6012-1/1 menu 15 valve, tilt
short circuit or open controllable component with diag-
circuit in the circuit for tilt not work- nostic menu.
Solenoid valve, tilt ing. Check the solenoid
lock 1 (Y6012-1). valve.
270 The transistor has Tilt locked, tilt Check cabling between D791-1/K1:9 ATTACH, 7.7.4 Lock
been triggered due to damping and the control unit and the – Y6012-2/1 menu 15 valve, tilt
short circuit or open controllable component with diag-
circuit in the circuit for tilt not work- nostic menu.
Solenoid valve, tilt ing. Check the solenoid
lock 2 (Y6012-2). valve.
272 The transistor has Indicator light, Check bulb. D791-1/K1:25 ATTACH, 7.9.1 Twist-
been triggered due to open twist- Check the lamp holder. – H562/1 menu 10 locks
short circuit or open locks, not
circuit in the circuit for working. Check cabling between
the control unit and the
Indicator light, open
component with diag-
twistlocks (H562).
nostic menu.
273 The transistor has Indicator light Check bulb. D791-1/K1:29 ATTACH, 7.9.1 Twist-
been triggered due to alignment Check the lamp holder. – H564/1 menu 10 locks
short circuit or open twistlock not
circuit in circuit for working. Check cabling between
alignment indicator the control unit and the
component with diag-
light (H564).
nostic menu.
274 The transistor has Indicator light, Check bulb. D791-1/K1:39 ATTACH, 7.9.1 Twist-
been triggered due to locked twist- Check the lamp holder. – H563/1 menu 10 locks
short circuit or open locks, not
circuit in the circuit for working. Check cabling between
Indicator light, locked the control unit and the
component with diag-
twistlocks (H563).
nostic menu.
287 Faulty signal from Rotation of at- Check cabling between D791-1/K1:16 ATTACH, 7.6.3 Control
Solenoid valve, rota- tachment not the control unit and the – Y6008/2 menu 11 valve attach-
tion clockwise working. component with diag- ment
(Y6008). Return cur- nostic menu.
rent does not match Check the solenoid
control current. valve.
289 Faulty signal from Spreading not Check cabling between D791-1/K1:18 ATTACH, 7.5.3 Control
Solenoid valve, working. the control unit and the – Y6018/2 menu 13 valve attach-
spreading out component with diag- ment
(Y6018). Return cur- nostic menu.
rent does not match Check the solenoid
control current. valve.
290 Faulty signal from Spreading not Check cabling between D791-1/K1:19 ATTACH, 7.5.3 Control
Solenoid valve, working. the control unit and the – Y6019/2 menu 14 valve attach-
spreading in (Y6019). component with diag- ment
Return current does nostic menu.
not match control cur- Check the solenoid
rent. valve.
298 Twistlock sensor indi- Lifting and ex- Check that Sensors - ATTACH, 7.9.1.9 Sen-
cates that left twist- tension not twistlock are clean and menu 7 sor twistlocks
lock is between open working. correctly adjusted.
and locked position. Check cabling between
the control unit and the
component with diag-
nostic menu.
299 Twistlock sensor indi- Lifting and ex- Check that Sensors - ATTACH, 7.9.1.9 Sen-
cates that right twist- tension not twistlock are clean and menu 7 sor twistlocks
lock is between open working. correctly adjusted.
and locked position. Check cabling between
the control unit and the
component with diag-
nostic menu.
300 Alignment sensor in- Twistlock not Check that the align- - ATTACH, 7.9.1.8 Sen-
dicates unreasonable working. ment sensors are clean menu 6 sor alignment
distance. and correctly adjusted.
Check that alignment
pin runs smoothly.
Check cabling between
the control unit and the
component with diag-
nostic menu.
302 Redundant voltage - Check cabling between D791-2/K2:8 CAN/ 11.5.1.2 Re-
feed left to Control the control unit and the POWER, dundant volt-
unit, attachment op- component with diag- menu 17 age feed of
tion (D791-2) does nostic menu. Control units
not reach destination. Check the control unit.
303 Incorrect power sup- Levelling, tilt Check fuse F58-3/1 D791-2/K2:1, CAN/ 11.5.1.4
ply to Control unit, at- and special and F52-1, change if K2:9, K2:10 – POWER, Emergency
tachment option function not needed. F52-1 – F58- menu 17 stop switch
(D791-2). Voltage un- working. Check cabling between 3/1 voltage
der 18 V or over 32 V. the control unit and the
component with diag-
nostic menu.
304 Incorrect emergency Functions Check fuse F58-3/1 D791-2/K2:11 CAN/ 11.5.1.4
stop switch voltage to supplied with and F52-1, change if – F52-1 – POWER, Emergency
Control unit, attach- emergency needed. F58-3/1 menu 17 stop switch
ment option (D791- stop switch Check cabling between voltage
2). voltage lack the control unit and the
feed. Level- component with diag-
ling, tilt and nostic menu.
special func-
tion not work-
ing.
311 The transistor has Levelling not Check cabling between D791-2/K1:2 ATTACH, 7.8.3 Control
been triggered due to working. the control unit and the – Y6035/1 menu 19 valve attach-
short circuit in the cir- component with diag- ment
cuit for Solenoid nostic menu.
valve, levelling right Check the solenoid
(Y6035). valve.
312 The transistor has Levelling not Check cabling between D791-2/K1:3 ATTACH, 7.8.3 Control
been triggered due to working. the control unit and the – Y6036/1 menu 20 valve attach-
short circuit in the cir- component with diag- ment
cuit for Solenoid nostic menu.
valve, levelling left Check the solenoid
(Y6036). valve.
314 The transistor has Controllable Check cabling between D791-2/K1:5 ATTACH, 7.7.5 Control
been triggered due to tilt not work- the control unit and the – Y6011/1 menu 17 valve attach-
short circuit in the cir- ing. component with diag- ment
cuit for Solenoid nostic menu.
valve, tilt in (Y6011). Check the solenoid
valve.
315 The transistor has Levelling is Check cabling between D791-2/K1:30 ATTACH, 7.8.6 Valve
been triggered due to locked, con- the control unit and the – Y6034-1/1 menu 18 block, level-
short circuit or open trollable level- component with diag- ling cylinders
circuit in the circuit for ling and float nostic menu.
Solenoid valve, level- position not Check the solenoid
ling lock(Y6034-1). working. valve.
316 The transistor has Levelling is Check cabling between D791-2/K1:31 ATTACH, 7.8.6 Valve
been triggered due to locked, con- the control unit and the – Y6034-2/1 menu 18 block, level-
short circuit or open trollable level- component with diag- ling cylinders
circuit in the circuit for ling and float nostic menu.
Solenoid valve, level- position not Check the solenoid
ling lock (Y6034-2). working. valve.
338 Faulty signal from Levelling not Check cabling between D791-2/K1:17 ATTACH, 7.8.3 Control
Solenoid valve, level- working. the control unit and the – Y6036/2 menu 18 valve attach-
ling left (Y6036). Re- component with diag- ment
turn current does not nostic menu.
match control cur- Check the solenoid
rent. valve.
339 Faulty signal from Controllable Check cabling between D791-2/K1:18 ATTACH, 7.7.5 Control
Solenoid valve, tilt tilt not work- the control unit and the – Y6010/2 menu 14 valve attach-
out (Y6010). Return ing. component with diag- ment
current does not nostic menu.
match control cur- Check the solenoid
rent. valve.
340 Faulty signal from Controllable Check cabling between D791-2/K1:19 ATTACH, 7.7.5 Control
Solenoid valve, tilt in tilt not work- the control unit and the – Y6011/2 menu 15 valve attach-
(Y6011). Return cur- ing. component with diag- ment
rent does not match nostic menu.
control current. Check the solenoid
valve.
351 Redundant voltage - Check cabling between D791-3/K2:7 CAN/ 11.5.1.2 Re-
feed left to Control the control unit and the POWER, dundant volt-
unit, attachment left component with diag- menu 18 age feed of
jack pair (D791-3) nostic menu. Control units
does not reach desti- Check the control unit.
nation.
352 Redundant voltage - Check cabling between D791-3/K2:8 CAN/ 11.5.1.2 Re-
feed right to Control the control unit and the POWER, dundant volt-
unit, attachment left component with diag- menu 18 age feed of
jack pair (D791-3) nostic menu. Control units
does not reach desti- Check the control unit.
nation.
353 Incorrect power sup- Left lifting Check fuse F58-3/1 D791-3/K2:1 CAN/ 11.5.1.4
ply to Control unit, at- jacks not and F52-2, change if – F52-2 – POWER, Emergency
tachment left jack working. needed. F58-3/1 menu 18 stop switch
pair (D791-3). Volt- Check cabling between voltage
age under 18 V or the control unit and the
over 32 V. component with diag-
nostic menu.
357 The transistor has Working Check bulb. D791-3/K1:1 - 9.6.11 Work-
been triggered due to lights left lift- Check the lamp holder. – E404-6L/1 ing lights at-
short circuit or open ing jacks not tachment
Check cabling between
circuit in the circuit for working.
Working lights left lift- the control unit and the
ing jacks (E404-6L). component with diag-
nostic menu.
358 The transistor has Levelling is Check cabling between D791-3/K1:15 ATTACH, 7.8.6 Valve
been triggered due to locked, con- the control unit and the – Y6034-1/1, menu 18 block, level-
short circuit or open trollable level- component with diag- Y6034-2/1 ling cylinders
circuit in the circuit for ling and float nostic menu.
Solenoid valve, level- position not Check the solenoid
ling lock(Y6034-1) working. valve.
and Solenoid valve,
levelling lock(Y6034-
2).
360 The transistor has Left lifting Check cabling between D791-3/K1:42 COMBI, 7.9.2.5
been triggered due to jacks not the control unit and the – Y6053L/1 menu 16 Valve, oper-
short circuit or open working. component with diag- ating position
circuit in the circuit for nostic menu.
Solenoid valve, oper- Check the solenoid
ating position valve.
(Y6053L).
361 The transistor has Levelling not Check cabling between D791-3/K1:2 ATTACH, 7.8.3 Control
been triggered due to working. the control unit and the – Y6035/1 menu 19 valve attach-
short circuit in the cir- component with diag- ment
cuit for Solenoid nostic menu.
valve, levelling right Check the solenoid
(Y6035). valve.
362 The transistor has Levelling not Check cabling between D791-3/K1:3 ATTACH, 7.8.3 Control
been triggered due to working. the control unit and the – Y6036/1 menu 20 valve attach-
short circuit in the cir- component with diag- ment
cuit for Solenoid nostic menu.
valve, levelling left Check the solenoid
(Y6036). valve.
364 The transistor has Left lifting Check cabling between D791-3/K1:5 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6056L/1 menu 10 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, front Check the solenoid
knee out (Y6056L). valve.
365 The transistor has Left lifting Check cabling between D791-3/K1:30 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6059L/1 menu 13 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, rear Check the solenoid
knee in (Y6059L). valve.
366 The transistor has Left lifting Check cabling between D791-3/K1:31 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6058L/1 menu 12 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, rear Check the solenoid
knee out (Y6058L). valve.
367 The transistor has Left lifting Check cabling between D791-3/K1:32 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6013L/1 menu 10 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, low- Check the solenoid
ering front jack valve.
(Y6013L).
368 The transistor has Left lifting Check cabling between D791-3/K1:33 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6060L/1 menu 11 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, front Check the solenoid
jack up (Y6060L). valve.
370 The transistor has Left lifting Check cabling between D791-3/K1:9 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6061L/1 menu 13 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, rear Check the solenoid
jack up (Y6061L). valve.
371 The transistor has Indicator light Check bulb. D791-3/K1:10 COMBI, 7.9.2 Lifting
been triggered due to alignment lift- Check the lamp holder. – H566R/1 menu 7 jacks
short circuit or open ing jack right
circuit in the circuit for front not Check cabling between
Indicator light working. the control unit and the
component with diag-
(H566R).
nostic menu.
372 The transistor has Indicator light Check bulb. D791-3/K1:25 COMBI, 7.9.2 Lifting
been triggered due to alignment lift- Check the lamp holder. – H567R/1 menu 7 jacks
short circuit or open ing jack right
circuit in the circuit for rear not work- Check cabling between
Indicator light ing. the control unit and the
(H567R). component with diag-
nostic menu.
373 The transistor has Indicator light Check bulb. D791-3/K1:29 COMBI, 7.9.2 Lifting
been triggered due to alignment lift- Check the lamp holder. – H566L/1 menu 7 jacks
short circuit or open ing jack left
Check cabling between
circuit in the circuit for front not
Indicator light working. the control unit and the
(H556L). component with diag-
nostic menu.
374 The transistor has Indicator light Check bulb. D791-3/K1:39 COMBI, 7.9.2 Lifting
been triggered due to alignment lift- Check the lamp holder. – H567L/1 menu 7 jacks
short circuit or open ing jack left
Check cabling between
circuit in the circuit for rear not work-
Indicator light ing. the control unit and the
(H556L). component with diag-
nostic menu.
376 The transistor has Left lifting Check cabling between D791-3/K1:12 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6055L/1 menu 15 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, Check the solenoid
clamp release valve.
(Y6055L).
377 The transistor has Left lifting Check cabling between D791-3/K1:26 COMBI, 7.9.2.9 Sen-
been triggered due to jacks not the control unit and the – B7212L/A, menu 2, 3, sor, operat-
short circuit or open working. component with diag- B7213L/A, 4, 5, 6 ing position
circuit in the circuit for nostic menu. B7214L/A, 7.9.2.10 Sen-
voltage feed to posi- Check the sensor. B7215L/A, sor, knee
tion sensor, left jack B7216L/A,
7.9.2.13 Sen-
pair. B7217L/A,
sor, lifting
B7218L/A,
B7219L/A, jacks
B7220L/A 7.9.2.15 Sen-
sor, align-
ment
7.9.2.16 Sen-
sor, clamp-
ing position
387 Faulty signal from Levelling not Check cabling between D791-3/K1:16 ATTACH, 7.8.3 Control
Solenoid valve, level- working. the control unit and the – Y6035/2 menu 19 valve attach-
ling right (Y6035). component with diag- ment
Return current does nostic menu.
not match control cur- Check the solenoid
rent. valve.
388 Faulty signal from Levelling not Check cabling between D791-3/K1:17 ATTACH, 7.8.3 Control
Solenoid valve, level- working. the control unit and the – Y6036/2 menu 20 valve attach-
ling left (Y6036). Re- component with diag- ment
turn current does not nostic menu.
match control cur- Check the solenoid
rent. valve.
402 Redundant voltage - Check cabling between D791-4/K2:8 CAN/ 11.5.1.2 Re-
feed right to Control the control unit and the POWER, dundant volt-
unit, attachment right component with diag- menu 19 age feed of
jack pair (D791-4) nostic menu. Control units
does not reach desti- Check the control unit.
nation.
403 Incorrect power sup- Right lifting Check fuse F58-3/1 D791-4/K2:1 CAN/ 11.5.1.4
ply to Control unit, at- jacks and and F52-2, change if – F52-2 – POWER, Emergency
tachment right jack controllable needed. F58-3/1 menu 19 stop switch
pair (D791-4). Volt- tilt not work- Check cabling between voltage
age under 18 V or ing. the control unit and the
over 32 V. component with diag-
nostic menu.
404 Incorrect emergency Control Check fuse F58-3/1 D791-4/K2:11 CAN/ 11.5.1.4
stop switch voltage to switch can- and F52-2, change if – F52-2 – POWER, Emergency
Control unit, attach- not be disen- needed. F58-3/1 menu 19 stop switch
ment right jack pair gaged. Right Check cabling between voltage
(D791-4). lifting jacks the control unit and the
and controlla- component with diag-
ble tilt not nostic menu.
working.
407 The transistor has Working Check bulb. D791-4/K1:1 - 9.1.11 Work-
been triggered due to lights left lift- Check the lamp holder. – E404-6R ing lights at-
short circuit or open ing jacks not tachment
Check cabling between
circuit in the circuit for working.
Working lights left lift- the control unit and the
ing jacks (E404-6R). component with diag-
nostic menu.
410 The transistor has Right lifting Check cabling between D791-4/K1:42 COMBI, 7.9.2.5
been triggered due to jacks not the control unit and the – Y6053R/1 menu 16 Valve, oper-
short circuit or open working. component with diag- ating position
circuit in the circuit for nostic menu.
Solenoid valve, oper- Check the solenoid
ating position valve.
(Y6053R).
412 The transistor has Controllable Check cabling between D791-4/K1:15 ATTACH, 7.7.5 Control
been triggered due to tilt not work- the control unit and the – Y6011/1 menu 17 valve attach-
short circuit in the cir- ing. component with diag- ment
cuit for Solenoid nostic menu.
valve, tilt in (Y6010). Check the solenoid
valve.
413 The transistor has Right lifting Check cabling between D791-4/K1:4 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6057R/1 menu 11 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, front Check the solenoid
knee in (Y6057R). valve.
414 The transistor has Right lifting Check cabling between D791-4/K1:5 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6056R/1 menu 10 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, front Check the solenoid
knee out (Y6056R). valve.
415 The transistor has Right lifting Check cabling between D791-4/K1:30 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6059R/1 menu 13 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, rear Check the solenoid
knee in (Y6059R). valve.
416 The transistor has Right lifting Check cabling between D791-4/K1:31 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6058R/1 menu 12 trol valve, lift-
short circuit in the cir- working. component with diag- ing jacks
cuit for Solenoid nostic menu.
valve, rear knee out Check the solenoid
(Y6058L). valve.
417 The transistor has Right lifting Check cabling between D791-4/K1:32 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6013R/1 menu 10 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, low- Check the solenoid
ering front jack valve.
(Y6013R).
419 The transistor has Right lifting Check cabling between D791-4/K1:7 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6014R/1 menu 12 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, low- Check the solenoid
ering rear jack valve.
(Y6014R).
420 The transistor has Right lifting Check cabling between D791-4/K1:9 COMBI, 7.9.2.3 Con-
been triggered due to jacks not the control unit and the – Y6061R/1 menu 13 trol valve, lift-
short circuit or open working. component with diag- ing jacks
circuit in the circuit for nostic menu.
Solenoid valve, rear Check the solenoid
jack up (Y6061R). valve.
421 The transistor has Indicator light Check bulb. D791-4/K1:10 COMBI, 7.9.2 Lifting
been triggered due to front jacks Check the lamp holder. – H580/1 menu 9 jacks
short circuit or open raised not
Check cabling between
circuit in the circuit for working.
the control unit and the
Indicator light (H580).
component with diag-
nostic menu.
422 The transistor has Indicator light Check bulb. D791-4/K1:25 COMBI, 7.9.2 Lifting
been triggered due to front jacks Check the lamp holder. – H581/1 menu 9 jacks
short circuit or open lowered not
Check cabling between
circuit in the circuit for working.
the control unit and the
Indicator light (H581).
component with diag-
nostic menu.
423 The transistor has Indicator light Check bulb. D791-4/K1:29 COMBI, 7.9.2 Lifting
been triggered due to clamping po- Check the lamp holder. – H578/1 menu 8 jacks
short circuit or open sition lifting
Check cabling between
circuit in the circuit for jacks front not
the control unit and the
Indicator light (H578). working.
component with diag-
nostic menu.
425 The transistor has Right lifting D791-4/K1:2 COMBI, 7.9.2.3 Con-
been triggered due to jacks not – Y6054R menu 15 trol valve, lift-
short circuit or open working. ing jacks
circuit in the circuit for
Solenoid valve,
clamp (Y6054R).
426 The transistor has Right lifting D791-4/K1:3 COMBI, 7.9.2.3 Con-
been triggered due to jacks not – Y6055R menu 15 trol valve, lift-
short circuit or open working. ing jacks
circuit in the circuit for
Solenoid valve,
clamp release
(Y6055R).
427 The transistor has Right lifting Check cabling between D791-4/K1:26 COMBI, 7.9.2.9 Sen-
been triggered due to jacks not the control unit and the – B7212R/A, menu 2, 3, sor, operat-
short circuit or open working. component with diag- B7213R/A, 4, 5, 6 ing position
circuit in the circuit for nostic menu. B7214R/A, 7.9.2.10 Sen-
voltage feed to posi- Check the sensor. B7215R/A, sor, knee
tion sensor, right jack B7216R/A,
pair. B7217R/A, 7.9.2.13 Sen-
B7218R/A, sor, lifting
jacks
B7219R/A,
B7220R/A 7.9.2.15 Sen-
sor, align-
ment
7.9.2.16 Sen-
sor, clamp-
ing position
437 Faulty signal from Controllable Check cabling between D791-4/K1:16 ATTACH, 7.7.5 Control
Solenoid valve, tilt tilt not work- the control unit and the – Y6010/2 menu 16 valve attach-
out (Y6010). Return ing. component with diag- ment
current does not nostic menu.
match control cur- Check the solenoid
rent. valve.
451 Redundant voltage - Check cabling between 795/K1:7 CAN/ 11.5.1.2 Re-
feed left to KID con- the control unit and the POWER, dundant volt-
trol unit (D795) does component with diag- menu 14 age feed of
not reach destination. nostic menu. Control units
452 Redundant voltage - Check cabling between 795/K1:8 CAN/ 11.5.1.2 Re-
feed right to KID con- the control unit and the POWER, dundant volt-
trol unit (D795) does component with diag- menu 14 age feed of
not reach destination. nostic menu. Control units
460 No messages re- Incorrect val- Use diagnostic menu to D795/K1:10, CAN/ 11.6.2 Re-
ceived on CAN-buffer ues in operat- check CAN-bus K1:11, K1:12, POWER, dundant
1. ing menus. K1:13 menu 1, 2, CAN-bus
21
461 No messages re- Error codes Use diagnostic menu to D795/K1:5, CAN/ 11.6.2 Re-
ceived on CAN-buffer from other check CAN-bus K1:6 POWER, dundant
2. Control units menu 1, 2, CAN-bus
cannot be 21
shown.
E Schematics
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth) ........... 4
Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss) 6
Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth) .......... 8
Hydraulic diagram joystick control (hydraulic oil pump alternative
Sauer-Danfoss) .................................................................................................... 10
Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth) ...................... 12
Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss) ........... 14
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump
alternative Rexroth) .............................................................................................. 16
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump
alternative Sauer-Danfoss) ................................................................................... 18
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling
(hydraulic oil pump alternative Rexroth) ............................................................... 20
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling
(hydraulic oil pump alternative Sauer-Danfoss) ................................................... 22
Hydraulic diagram combi yoke (part 1 of 3)
(hydraulic oil pump alternative Rexroth) ............................................................... 24
Hydraulic diagram combi yoke (part 1 of 3)
(hydraulic oil pump alternative Sauer-Danfoss) ................................................... 26
Hydraulic diagram combi yoke (part 2 of 3) ......................................................... 28
Hydraulic diagram combi yoke (part 3 of 3) ......................................................... 30
Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth) ............... 32
Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss) ... 34
Hydraulic diagram cab lift and support jacks
(hydraulic oil pump alternative Rexroth) ............................................................... 36
Hydraulic diagram cab lift and support jacks
(hydraulic oil pump alternative Sauer-Danfoss) ................................................... 38
Hydraulic diagram sliding cab and support jacks
(hydraulic oil pump alternative Rexroth) ............................................................... 40
Hydraulic diagram sliding cab and support jacks
(hydraulic oil pump alternative Sauer-Danfoss) ................................................... 42
11 Common electrics ........................................................................................ 44
Circuit diagram, description ................................................................................. 44
Component designations ...................................................................................... 46
Circuit diagrams, compilation ............................................................................... 46
10 Common hydraulics
mm mm mm mm mm mm
Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss) page 6 A40740.0400
Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth) page 8 A48056.0100
Hydraulic diagram joystick control (hydraulic oil pump alternative Sauer-Danfoss) page 10 -
Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth) page 12 A40853.0100
Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss) page 14 -
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Rexroth) page A40853.0200
16
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Sauer-Danfoss) -
page 18
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alter- A43123.0100
native Rexroth) page 20
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alter- -
native Sauer-Danfoss) page 22
Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Rexroth) page 24 A41791.0100
Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Sauer-Danfoss) page 26 -
Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth) page 32 A40855.0100
Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss) page 34 A54505.0100
Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Rexroth) page 36 A43276.0100
Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Sauer-Danfoss) page 38 -
Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Rexroth) page 40 A40854.0100
Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Sauer-Danfoss) -
page 42
1 3 4 5
C+ C-
VDRF03.02GB
C+ 2 C- C+ 6 C-
8
B
PT
7
11
9 10
VA VA D VB
VA D T VA D T
ACC B 16 H
17 15 14
12
45 47 B1 A1 B2 A2 M
44 A
13
P H
46 PP
T H
10
11
LS
25
28
P M T
T T 29
Rexroth)
P P
D
24
18
43 40 34 30
36
33 23
39
20
33 33 33 19
X1 X2 X1
33 X2
T P
38 31 LS CF EF LS
42 21
T PP
B1 B2 B1 B2
P
37 32
22
S L1 L2 L4 L3 S L1 L2 L4 L3
41 35
(hydraulic oil pump alternative
VDRF03.02GB
1 2 3 4 5 6
C+ C-
C+ C- C+ C- 8
11
9 10
VA VA D VB
VA D T VB D T
17 ACC B 16 H
15 14
45 12
B1 A1 B2 A2 M
44 A
P H 46 PP 13
47
T H 10
11
LS
25
28
P M T
T T 29
P P
D 26
27
Sauer-Danfoss)
40 36 34 30
2 1
3 23
33 392 1 20
43 3
33 X1 X1
19
33 T P
38 LS CF EF
42 LS
B1 B1
T PP 21
P
37 32 31
35 22
41
S L2 L1 S L2 L1
(hydraulic oil pump alternative
Hydraulic diagram base machine
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
6
LS
L3
X2
1
L4
P
T1
7
B2
L2
X1
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
6
LS
1
P
T1
L1
X1
L2
S
B1
7
013012
TPB
P2B
T2B
T3B
8
PS
LSPB
7
A
6
B
A
9
B
5
A
B
4
3
A
B
3
P1
T1
11
10
1
C
A
12
B
A
13
T
T
L3
C2-
X2
L4
C2+ C1+
2
B2
X1
C1-
S L1
P
P
B1
B
14
1
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Control valve attachment
10. Filter hydraulic oil
TPB
P2B
T2B
T3B
8
PS
LSPB
7
A
6
B
A
9
B
5
5
A
B
4
3
A
B
3
P1
T1
11
10
1
A
T
T
12
2
14
C2-
13
L1
X1
L2
C2+ C1+
2
S
PP
15
B1
C1-
15
16
P
P
012496
1
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Control valve attachment
10. Filter hydraulic oil
TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
10
11
1
12
A
13
T
L3
X2
C1+ C2-
L4
T
2
C2+
B2
L2
X1
S L1
C1-
B1
P
P
B
14
1
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Control valve attachment
10. Filter hydraulic oil
TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
10
11
1
A
T
12
C1+ C2-
13 2
14
T
L2 L1
X1
2
C2+
PP
S
C1-
15
B1
15
16
P
P
B
013010
1
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Control valve attachment
10. Filter hydraulic oil
T3
TP
T2
PS
8
8
A
7
B
6
A
5
14
B
5
15
16
A
3
B
3
9
14
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
12
10
11
L4 L3
X2
L1 L2
X1
S
B1
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Control valve attachment
10. Solenoid valve, engagement of hydraulic pressure
11. Shuttle valve
12. Oil filter
13. Hydraulic oil pumps 1 and 2
14. Levelling cylinders
15. Valve block, levelling cylinders
16. Overcentre valve, levelling
T3
TP
T2
PS
8
8
A
7
B
6
A
5
B
5
9
10
11
A
3
B
3
12
9
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
13
1
14
2
15
L1
X1
L2
S
17
18
B1
16
013011
17
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Levelling cylinders
10. Valve block, levelling cylinders
11. Overcentre valve, levelling
12. Control valve attachment
13. Oil filter
14. Valve block top lift hydraulics
15. Shuttle valve
16. Attachment relief valve
17. Non-return valve
18. Hydraulic oil pump 1
VDRF03.02GB
P C1- C2+ C2- T
B A
3
1 1
5 6 8
4 7
P PP T T
9 9
10
11
010532 :E
B A B A B A B A B A B A PS
alternative Rexroth)
1413
TP
15 X1 X2
T1
P2
B1 B2
010532:F
T2
Hydraulic diagram combi yoke
(part 1 of 3) (hydraulic oil pump
S L1 L2 T3
L4 L3
P1
12
010520 (A41791.0100 ver. 1 - part 1/3)
E Schematics – 10 Common hydraulics 25
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Levelling cylinders
10. Valve block, levelling cylinders
11. Overcentre valve, levelling
12. Control valve attachment
13. Valve block top lift hydraulics
14. Shuttle valve
15. Hydraulic oil pumps 1 and 2
010532 :E
010532:F
010532:D
T3
T2
P2
TP
PS
8
A
7
B
6
A
B
5
9
10
11
A
4
B
3
12
9
A
B
1
A
T
T
C2-
A
2C1+
T
C2+
PP
B
C1-
P
P
B
A
1
B
010526:C
010526:B
P1
T1
1
13
2
010526:A
14
L1
X1
L2
S
15
B1
15
16
013016
1. Tilt cylinder
2. Damping block
3. Rotation motor unit
4. Valve block rotation motor
5. Side shift cylinders
6. Spreading motor
7. Valve block spreading motor
8. Twistlock cylinders
9. Levelling cylinders
10. Valve block, levelling cylinders
11. Overcentre valve, levelling
12. Control valve attachment
13. Valve block top lift hydraulics
14. Shuttle valve
15. Non-return valve
16. Hydraulic oil pump 1
(part 2 of 3)
Rexroth: 010520:A
1 TP P2 T2 T3 Sauer-Danfoss: 013016:A
A
3
A
5
A
P T
B
6
A
7
B
8
B
9
010526 (A41791.0100 ver. 2 - part 2/3)
10
P1
(part 3 of 3)
Rexroth: 010520:D
Sauer-Danfoss: 013016:D T3 T2 P2 TP
1
A 3
A
5
B
6
A
7
B
8
B
9
010532 (A41791.0100 ver. 1 - part 3/3)
10
P1
T1
2
TP
A
B
3
4
5
LS
1
L3
X2
L4
P
T1
6
B2
L2
X1
L1
3
1
L1
4
3
3
2
65
TP
T3
A
B
A
7
B
10
9
LS
L3
1
X2
L4
P
T1
11
B2
L2
L1
S
B1
4
3
3
2
65
TP
T3
A
B
A
7
B
9
LS
L1
1
L2
P
T1
S
10
11
013014
3
2
2
4
P
A
B
A
5
B
6
7
8
LS
L4 L3
X2
1
P
T1
9
B2
S
B1
3
2
2
4
P
A
B
A
5
B
7
LS
L1
1
L2
P
T1
S
8
013015
11 Common electrics
mm mm mm mm mm mm
Connectors
Connectors in the wiring start with an X followed by a number and end
-XM674m -XM674f
2 2 with f = female or m = male. If a connector is connected to a compo-
nent then the component number is inherited into the connector’s
number, e.g. XB72002Rm which is the connector for Sensor align-
ment front right (B7202R).
Under the connector’s number the pin is specified with numbers or let-
013017
Components
+CHASSIS Components are described with component number (S220-2) and a
-S220-2 short descriptive text. Components (sensors, switches, etc.) are
P shown in standby mode i.e. de-energised mode or not mechanical
standby mode.
1 1 2 1
• S indicates the type of component, see Component designations
013018
DECLUCHING
3,0MPa
page 46.
• 220 is component number and indicates the function the compo-
nent has.
• -2 indicates that it is the second component of this type for the
specific diagram.
Cable labelling
013019
W212A
• W212D: cables that end with a capital letter are jointed in the wir-
ing from a main cable with the same number. Each joint will have
its own letter.
References
0 An arrow symbol means that the circuit continues on another page in
the circuit diagram at the specified coordinates. Sometimes there are
1
00816 also references for components that can then be part of a component
/4.0_1.B1 5 1
013020
00816
whose other parts are on a different diagram. In some cases there is
/9.10_1.A2 also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
MEASUREPOINT SCALE For more information about the different connection types on the con-
trol units, see section 11 Common electrics , group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box 3
with 8 fuses.
For most fuse boxes there is also a table and an explanation of the cir-
cuits that the various fuses protect.
Component designations
page
–
Prefix Description
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
Sheet Designation
0.0-1 Circuit Cross references
Sheet Designation
2.0-3 Circuit Dana TE 32000
Sheet Designation
7.9-14 Circuit Combi Att
Sheet Designation
9.7-3 Circuit Indicators, Hazard flashers
11.5-7 Circuit 24 V
Electrically op-
erated mirrors
1 Circuit diagram Mirrors
Cab tilt
1 Circuit diagram Cab tilt
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E Schema - Koponentförteckning / E Schematics - List of Components 1
H 417 G-lampa sidomarkering hö bak Light bulb, side position light, right-hand rear
H 420 G-lampa positionsljus vänster Light bulb, position light, left-hand
H 421 G-lampa positionsljus höger Light bulb, position light, right-hand
H 422 G-lampa körvisare vä fram Light bulb, direction indicator left-hand forward
H 423 G-lampa körvisare hö fram Light bulb, direction indicator right-hand forwrd
H 426 G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
H 427 G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear
H 428 G-lampa roterande varningsljus Light bulb, flashing beacon lamp
H 445 G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
H 446 G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
H 451 G-lampa dimbakljus vänster Light bulb, fog light rear left
K 3311 Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction indicator
right
K 3312 Relä drivning fram Relay forward driving
K 3320 Relä drivning bak Relay reversing driving